Foreword

The Operator's Manual

You and others can be killed or seriously injured

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

SERVICE MANUAL Do not operate the machine without an Operator's

Manual, or if there is anything on the machine you
do not understand.

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

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

PS760, PS764, PS766

Contents
01 - Machine
06 - Body and Framework
24 - Brake System
27 - Driveline
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales

EN - 9823/1600 - ISSUE 1 - 07/2018

This manual contains original instructions, verified by

the manufacturer (or their authorized representative).

Copyright 2018 © JCB SERVICE

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

www.jcb.com
Notes:

9823/1600-1
 Spine Cards

SERVICE MANUAL SERVICE MANUAL

Volume 1 Volume 2

PS760, PS764, PS766 PS760, PS764, PS766

EN 9823/1600 EN 9823/1600

SERVICE MANUAL SERVICE MANUAL

Volume 3 Volume 4

PS760, PS764, PS766 PS760, PS764, PS766

EN 9823/1600 EN 9823/1600

9823/1600-1
Notes:

9823/1600-1
 01 - Machine
Contents Page No.

Acronyms Glossary .................................................................................................................................... 01-2

01-03 Safety
01-03-03 Safety - Yours and Others ............................................................................................... 01-3
01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8
01-06 About this Manual
01-06-00 General ........................................................................................................................... 01-13
01-06-06 Using the Manual ........................................................................................................... 01-14
01-30 Towing
01-30-00 General ........................................................................................................................... 01-17

9823/1600-1
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Acronyms Glossary

PIL Parts Identification List

9823/1600-1
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 01 - Machine
03 - Safety

03 - Safety

Contents Page No.

01-03-03 Safety - Yours and Others ............................................................................................... 01-3

01-03-06 Safety Warnings ............................................................................................................... 01-4
01-03-09 General Safety ................................................................................................................. 01-5
01-03-12 Maintenance Safety ......................................................................................................... 01-6
01-03-18 Operating Safety .............................................................................................................. 01-8

01 - 1 9823/1600-1 01 - 1
Notes:

01 - 2 9823/1600-1 01 - 2
 01 - Machine
03 - Safety
03 - Safety - Yours and Others

03 - Safety - Yours and Others

Health and Safety

All machinery can be hazardous. When a machine

is correctly operated and maintained, it is a safe
machine to work with. When it is carelessly operated
or poorly maintained it can become a danger to you
(the operator) and others.

In this manual and on the machine you will find

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

Safety is not just a matter of responding to the

warnings. All the time you are working on or with the
machine you must be thinking of what hazards there
might be and how to avoid them.

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

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

If you are not sure of anything, about the machine or

the work, ask someone who knows. Do not assume
anything.

Remember:

• Be careful
• Be alert
• Be safe.

01 - 3 9823/1600-1 01 - 3
 01 - Machine
03 - Safety
06 - Safety Warnings

06 - Safety Warnings

Health and Safety

In this manual there are safety notices. Each notice

starts with a signal word. The signal word meanings
are given below.

The signal word 'DANGER' indicates a hazardous

situation which, if not avoided, will result in death or
serious injury.

The signal word 'WARNING' indicates a hazardous

situation which, if not avoided, could result in death
or serious injury.

The signal word 'CAUTION' indicates a hazardous

situation which, if not avoided, could result in minor
or moderate injury.

The signal word 'Notice' indicates a hazardous

situation which, if not avoided, could result in
machine damage.

The safety alert system symbol (shown) also helps

to identify important safety messages in this manual.
When you see this symbol your safety is involved,
carefully read the message that follows.

Figure 1. The safety alert system symbol

01 - 4 9823/1600-1 01 - 4
 01 - Machine
03 - Safety
09 - General Safety

09 - General Safety Lifting Equipment

You can be injured if you use incorrect or faulty lifting
Health and Safety equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
Training equipment is in good condition and complies with all
To operate the machine safely you must know the local regulations.
machine and have the skill to use it. You must abide Raised Equipment
by all relevant laws, health and safety regulations
that apply to the country you are operating in. The Never walk or work under raised equipment unless
operator's manual instructs you on the machine, its it is supported by a mechanical device. Equipment
controls and its safe operation; it is not a training which is supported only by a hydraulic device can
manual. Ensure that you receive the correct training drop and injure you if the hydraulic system fails
before operating any machinery. Failing to do so will or if the control is operated (even with the engine
result in incorrect operation of the machine and you stopped).
will be putting yourself and others at risk. In some Make sure that no-one goes near the machine while
markets, and for work on certain jobsites, you may you install or remove the mechanical device.
be required to have been trained and assessed in
accordance with an operator competence scheme. Raised Machine
Make sure that you and your machine comply with Never position yourself or any part of your body
relevant local laws and jobsite requirements – it is under a raised machine which is not correctly
your responsibility. supported. If the machine moves unexpectedly you
Care and Alertness could become trapped and suffer serious injury or be
killed.
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always Lightning
be alert for hazards. Lightning can kill you. Do not use the machine if there
Clothing is lightning in your area.
You can be injured if you do not wear the correct Machine Modifications
clothing. Loose clothing can get caught in the This machine is manufactured in compliance with
machinery. Keep cuffs fastened. Do not wear a prevailing legislative requirements. It must not be
necktie or scarf. Keep long hair restrained. Remove altered in any way which could affect or invalidate its
rings, watches and personal jewellery. compliance. For advice consult your JCB dealer.
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be
aware of medicines which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are
feeling unwell. By doing so you could be a danger to
yourself and those you work with.
Mobile Phones
Switch off your mobile phone before entering an
area with a potentially explosive atmosphere. Sparks
in such an area could cause an explosion or fire
resulting in death or serious injury.
Switch off and do not use your mobile phone when
refuelling the machine.

01 - 5 9823/1600-1 01 - 5
 01 - Machine
03 - Safety
12 - Maintenance Safety

12 - Maintenance Safety Hydraulic Pressure

Hydraulic fluid at system pressure can injure you.
Health and Safety Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose
Raised Machine service line has been vented before connecting or
Never position yourself or any part of your body removing hoses. Make sure the engine cannot be
under a raised machine which is not correctly started while the hoses are open.
supported. If the machine moves unexpectedly you 'O' rings, Seals and Gaskets
could become trapped and suffer serious injury or be
killed. Badly installed, damaged or rotted 'O' rings, seals
and gaskets can cause leakages and possible
Air Conditioning Maintenance accidents. Renew whenever disturbed unless
The air conditioning system is a closed loop system otherwise instructed. Do not use Triochloroethane or
and contains pressurised refrigerant. No part of the paint thinners near 'O' rings and seals.
system should be disconnected until the system Arc Welding
has been discharged by a refrigeration engineer
or a suitably trained person. You can be severely To prevent the possibility of damage to electronic
frostbitten or injured by escaping refrigerant. components, disconnect the battery and the
alternator before arc-welding on the machine or
Compressed Air attached implements.
Compressed air is dangerous. Wear personal If the machine is equipped with sensitive electrical
protective equipment. Never point a compressed air equipment, i.e. amplifier drivers, electronic control
jet at yourself or others. units (ECUs), monitor displays, etc., then disconnect
Springs them before welding. Failure to disconnect the
sensitive electrical equipment could result in
Always wear personal protective equipment when
irreparable damage to these components.
dismantling assemblies containing components
under pressure from springs. This will protect against Parts of the machine are made from cast iron, welds
eye injury from components accidentally flying out. on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable
Metal Splinters
or apply any weld to any part of the engine.
You can be injured by flying metal splinters when
Always connect the welder earth (ground) cable to
driving metal pins in or out. Use a soft faced hammer
the same component that is being welded to avoid
or copper drift to remove and install metal pins.
damage to pivot pins, bearings and bushes. Attach
Always wear personal protective equipment.
the welder earth (ground) cable a distance from the
Communications part being welded no more than 0.6 m.
Bad communications can cause accidents. If two Counterweights
or more people are working on the machine, make
Your machine may be installed with counterweights.
sure each is aware of what the others are doing.
They are extremely heavy. Do not attempt to remove
Before starting the engine make sure the others are
them.
clear of the danger areas. Examples of danger areas
are: the rotating blades and belt on the engine, the Accumulators
attachments and linkages, and anywhere beneath or The accumulators contain hydraulic fluid and gas at
behind the machine. People can be killed or injured high pressure. Prior to any work being carried out
if these precautions are not taken. on systems incorporating accumulators, the system
Repairs pressure must be discharged by a JCB dealer, as
the sudden release of the hydraulic fluid or gas may
If your machine does not function correctly in
cause serious injury or death.
any way, get it repaired straight away. Neglect of
necessary repairs could result in an accident or affect Hot Components
your health. Do not try to do repairs or any other Touching hot surfaces can burn skin. The engine and
type of maintenance work you do not understand. To machine components will be hot after the unit has
avoid injury and/or damage get the work done by a been running. Allow the engine and components to
specialist engineer. cool before servicing the unit.
Soft Ground
A machine can sink into soft ground. Never work
under a machine on soft ground.

01 - 6 9823/1600-1 01 - 6
 01 - Machine
03 - Safety
12 - Maintenance Safety

Working Under the Machine

Make the machine safe before getting beneath it.
Make sure that any attachments on the machine are
correctly attached. Engage the park brake, remove
the ignition key, disconnect the battery. If the machine
has wheels use blocks to prevent unintentional
movement.
Lifting the Machine
Under no circumstances must the engine be run with
the transmission in gear and only one driving wheel
jacked clear of the ground, since the wheel on the
ground will move the machine.
Chemicals
Certain seals and gaskets (e.g. crankshaft oil
seal) on JCB machines contain fluoroelastomeric
materials such as Viton®, FluorelTM and
Technoflon®. Fluoroelastomeric materials subjected
to high temperatures can produce highly
corrosive hydrofluoric acid. This acid can severely
burn. New fluoroelastomeric components at
ambient temperature require no special safety
precautions. Used fluoroelastomeric components
whose temperatures have not exceeded 300 °C
( 571.6 °F) require no special safety precautions. If
evidence of decomposition (e.g. charring) is found,
refer to the next paragraph for safety instructions.
Do not touch component or surrounding area.
Used fluoroelastomeric components subjected to
temperatures greater than 300 °C ( 571.6 °F) (e.g.
engine fire) must be treated using the following
safety procedure. Make sure that heavy duty gloves
and special safety glasses are worn: Thoroughly
wash contaminated area with 10% calcium hydroxide
or other suitable alkali solution, if necessary use
wire wool to remove burnt remains. Thoroughly
wash contaminated area with detergent and water.
Contain all removed material, gloves etc. used in this
operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations. Do not
burn fluoroelastiometric materials.
Hydraulic Hoses
Never re-use hydraulic hose end crimps or use
reusable hose end crimps.
Personal Protective Equipment
Use the appropriate personal protective equipment
before performing maintenance on the machine,
otherwise you could be injured.
Working at Height
Use appropriate access equipment such as ladders
or a working platform if it is necessary to work at
height to perform maintenance tasks on the machine.
If you do not use suitable access equipment there is
a risk of falling, resulting in personal injury or death.

01 - 7 9823/1600-1 01 - 7
 01 - Machine
03 - Safety
18 - Operating Safety

18 - Operating Safety exhaust extractor. If you begin to feel drowsy, stop

the machine at once and get into fresh air.

Health and Safety Worksites

Worksites can be hazardous. Examine the site
Training before working on it. You could be killed or injured
if the ground gives way under your machine or if
Make sure that you have had adequate training and piled material collapses onto it. Check for potholes
that you are confident in your ability to operate the and hidden debris, logs, ironwork etc. Any of these
machine safely before you use it. Practice using the could cause you to lose control of your machine.
machine and its attachments until you are completely Check for utilities such as electric cables (overhead
familiar with the controls and what they do. With and underground), gas and water pipes etc. Mark
a careful, well trained and experienced operator, the positions of the underground cables and pipes.
your machine is a safe and efficient machine. With Make sure that you have enough clearance beneath
an inexperienced or careless operator, it can be overhead cables and structures.
dangerous. Do not put your life, or the lives of others,
at risk by using the machine irresponsibly. Before you
start to work, tell your colleagues what you will be Communications
doing and where you will be working. On a busy site,
use a signalman. Before doing any job not covered Bad communications can cause accidents. Keep
in this manual, find out the correct procedure. Your people around you informed of what you will be
local JCB distributor will be glad to advise you. doing. If you will be working with other people,
make sure any hand signals that may be used are
understood by everybody. Worksites can be noisy, do
Fuel not rely on spoken commands.
Fuel is flammable, keep naked flames away from the
fuel system. Stop the engine immediately if a fuel Parking
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the An incorrectly parked machine can move without an
engine running. Completely wipe off any spilt fuel operator. Follow the instructions in the Operator's
which could cause a fire. There could be a fire and Manual to park the machine correctly.
injury if you do not follow these precautions.
Banks and Trenches
Machine Condition
Banked material and trenches can collapse. Do not
A defective machine can injure you or others. Do not work or drive too close to banks and trenches where
operate a machine which is defective or has missing there is danger of collapse.
parts. Make sure the maintenance procedures in this
manual are completed before using the machine. Safety Barriers

Machine Limits Unguarded machines in public places can be

dangerous. In public places, or where your visibility
Operating the machine beyond its design limits can is reduced, place barriers around the work area to
damage the machine, it can also be dangerous. keep people away.
Do not operate the machine outside its limits. Do
not try to upgrade the machine performance with Sparks
unapproved modifications or additional equipment.
Explosions and fire can be caused by sparks from
Engine/Steering Failure the exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
If the engine or steering fails, stop the machine as material, vapour or dust.
quickly as possible. Do not operate the machine until
the fault has been corrected. Hazardous Atmospheres

Exhaust Gases This machine is designed for use in normal out

door atmospheric conditions. It must not be used
Machine exhaust gases can harm and possibly kill in an enclosed area without adequate ventilation.
you or bystanders if they are inhaled. Do not operate Do not use the machine in a potentially explosive
the machine in closed spaces without making sure atmosphere, i.e. combustible vapours, gas or dust,
there is good ventilation. If possible, install an without first consulting your JCB dealer.

01 - 8 9823/1600-1 01 - 8
 01 - Machine
03 - Safety
18 - Operating Safety

Regulations clearly. Modification of the machine's configuration

by the user (e.g. the fitting of large and non-
Obey all laws, worksite and local regulations which approved attachments) may result in a restriction of
affect you and your machine. the machine visibility.

Electrical Power Cables Hands and Feet

You could be electrocuted or badly burned if you get Keep your hands and feet inside the machine. When
the machine or its attachments too close to electrical using the machine, keep your hands and feet clear
power cables. You are strongly advised to make of moving parts. Keep your hands and feet within the
sure that the safety arrangements on site comply operator compartment while the vehicle is in motion.
with the local laws and regulations concerning work
near electric power lines. Before you start using the Controls
machine, check with your electricity supplier if there
are any buried power cables on the site. There is You or others can be killed or seriously injured
a minimum clearance required for working beneath if you operate the control levers from outside the
overhead power cables. You must obtain details from machine. Operate the control levers only when you
your local electricity supplier. are correctly seated.

Working Platform Passengers

Using the machine as a working platform is Passengers in or on the machine can cause
hazardous. You can fall off and be killed or injured. accidents. Do not carry passengers.
Never use the machine as a working platform
unless with approved man-basket or man-crate (if Fires
applicable).
If your machine is equipped with a fire extinguisher,
Machine Safety make sure it is checked regularly. Keep it in the
correct machine location until you need to use it. Do
Stop work at once if a fault develops. Abnormal not use water to put out a machine fire, you could
sounds and smells can be signs of trouble. Examine spread an oil fire or get a shock from an electrical
and repair before resuming work. fire. Use carbon dioxide, dry chemical or foam
extinguishers. Contact your nearest fire department
Hot Components as quickly as possible.

Touching hot surfaces can burn skin. The engine and Roll Over Protection
machine components will be hot after the unit has
been running. Allow the engine and components to If the machine starts to roll over, you can be crushed
cool before servicing the unit. if you try to leave the cab. If the machine starts to roll
over, do not try and jump from the cab. Stay in the
Travelling at High Speeds cab, with your seat belt fastened.

Travelling at high speeds can cause accidents. Confined Areas

Always travel at a safe speed to suit working
conditions. Pay extra attention to proximity hazards when
operating in confined areas. Proximity hazards
Hillsides include buildings, traffic and bystanders.

Operating the machine on hillsides can be Safe Working Loads

dangerous if the correct precautions are not taken.
Ground conditions can be changed by rain, snow, ice Overloading the machine can damage it and make it
etc. Check the site carefully. When applicable, keep unstable. Study the specifications in the Operator's
all attachments low to the ground. Manual before using the machine.

Visibility Lightning
Accidents can be caused by working in poor visibility. If you are inside the machine during a lightning storm
Use your lights to improve visibility. Keep the road stay in the machine until the storm has passed. If
lights, windows, mirrors and cameras clean (when you are outside of the machine during a lightning
fitted). Do not operate the machine if you cannot see storm stay away from the machine until the storm

01 - 9 9823/1600-1 01 - 9
 01 - Machine
03 - Safety
18 - Operating Safety

has passed. Do not attempt to mount or enter the

machine. If the machine is struck by lightning do
not use the machine until it has been checked for
damage and malfunction by trained personnel.

01 - 10 9823/1600-1 01 - 10
 01 - Machine
06 - About this Manual

06 - About this Manual

Contents Page No.

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

01-06-06 Using the Manual ........................................................................................................... 01-14

01 - 11 9823/1600-1 01 - 11
Notes:

01 - 12 9823/1600-1 01 - 12
 01 - Machine
06 - About this Manual
00 - General

00 - General

Introduction

This manual is built up in a modular way to

include procedures for disassembling, inspection
and assembly of JCB axles and gearboxes. It should
be noted that procedures given in this manual are for
transmission assemblies only. Service procedures
specific to machine transmission installations are
given in the relevant machine service manual.

When applicable, procedures in this manual

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

01 - 13 9823/1600-1 01 - 13
 01 - Machine
06 - About this Manual
06 - Using the Manual

06 - Using the Manual

Introduction

Information in this manual conforms to a standard List). These headings are assigned numerical
JCB service manual format. The format uses section identification references.
headings taken from a PIL (Parts Identification

Table 1.
Example Section Main Assembly / Head- Component / Sub-head-
ing ing
PIL reference 27 06 09
Heading Driveline Semi automatic gearbox Clutch- mainshaft

Information within each PIL reference is included • Make sure that the applicable fixings are to the
under a set of standard headings such as correct specification. If necessary discard the
Introduction, Component Identification, Technical original fixings and replace them with new ones.
Data and Operation for example. Where additional The relevant procedures indicate when this is
relevant information is contained within another PIL necessary.
reference a cross reference is provided. • Make sure that the applicable fixings and
threaded holes are free from contamination.
Diagnostics This includes dirt, debris, old sealants and
compounds, fluids and lubricants.
Information in this manual can help you diagnose
machine faults.

Before attempting to diagnose possible faults check

the following.

• Ensure that the operator understands the

machine controls, functions and use. Refer to
the applicable Operator Manual.
• Check that the maintenance record complies
with the applicable schedule for the operating
environment. Refer to PIL 78-24.
• Check that the fluids in use comply with the
standards specified. Refer to PIL 75-00.
• Ensure that the machine electronic set-up is
applicable. Use the applicable Servicemaster
vehicle set-up tool. Refer to PIL 33-57-03.
• Use the applicable Servicemaster diagnostics
tools. Refer to PIL 33-57-03.

Torque Tightening
When you replace components, always tighten the
applicable fixings to the correct torque value. Use the
torque tightening values contained in the individual
procedures (Remove and Install, Disassemble and
Assemble etc.). If no torque values are specified,
use the standard torque tightening values. Refer
to Fasteners and Fixings, Screws, Bolts, Nuts,
Technical Data (PIL 72-00). For the torque setting to
be effective, do the following before you install the
fixings.

• Make sure that all the applicable component

assemblies are correct.

01 - 14 9823/1600-1 01 - 14
 01 - Machine
30 - Towing

30 - Towing

Contents Page No.

01-30-00 General ........................................................................................................................... 01-17

01 - 15 9823/1600-1 01 - 15
Notes:

01 - 16 9823/1600-1 01 - 16
 01 - Machine
30 - Towing
00 - General

00 - General

Introduction

(For: PS764, PS766)

If there is no transmission damage, the machine
may be towed for a distance of approximately 1.5
kilometres (1 mile). Always use a rigid tow bar,
ensure that the gear lever is in neutral. Restrict
towing speed to 25 k.p.h. (15 m.p.h.).

If it is necessary to tow the machine for a distance

in excess of 1.5 kilometres (1 mile) the propshafts
should be disconnected to prevent damage to the
transmission system.

Position the machine on firm level ground and

block the wheels securely to prevent any movement.
Select neutral and release the parking brake.

Disconnect the forward and rear propshaft(s) from

the axle(s), and tie up the shaft securely well clear
of the rotating axle yoke. Alternatively remove the
propshaft(s) completely.

Connect the towing vehicle via the towbar before

removing the blocks from the wheels. Restrict the
towing speed to 25 k.p.h. (15 m.p.h.).

When towing is complete, block the wheels securely

before removing the towbar and reconnecting the
propshafts.

Important: In some countries neither of the above

procedures may be legally acceptable for towing on
public highways.

01 - 17 9823/1600-1 01 - 17
Notes:

01 - 18 9823/1600-1 01 - 18
 06 - Body and Framework
Contents Page No.

06-63 Identification Label

06-63-12 Gearbox ............................................................................................................................ 06-3

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 06 - Body and Framework
63 - Identification Label

63 - Identification Label

Contents Page No.

06-63-12 Gearbox ............................................................................................................................ 06-3

06 - 1 9823/1600-1 06 - 1
Notes:

06 - 2 9823/1600-1 06 - 2
 06 - Body and Framework
63 - Identification Label
12 - Gearbox

12 - Gearbox

Introduction

(For: PS760, PS766)

The gearbox has a serial number stamped on a data
plate as shown.

Figure 2.

A Data plate- SS700 Synchro shuttle transmission

Figure 3. Figure 4.

A
A Data plate- PS760 Powershift transmission
A Data plate- SS750 Synchro shuttle transmission

06 - 3 9823/1600-1 06 - 3
Notes:

06 - 4 9823/1600-1 06 - 4
 24 - Brake System
Contents Page No.

24-18 Park Brake

24-18-00 General ............................................................................................................................. 24-3
24-18-48 Actuator .......................................................................................................................... 24-10

9823/1600-1
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Notes:

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 24 - Brake System
18 - Park Brake

18 - Park Brake

Contents Page No.

24-18-00 General ............................................................................................................................. 24-3

24-18-48 Actuator .......................................................................................................................... 24-10

24 - 1 9823/1600-1 24 - 1
Notes:

24 - 2 9823/1600-1 24 - 2
 24 - Brake System
18 - Park Brake
00 - General

00 - General Introduction
Introduction ...................................................... 24-3 The park brake also called the hand brake is a
Technical Data ................................................. 24-4 latching brake usually used to keep the vehicle
Check (Condition) ............................................ 24-4 stationary. It is also used to prevent a vehicle from
Disassemble and Assemble ............................ 24-5 rolling when the operator needs both feet to operate
the clutch and throttle pedals.

The park brake usually consists of a cable directly

connected to the brake mechanism on one end, and
to a hand-operated lever, on the floor at the side of
the driver.

24 - 3 9823/1600-1 24 - 3
 24 - Brake System
18 - Park Brake
00 - General

Technical Data Check (Condition)

Table 2. Park Brake Multi- (For: PS764, PS766)

pack Brakes (If Installed)
Description Acceptable Tolerances Before inspecting the brake components carefully
(mm) remove all traces of sealing compound from
Friction pack assembly 37.1 to 39.6 component mating faces. Use a suitable degreaser,
thickness clean the brake components including the brake
housing in the gearbox rear case.

Multi-Plate Pack
1. Carefully inspect the friction plates and counter
plates. If any of the plates show signs of damage
or distortion, renew the complete plate pack.
Figure 5.

1 Thrust plate
2 Counter plates
3 Friction plates
2. Assemble the friction and counter plates
(including the thrust plate) on a suitable datum
table. Measure the overall thickness of the
assembled friction pack. The thickness X must
be between the recommended tolerances, refer
to Technical Data.
Figure 6.

X Friction pack assembly thickness

2.1. If the friction pack is outside these limits,
the complete friction pack assembly must
be renewed.

Note: The friction pack may be outside the maximum

thickness value if the plates are distorted, typically
after the brake has performed an emergency stop.

24 - 4 9823/1600-1 24 - 4
 24 - Brake System
18 - Park Brake
00 - General

Disassemble and Assemble

(For: PS764, PS766)

Consumables
Description Part No. Size
JCB Multi-Gasket 4102/1212 0.05 L

24 - 5 9823/1600-1 24 - 5
 24 - Brake System
18 - Park Brake
00 - General

Disassemble

Figure 7.

D
E

X
A

A Bolt (x2) B Screw (x5)

C Cover plate D Cover
E Needle roller thrust bearing. F Reaction pins
G Thrust plate H Friction plate
J Counter plate X Location1 and Location 2 for bolt removal

24 - 6 9823/1600-1 24 - 6
 24 - Brake System
18 - Park Brake
00 - General

1. Position the output yoke as shown. Refer to 5.3. Friction plates.

Figure 8.
5.4. Counter plates.
Figure 8.
6. If the brake assembly is being removed before
you disassemble the gearbox, then remove the
reaction pins. Refer to Figure 7.
7. If the brake actuator is to be disassembled, or the
cable is to replaced, then remove the park brake
cable as follows: Refer to Figure 9.
Figure 9.

M
K
K Output yoke
2. Remove the cover plate as follows: Refer to
Figure 7.
2.1. Remove only two bolts from location1 and
location 2.
2.2. Remove the screws.
2.3. Before the cover plate is removed, place a
container below to collect the gearbox oil.
2.4. Remove the cover plate with a flat bladed
screwdriver.
3. Remove the remaining bolts (x4) and carefully N
remove the cover, keeping it parallel to the
mating face of the gearbox. Refer to Figure 7.
4. Be aware that the needle roller thrust bearing and
the reaction pins may come away with the cover. L Brake cable
Refer to Figure 7. M Circlip
N Clevis pin
5. Remove the following: Refer to Figure 7.
7.1. Remove the clevis pin.
5.1. Needle roller thrust bearing. 7.2. Remove the circlip and then remove the
5.2. Thrust plate cable from the cover.

24 - 7 9823/1600-1 24 - 7
 24 - Brake System
18 - Park Brake
00 - General

Assemble

Figure 10.

G
D
E

A X

C
Z

A Bolt (x2) B Screw (x5)

C Cover plate D Cover
E Needle roller thrust bearing. F Reaction pins
G Thrust plate H Friction plate
J Counter plate X Location 1 and Location 2 for bolt installation
Y Sealant location on gearbox case Z Sealant location on cover

24 - 8 9823/1600-1 24 - 8
 24 - Brake System
18 - Park Brake
00 - General

1. Inspect the brake pack. 5. Apply a bead of sealant to the mating face on the
gearbox case. Refer to Figure 10.
2. Assemble the reaction pins and then install the
friction pack in the gearbox case. Refer to Figure Consumable: JCB Multi-Gasket
10. 6. Attach the cover with the bolts (x4). Refer to
2.1. Note that a counter plate is installed first Figure 10.
followed by a friction plate and so on. 6.1. Note that 2 bolts at location 1 and location
2.2. Install the thrust plate last. 2 are not installed at this stage.

3. If removed during disassembly install the park 7. Tighten the bolts to the correct torque value.
brake cable as follows: Refer to Figure 11. Refer to Figure 10.

Figure 11. 8. Apply a bead of sealant to the mating face on the

cover. Refer to Figure 10.
L R Consumable: JCB Multi-Gasket

M 9. Attach the cover plate with screws (x5) and the

bolts (x2). Refer to Figure 10.
10. Tighten the screws and bolts to the correct torque
value. Refer to Figure 10.

It is essential that the park brake cable is adjusted

Q correctly when the gearbox is installed into the
machine. Incorrect adjustment of the cable can
result in damage to the brake components and
excessive overheating of the brake assembly. See
the applicable machine Service Manual for the cable
adjustment procedure.

Table 3. Torque Values

Item Nm
A 56
B 16
N N 9

L Brake cable
M Circlip
N Clevis pin
P Brake actuator
Q O-ring
R Collar
3.1. Put the cable into the housing and connect
the fork end to the brake actuator with clevis
pin.
3.2. Never replace the clevis pin with a normal
bolt or screw.
3.3. Make sure that the O-ring is not damaged
and correctly installed on the collar.
3.4. Locate the collar inside the brake housing
and secure with the circlip.
4. Make sure that the needle roller thrust bearing is
correctly installed on the actuator assembly.

24 - 9 9823/1600-1 24 - 9
 24 - Brake System
18 - Park Brake
48 - Actuator

48 - Actuator Check (Condition)

Check (Condition) .......................................... 24-10
Disassemble and Assemble .......................... 24-12
(For: PS764, PS766)
1. Before you check the brake components use
a suitable degreaser to clean the brake
components.
2. Check the ball bearings and their tapered
locating slots for signs of excessive wear or
damage.
3. Check the needle roller thrust bearing and the
corresponding bearing surfaces for signs of
excessive wear or damage.
3.1. Make a note that some discolouration of
the needle rollers is acceptable providing
the surface of the rollers is otherwise
undamaged.
Figure 12.

4
1 Tapered locating slots
2 Ball bearings
3 Tapered locating slots
4 Needle roller thrust bearing
4. Check condition of the park brake cable as
follows.
4.1. Make sure that the cable is smooth and free
in operation.

24 - 10 9823/1600-1 24 - 10
 24 - Brake System
18 - Park Brake
48 - Actuator

4.2. Make sure that the cable cover is not cut or

split. They cut cable cover may allow water
ingress into the transmission.
4.3. Make sure that there is no corrosion or
debris passed through the O-ring seal.
4.4. Replace the cable if it is damaged or hard
to operate.
4.5. Tighten the screw to the correct torque
value.
Figure 13.

C
D

A Park brake cable

B Collar
C Circlip
D O-ring
E Screw
F Brake actuator

Table 4. Torque Values

Item Nm
E 9

24 - 11 9823/1600-1 24 - 11
 24 - Brake System
18 - Park Brake
48 - Actuator

Disassemble and Assemble

(For: PS764, PS766) 2. Remove the washer 1 and washer 2.

3. Remove the spring 1 and spring 2.
Disassembly
4. Remove the brake actuator plate then the ball
1. Carefully remove the screw. bearings.
1.1. Be careful the screw is under tension from
spring 1 and spring 2.

Figure 14.

Item Description
Table 5. F Actuator plate
Item Description G Ball bearings (x5)
A Screw H Brake actuator cover
B Spring 1
C Spring 2 Assembly
D Washer 1 1. Locate the ball bearings in their slots in the cover.
E Washer 2

24 - 12 9823/1600-1 24 - 12
 24 - Brake System
18 - Park Brake
48 - Actuator

2. Install the actuator plate then the springs.

3. Install the washers.
4. Compress the springs and install the screw.
4.1. Tighten the screw to the correct torque
value.

Table 6. Torque Values

Item Description Nm
A Screw 16

24 - 13 9823/1600-1 24 - 13
Notes:

24 - 14 9823/1600-1 24 - 14
 27 - Driveline
Contents Page No.

Acronyms Glossary .................................................................................................................................... 27-2

27-06 Semi-Automatic Gearbox

27-06-00 General ............................................................................................................................. 27-3
27-06-06 Clutch - Reverse ............................................................................................................ 27-34
27-06-07 Clutch - 2WD/4WD ......................................................................................................... 27-37
27-06-08 Clutch - Layshaft ............................................................................................................ 27-58
27-06-09 Clutch - Main Shaft ........................................................................................................ 27-70
27-06-10 Clutch - 6 Speed ............................................................................................................ 27-78
27-06-11 Clutch - Forward (Input) ................................................................................................. 27-86
27-06-15 Solenoid Control Valve ................................................................................................... 27-95
27-06-18 Pressure Relief Valve ..................................................................................................... 27-98
27-06-24 Oil Pump ........................................................................................................................ 27-99
27-06-39 Filter ............................................................................................................................. 27-101
27-06-40 Suction Strainer ............................................................................................................ 27-103
27-06-45 Piston Ring Seal .......................................................................................................... 27-105
27-06-47 Oil Seal ........................................................................................................................ 27-107
27-06-52 Driveshaft ..................................................................................................................... 27-109
27-06-54 Main Shaft .................................................................................................................... 27-112
27-06-56 Layshaft ........................................................................................................................ 27-114
27-06-57 Input Shaft .................................................................................................................... 27-115
27-06-58 Output Shaft ................................................................................................................. 27-116
27-06-85 Oil Feed Pipe ............................................................................................................... 27-122
27-06-86 Oil Transfer Pipe .......................................................................................................... 27-123
27-06-90 Front Case ................................................................................................................... 27-124
27-06-91 Rear Case .................................................................................................................... 27-131
27-06-95 Coupling Yoke 4WD ..................................................................................................... 27-133
27-14 Torque Converter
27-14-00 General ......................................................................................................................... 27-137
27-14-06 Control Valve ................................................................................................................ 27-145
27-47 Propshaft
27-47-00 General ......................................................................................................................... 27-149

9823/1600-1
2018-06-15
Acronyms Glossary

2WD Two Wheel Drive

4WD Four Wheel Drive
DTI Dial Test Indicator
LSRV Load Sense Relief Valve
PTFE Polytetrafluoroethylene
PTO Power Take-Off
RPM Revolutions Per Minute

9823/1600-1
2018-06-15
 27 - Driveline
06 - Semi-Automatic Gearbox

06 - Semi-Automatic Gearbox

Contents Page No.

27-06-00 General ............................................................................................................................. 27-3

27-06-06 Clutch - Reverse ............................................................................................................ 27-34
27-06-07 Clutch - 2WD/4WD ......................................................................................................... 27-37
27-06-08 Clutch - Layshaft ............................................................................................................ 27-58
27-06-09 Clutch - Main Shaft ........................................................................................................ 27-70
27-06-10 Clutch - 6 Speed ............................................................................................................ 27-78
27-06-11 Clutch - Forward (Input) ................................................................................................. 27-86
27-06-15 Solenoid Control Valve ................................................................................................... 27-95
27-06-18 Pressure Relief Valve ..................................................................................................... 27-98
27-06-24 Oil Pump ........................................................................................................................ 27-99
27-06-39 Filter ............................................................................................................................. 27-101
27-06-40 Suction Strainer ............................................................................................................ 27-103
27-06-45 Piston Ring Seal .......................................................................................................... 27-105
27-06-47 Oil Seal ........................................................................................................................ 27-107
27-06-52 Driveshaft ..................................................................................................................... 27-109
27-06-54 Main Shaft .................................................................................................................... 27-112
27-06-56 Layshaft ........................................................................................................................ 27-114
27-06-57 Input Shaft .................................................................................................................... 27-115
27-06-58 Output Shaft ................................................................................................................. 27-116
27-06-85 Oil Feed Pipe ............................................................................................................... 27-122
27-06-86 Oil Transfer Pipe .......................................................................................................... 27-123
27-06-90 Front Case ................................................................................................................... 27-124
27-06-91 Rear Case .................................................................................................................... 27-131
27-06-95 Coupling Yoke 4WD ..................................................................................................... 27-133

27 - 1 9823/1600-1 27 - 1
Notes:

27 - 2 9823/1600-1 27 - 2
 27 - Driveline
06 - Semi-Automatic Gearbox
00 - General

00 - General Introduction
Introduction ...................................................... 27-3
Technical Data .......................................... 27-
(For: PS760, PS764, PS766)
Component Identification ................................. 27-4 Semi-automatic gearboxes are a hybrid form of
Operation .................................................. 27- transmission where an integrated control system
Fault-Finding .................................................. 27-10 handles manipulation of the clutch automatically,
but the driver can still take manual control of gear
Drain and Fill ................................................. 27-16
selection.
Clean ............................................................. 27-17
Check (Condition) .......................................... 27-17 Many of these transmissions allow the driver to fully
Check (Level) ................................................ 27-18 delegate gear shifting choice to the control system,
which then effectively acts as if it is an automatic
Check (Pressure) .......................................... 27-19
transmission. An automatic transmission uses a
Remove and Install .................................. 27- torque converter instead of a straight friction clutch
Disassemble and Assemble .......................... 27-32 to manage the connection between the transmission
gearing and the engine.

A typical JCB semi-automatic transmission is called

Powershift, it has an (A) on the gearshift to signify
Automatic. In this mode the machine will gear change
automatically according to road speed. The following
types exist:

• PS700
• PS750
• PS764
• PS766
• P-Tronic 6x4 Smoothshift

Not all types of transmission are available on all

types of machine. Check the operators manual or
transmission dataplate for the type of transmission
installed on your machine.

27 - 3 9823/1600-1 27 - 3
 27 - Driveline
06 - Semi-Automatic Gearbox
00 - General

Component Identification

(For: PS764, PS766) Figure 15.

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

A Identification plate

27 - 4 9823/1600-1 27 - 4
 27 - Driveline
06 - Semi-Automatic Gearbox
00 - General

Main component identification

Figure 16.

H N

A
S J
B
C
D
R

Q
T
U

K L E
C
P
M V

Item Description
M Hose connection (to oil
Table 7.
cooler)
Item Description N Hose connection (from
A Torque converter oil cooler)
B Forward and input clutch P 6 speed assembly (if in-
C Reverse clutch stalled)
D Main shaft assembly Q Oil filter
E Layshaft assembly R Driveshaft (typically dri-
F 2 and 4 Wheel drive ves a hydraulic pump)
clutch S Gear drive to reverse
G Torque converter relief clutch
valve T Solenoid control valves
H Oil pressure mainte- U Transmission oil pres-
nance valve sure switch
J Transmission oil pump V Speed sensor
K Park brake actuator
L Park brake friction pack

27 - 5 9823/1600-1 27 - 5
 27 - Driveline
06 - Semi-Automatic Gearbox
00 - General

Sectional Drawing

Figure 17.

1 2

23

22 3

21 4
17

18
20

12

16
14
15

13
11 5
10
9 19
7 6
8

27 - 6 9823/1600-1 27 - 6
 27 - Driveline
06 - Semi-Automatic Gearbox
00 - General

Item Description
13 Bearing end float control
Table 8.
spacer
Item Description 14 Oil seal
1 Rear case 15 Transfer gear and shaft
2 Front case 16 Yoke - drive shaft cou-
3 Torque converter hous- pling
ing 17 Auxiliary device mount-
4 Gearbox oil pump ing interface
5 Yoke - drive shaft cou- 18 Auxiliary device drive
pling shaft
6 Oil seal 19 Layshaft and layshaft
7 4WD (Four Wheel Drive) clutch assembly
case 20 Main shaft and clutch
8 4WD clutch assembly assembly
9 Integral park brake as- 21 Input shaft and forward
sembly cover (if in- clutch assembly
stalled) 22 Reverse shaft and clutch
10 Park brake friction plate assembly
pack (if installed) 23 6 speed shaft and clutch
11 Park brake actuator (if assembly (if installed)
installed)
12 Transfer gear shaft sup- The drawing is not a true sectional view. It is drawn
port bearings to show the main components as clearly as possible.

Clutch Control Solenoids

PS764

Figure 18. PS764

A B C D

G F E

27 - 7 9823/1600-1 27 - 7
 27 - Driveline
06 - Semi-Automatic Gearbox
00 - General

Table 9.
Gear Clutches engaged Solenoids engaged Refer to Fig-
ure 18.
1st gear forward Forward low A
Layshaft E
2nd gear forward Forward high B
Layshaft E
3rd gear forward Forward low A
Mainshaft F
4th gear forward Forward high B
Mainshaft F
1st gear reverse Reverse low C
Layshaft E
2nd gear reverse Reverse high D
Layshaft E
3rd gear reverse Reverse low C
Mainshaft F
4th gear reverse Reverse High D
Mainshaft F

PS766

Figure 19. PS766

A B C D

G F E

Table 10.
Gear Clutches engaged Solenoids engaged Refer to Fig-
ure 19.
1st gear forward 6 speed E
Layshaft F
2nd gear forward Forward low A

27 - 8 9823/1600-1 27 - 8
 27 - Driveline
06 - Semi-Automatic Gearbox
00 - General

Gear Clutches engaged Solenoids engaged Refer to Fig-

ure 19.
Layshaft F
3rd gear forward Forward high B
Layshaft F
4th gear forward 6 speed E
Mainshaft G
5th gear forward Forward low A
Mainshaft G
6th gear forward Forward high B
Mainshaft G
1st gear reverse Reverse low C
Layshaft F
2nd gear reverse Reverse high D
Layshaft F
3rd gear reverse Reverse low C
Mainshaft G
4th gear reverse Reverse High D
Mainshaft G

27 - 9 9823/1600-1 27 - 9
 27 - Driveline
06 - Semi-Automatic Gearbox
00 - General

Fault-Finding

(For: PS760, PS764, PS766)

Fault
Machine drives but lacks power in all gears. Gearbox oil may also be Table 11. Page 27-10
overheating.
Machine does not drive in any gear. Table 12. Page 27-11
Some gears fail to engage or lack power. Table 13. Page 27-11
Gearbox oil overheating. Table 14. Page 27-12
Noisy operation. Table 15. Page 27-13
Cannot engage 4WD (Four Wheel Drive) (Spring ON clutch). Table 16. Page 27-13
Cannot engage 2WD (Spring ON clutch). Table 17. Page 27-13
Gearbox oil contaminated with water. Table 18. Page 27-14
Consequential Faults (Gearbox faults caused typically by water Table 19. Page 27-14
contamination and other factors related to the gearbox oil.)- Pressurisation
of gearbox casing. Dipstick blows out and oil escapes from dipstick tube.
Consequential Faults (Gearbox faults caused typically by water Table 20. Page 27-14
contamination and other factors related to the gearbox oil.)- Clutch failure
due to friction lining separation.
Consequential Faults (Gearbox faults caused typically by water Table 21. Page 27-14
contamination and other factors related to the gearbox oil.)- Badly worn or
noisy bearings.
Machine does not achieve maximum speed when travelling on the highway Table 22. Page 27-15
(Lock-up torque converter variants only).
Gear shifts fail to function normally or shifts occur at the incorrect road Table 23. Page 27-15
speed.

Table 11. Machine drives but lacks power in all gears. Gearbox oil may also be overheating.
Cause Remedy
Gearbox oil level low. Check for leaks and top up oil level as required.
Gearbox oil contaminated or wrong grade. Investigate the reason for the contamination and
rectify as required. Drain the oil and flush the
gearbox. Refer to driveline- semi automatic gearbox,
refer to (PIL 27-06).
Suction strainer restricted or blocked. Remove the suction strainer and clean or install new
as applicable. Refer to driveline- semi-automatic
gearbox, refer to (PIL 27-06).
Pressure maintenance valve defective. Carry out oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Remove the pressure maintenance valve and inspect
for signs of damage or excessive wear. Clean or
install new as applicable.
Torque converter relief valve defective. Carry out oil pressure and flow tests. Refer to
driveline- Torque converter, refer to (PIL 27-14).
Remove the torque converter relief valve and inspect
for signs of damage or excessive wear. Clean or
install new as applicable.
Oil cooler lines restricted or blocked. Internal Carry out oil pressure and flow tests. Refer to
blockage within the oil cooler matrix due to driveline- semi-automatic gearbox, refer to (PIL
contamination. 27-06).
Clear the restriction. Inspect the hose routing
and install new the hoses or oil cooler matrix as
applicable.

27 - 10 9823/1600-1 27 - 10
 27 - Driveline
06 - Semi-Automatic Gearbox
00 - General

Cause Remedy
Faulty torque converter. Carry out torque converter stall tests to confirm stall
speeds are within specification. Refer to driveline-
Torque converter, refer to (PIL 27-14).
Remove the gearbox and install new the torque
converter. Note that the torque converter assembly is
a non serviceable item.
Failure of oil pump assembly. Carry out the oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Remove the gearbox and inspect the oil pump for
signs of damage or excessive wear. Install new oil
pump as applicable.
Gearbox internal leakage fault. Carry out oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Remove and disassemble the gearbox. Inspect all
components for signs of damage or excessive wear.
In particular, check the seals and install new as
applicable.

Table 12. Machine does not drive in any gear.

Cause Remedy
Gearbox oil level low. Check for leaks and top up oil level as required.
Refer to driveline- semi-automatic gearbox, refer to
(PIL 27-06).
Gear selector switch defective. Check the function of the gear selector switch.
Inspect the condition of the associated electrical
wiring, plugs and connectors for damage and check
that the relevant fuses are intact.
Clutch solenoid wiring defective Inspect the condition of the associated electrical
wiring, plugs and connectors for damage and check
that the relevant fuses are intact.
Low mainline oil pressure. Carry out oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Failure of oil pump assembly. Carry out oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Remove the gearbox and inspect oil pump for signs
of damage or excessive wear. Install new oil pump as
applicable.

Table 13. Some gears fail to engage or lack power.

Cause Remedy
Gear selector switch defective. Check the function of the gear selector switch.
Inspect the condition of the associated electrical
wiring, plugs and connectors for damage and check
that the relevant fuses are intact.
The relevant solenoid valve is not being energised. Inspect the condition of the associated electrical
wiring, plugs and connectors for damage and check
that the relevant fuses are intact.
Solenoid coil faulty. Check the solenoid for open or short circuits.
Measure the solenoid coil resistance. If required,
install new solenoid coil.

27 - 11 9823/1600-1 27 - 11
 27 - Driveline
06 - Semi-Automatic Gearbox
00 - General

Cause Remedy
Clutch operating oil pressure low. Carry out oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Failure of clutch assembly. Check for clutch internal leakage. Carry out oil
pressure and flow tests. Refer to driveline- semi-
automatic gearbox, refer to (PIL 27-06).
Check for clutch slippage. Carry out torque
converter stall tests to confirm stall speeds are within
specification. Refer to driveline- Torque converter,
refer to (PIL 27-14).
Remove and disassemble the gearbox. Inspect
relevant clutch components for signs of damage or
excessive wear. Install new as applicable.

Table 14. Gearbox oil overheating.

Cause Remedy
Gearbox oil level low. Check for leaks and top up oil level as required.
Oil cooler heat exchanger matrix clogged with dirt Clean the oil cooler matrix. Refer to operators
particles or chaff. (Air blast coolers only. Some manual.
machines have liquid to liquid type coolers.)
Gearbox oil contaminated or wrong grade. Investigate the reason for the contamination and
rectify as required. Drain the oil and flush the
gearbox. Refer to driveline- semi-automatic gearbox,
refer to (PIL 27-06).
Suction strainer restricted or blocked. Remove the suction strainer and clean or renew
as applicable. Refer to driveline- semi-automatic
gearbox, refer to (PIL 27-06).
Oil cooler hoses kinked or trapped. Clear the restriction. Inspect the hose routing and
reroute or renew the hoses as applicable.
Machine being operated incorrectly i.e. Incorrect gear Educate the operator.
ratio.
Torque converter relief valve defective. Carry out oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Failure of oil pump assembly. Carry out oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Remove the gearbox and inspect oil pump for signs
of damage or excessive wear. Install new the pump
as applicable.

27 - 12 9823/1600-1 27 - 12
 27 - Driveline
06 - Semi-Automatic Gearbox
00 - General

Table 15. Noisy operation.

Cause Remedy
Gearbox oil level low. Check for leaks and top up oil level as required.
Gearbox oil contaminated or wrong grade. Investigate the reason for the contamination and
rectify as required. Drain the oil and flush the
gearbox. Refer to driveline- semi automatic gearbox,
refer to (PIL 27-06).
Suction strainer restricted or blocked. Remove the suction strainer and clean or install new
as applicable. Refer to driveline- semi-automatic
gearbox, refer to (PIL 27-06).
Low lubrication oil pressure. Carry out oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Gearbox components damaged or excessively worn. Remove and disassemble the gearbox. Inspect all
the components for signs of damage or excessive
wear. In particular, check shaft seals and bearings.
Install new as applicable.

Table 16. Cannot engage 4WD (Four Wheel Drive) (Spring ON clutch).
Cause Remedy
4 wheel drive solenoid valve spool is sticking in Remove and inspect the solenoid valve cartridge.
the 2WD (Two Wheel Drive) drive position due to Clean the valve or renew as applicable.
contamination.
Solenoid coil permanently energised. Check the function of the 4WD selector switch.
Inspect the condition of the associated electrical
wiring, plugs and connectors for damage and check
that the relevant fuses are intact.
Failure of clutch assembly Remove the 4WD clutch assembly. Inspect the clutch
components for signs of damage or excessive wear.
Renew as applicable.

Table 17. Cannot engage 2WD (Spring ON clutch).

Cause Remedy
Gearbox oil level low. Check for leaks and top up oil level as required.
4WD selector switch defective. Check the condition of the 4WD selector switch.
Inspect the condition of the associated electrical
wiring, plugs and connectors for damage and check
that the relevant fuses are intact.
4WD solenoid valve is not being energised. Inspect the condition of the associated electrical
wiring, plugs and connectors for damage and check
that the relevant fuses are intact.
Solenoid coil faulty. Check the solenoid for open or short circuits.
Measure the solenoid coil resistance. If required,
install a new solenoid coil.
4WD solenoid valve spool is sticking in the 4WD Remove and inspect the solenoid valve cartridge.
position due to contamination. Clean the valve or install new as applicable.
Clutch operating oil pressure low. Carry out oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Failure of clutch assembly. Check for clutch internal leakage. Carry out oil
pressure and flow tests. Refer to driveline- semi-
automatic gearbox, refer to (PIL 27-06).
Remove the 4WD clutch assembly. Inspect the clutch
components for signs of damage or excessive wear.
Install new as applicable.

27 - 13 9823/1600-1 27 - 13
 27 - Driveline
06 - Semi-Automatic Gearbox
00 - General

Table 18. Gearbox oil contaminated with water.

Cause Remedy
Water ingress during filling or topping-up. Drain the oil and flush the gearbox. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Missing or incorrect dipstick. Damaged filler tube. Install new parts as required. Drain the oil and flush
the gearbox.
Machine operated in deep water. Drain the oil and flush the gearbox. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Gearbox oil cooler faulty, gearbox oil contaminated Remove and test the oil cooler.
with engine coolant. (Liquid to liquid oil coolers only.)
Gearbox casings damaged. Inspect the gearbox casing. Renew missing or
damaged parts. Drain the oil and flush the gearbox.
Refer to driveline- semi-automatic gearbox, refer to
(PIL 27-06).
Gearbox oil circuit pipework or hoses damaged. Inspect the pipework and hoses. Renew missing or
damaged parts. Drain the oil and flush the gearbox.
Refer to driveline- semi-automatic gearbox, refer to
(PIL 27-06).

Table 19. Consequential Faults (Gearbox faults caused typically by water contamination and other
factors related to the gearbox oil.)- Pressurisation of gearbox casing. Dipstick blows out and oil escapes
from dipstick tube.
Cause Remedy
Water in the oil combined with heat from torque Replace or renew the dipstick.
converter causes steam. Drain the oil and flush the gearbox. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).

Table 20. Consequential Faults (Gearbox faults caused typically by water contamination and other
factors related to the gearbox oil.)- Clutch failure due to friction lining separation.
Cause Remedy
Water ingress. Remove and dismantle gearbox. Inspect relevant
clutch components for signs of damage or excessive
wear. Install new as applicable.
Overheating transmission oil. Drain the oil and flush the gearbox. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).

Table 21. Consequential Faults (Gearbox faults caused typically by water contamination and other
factors related to the gearbox oil.)- Badly worn or noisy bearings.
Cause Remedy
Water ingress. Remove and dismantle the gearbox. Inspect all
components for signs of damage or excessive wear.
Install new components as applicable.
Insufficient lubrication. Drain the oil and flush the gearbox. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).
Carry out oil pressure and flow tests. Refer to
driveline- semi-automatic gearbox, refer to (PIL
27-06).

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Table 22. Machine does not achieve maximum speed when travelling on the highway (Lock-up torque
converter variants only).
Cause Remedy
Operator error. Educate the operator. Ensure operator fully
understands the characteristics of the lock up
function.
Lock up torque converter solenoid not being Inspect the condition of the associated electrical
energised. wiring, plugs and connectors for damage and check
that the relevant fuses are intact.
Lock up torque converter solenoid coil faulty. Check the solenoid for open or short circuits.
Measure the solenoid coil resistance. If required,
renew the solenoid coil.
Engine or transmission speed sensor faulty. Inspect the condition of the associated electrical
wiring, plugs and connectors or damage and check
that the relevant fuses are intact. If required, install a
new speed sensor.
Faulty lock up torque converter. Remove the gearbox and renew the lock up torque
converter. Note that the torque converter assembly is
a non serviceable item.

Table 23. Gear shifts fail to function normally or shifts occur at the incorrect road speed.
Cause Remedy
Gear selector switch faulty Check the function of the gear selector switch. Also
Inspect the condition of the associated electrical
wiring, plugs and connectors for damage and make
sure that the relevant fuses are intact.

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Drain and Fill 13. Continue this procedure for the specified
duration, if possible during machine operation.
Duration: 30 min
(For: PS764, PS766)
14. Allow the machine to cool then drain the
Transmission Oil and Filter transmission oil through the suction strainer
aperture. Refer to (PIL 27-06-40).
Refer to driveline, semi-automatic gearbox, Filter,
15. Test the oil for contamination. If the oil is still
(PIL 27-06-39).
contaminated, repeat the flushing procedure
from step 3
Transmission Oil Suction Strainer
16. If the oil is clean:
Refer to driveline, semi-automatic gearbox, Suction
Strainer, (PIL 27-06-40). 16.1. Replace the suction strainer. Refer to (PIL
27-06-40).
Flushing the Transmission Oil 16.2. Install a new oil filter. Refer to (PIL
27-06-39).
1. If the transmission oil has been contaminated
with water or incorrect oil types, the transmission 16.3. Fill the transmission with the correct grade
must be flushed to effectively remove the of fresh oil. Refer to (PIL 75-00)
contaminated oil. 16.4. Check the oil level and top up as required.
Refer to (PIL 27-06-00).
2. Park the machine and make it safe.
3. Drain the oil from the gearbox. Refer to (PIL
27-06-40).
4. Remove the suction strainer. Refer to (PIL
27-06-40).
5. Clean the suction strainer and install. Refer to
(PIL 27-06-40).
6. Replace the oil filter. Note that the filter may be
remotely mounted on some installations. Refer to
(PIL 27-06-39).
7. Fill the transmission with the correct grade of
fresh oil. Refer to (PIL 75-00).
8. Check the oil level and top up as required. Refer
to (PIL 27-06-00).
9. Start the engine and run the machine until the
normal operating temperature is as specified.
Temperature: 50 –100 °C ( 121.9 –211.9 °F)
10. Stall the torque converter for the specified
duration. Refer to (PIL 27-14).
Duration: 5 s
10.1. Do not stall the torque converter for
longer than the maximum duration or the
transmission oil will overheat.
Duration: 10 s
11. Continue running the engine under normal
conditions for the specified duration.
Duration: 5 min
12. Repeat step 10.

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Clean Check (Condition)

For: PS760, PS764, PS766 ....... Page 27-17
Otherwise .................................. Page 27-17 (For: PS764, PS766)
Consumables
(For: PS760, PS764, PS766) Description Part No. Size
Consumables JCB Threadlocker 4101/0250 0.01 L
Description Part No. Size and Sealer (Medium 4101/0251 0.05 L
Strength)
Cleaner/Degreaser 4104/1557 0.4 L
- General purpose
solvent based parts Before assembling the gearbox, make sure that a
cleaner thorough inspection of all components is carried out.
Remember that although a failed component may
be easy to identify, the cause of that failure may be
1. Carefully remove all traces of the gasket
less easy to trace. It is also possible that a failed
or gasket compound from the following
component may have caused damage to other areas
components:
of the gearbox.
1.1. Front and rear case mating faces
1. Cleaning: Refer to Semi-Automatic Gearbox -
1.2. Front case and torque converter housing Clean, refer to (PIL 27-06).
mating faces
2. General Inspection:
1.3. Solenoid control valve manifold and case
mating faces 2.1. Carefully inspect all gears, bearings and
1.4. 4WD case mating faces (if applicable) shafts for signs of excessive wear or
damage. If wear or damage is evident, the
1.5. Layshaft cover and rear case mating faces. components must be renewed.
2. Clean the inside of the cases using a suitable 2.2. Make sure that all oil way cross drillings are
degreasing agent. clear and free from debris. Blocked oil ways
are a common cause of bearing failure. If
Consumable: Cleaner/Degreaser - General necessary use an air line to blow through
purpose solvent based parts cleaner the oil ways.
(Otherwise) 3. Clutch Units:

1. Carefully remove all traces of the gasket 3.1. If a clutch failure is suspected see the
or gasket compound from the following relevant clutch dismantling and assembly
components: procedure, refer to (PIL 27-06).

1.1. Front and rear case mating faces 4. Gearbox Oil Pump-Renew:
1.2. Front case and torque converter housing 4.1. If tests have shown the pump performance
mating faces to be unacceptable, the pump must be
1.3. Solenoid control valve manifold and case renewed as a complete unit.
mating faces 4.2. Make sure that the pump mating face on the
1.4. 4WD case mating faces (if applicable) gearbox front cover is clean and free from
surface damage.
1.5. Layshaft cover and rear case mating faces.
5. Gearbox Oil Pump-Replace: If the existing pump
2. Clean the inside of the cases using a suitable is to be re-installed proceed as follows:
degreasing agent.
5.1. Undo the security screw and separate
Consumable: Cleaner/Degreaser - General
the pump body. Carefully inspect the gear
purpose solvent based parts cleaner
teeth, white metal bearing and gear/body
mating faces for signs of wear and damage,
(If either is evident, the pump must be
renewed).
5.2. Carefully remove and discard the oil seal.
Take care not to damage the seal housing.

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5.3. Install a new seal. Install the seal the correct Check (Level)
way around. Push the seal flush with the
front of the housing.
5.4. Re-assemble the pump. (For: PS760, PS764, PS766)
Figure 20. 1. Make the machine safe. Refer to (PIL 01-03).
2. Start the engine and operate at low idle for the
specified time. This allows the oil to fill the filter,
pump, torque converter, oil cooler and hoses.
Duration: 4 min
3. Stop the engine.
4. Remove the ignition key.
5. Gain access to the dipstick. Refer to (PIL 06-06).

A 6. Before you complete a check of the oil level, you

must wait as shown on the instructional label.
B The instructional label shows the waiting time in
seconds.
7. Make sure that the area around the dipstick and
tube are clean and free of debris before removing
the dipstick.
B 8. Check the gearbox oil level on the dipstick. The
oil level must be between the end of the dipstick
and maximum mark on the dipstick.
C
A Security screw 9. Clean the dipstick with a clean lint free cloth.
B Oil seal Make sure that no debris remain on the dipstick
C Housing or enters the transmission via the dipstick tube.

6. Cases: 10. If necessary add clean new oil through the

dipstick tube.
6.1. If the gearbox cases are to be renewed, be
sure to install blanking plugs and adaptors Water Contamination
as required. Inspect the original cases
and identify the blanking plug and adaptor Carefully inspect the gearbox oil for signs of water
positions. Transfer the plugs and adaptors contamination. Contaminated oil will contain water
to the new cases. Apply JCB Threadlocker droplets or be visibly emulsified.
and Sealer to the threads. Note that new
plugs may be supplied with a sealant patch, Water droplets may be visible on the dipstick or
in which case sealant need not be applied. inside the filler tube. For oil analysis purposes, the
maximum permissible water content of the oil is
Consumable: JCB Threadlocker and Sealer
0.10%. If the gearbox oil has been contaminated
(Medium Strength)
with water, faults or damage to the gearbox may
be apparent as a result. Before trying to remedy,
thoroughly investigate and rectify the cause of the
water contamination.

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Check (Pressure)

(For: PS764, PS766) Before you start any of the transmission pressure/
flow test, make sure that the oil level is correct and
Special Tools at normal operating temperature (not less than 50
Description Part No. Qty. °C ( 121.9 °F)).
Flowmeter 892/00229 1
Pressure Gauge (0-40 892/00278 1 Do the these test procedures:
Bar)
• Pump flow test
• Mainline pressure test
To help with fault identification, record the test results
• Converter in pressure
on a check list. The check list will help the engineer to
• Converter relief (safety) valve pressure
identify the cause of a gearbox fault and if needed it
• Converter out pressure and oil cooler flow rate
can be sent to JCB Technical Service by email. Refer
• Lubrication pressure
to Figure 27.
• Clutches- Isolating a suspect clutch
Make sure you follow all safety procedures before • Clutches- Individual clutch leakage test
working on the machine. Refer to (PIL 01-03).

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Figure 21. Test points

A D
H

Item Description
F Reverse high ratio clutch
Table 24. Test points
pressure
Item Description G Reverse low ratio clutch
A Mainline pressure pressure
B Mainshaft clutch pres- H Layshaft clutch pressure
sure J 2/4 wheel drive clutch
C Converter inlet and con- pressure
(1)

verter relief valve pres-

sure (1) Machines with selectable 2/4 wheel drive option.
D Forward high ratio clutch
pressure
E Forward low ratio clutch
pressure

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Mainline pressure 2.1. A low reading can be caused by either

a faulty pressure maintenance valve or a
1. Stop the engine, connect a pressure gauge of the worn pump. Refer to Figure 22.
specified limit to the mainline pressure test point.
2.2. A high or low reading may indicate a
Refer to Figure 22.
faulty pressure maintenance valve. Refer to
Pressure: 0 –20 bar ( 0.0 –289.9 psi) Figure 22.
2. Start engine and run at 1000 RPM (Revolutions 3. Do the 2 again with engine running at 2000 RPM
Per Minute). With the transmission in neutral the note the gauge readings. Refer to Figure 22.
pressure gauge will show the main line pressure.
Refer to Figure 22. 4. Stop engine and remove the test gauge. Refer to
Figure 22.

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Figure 22. Pump flow test

A
L

X Y Z

P
Q
N

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3.5. Connect the flowmeter to the flow and

return adapters (shown with arrows). Refer
Table 25. to Figure 22.
Item Description Special Tool: Flowmeter (Qty.: 1)
A Mainline pressure test
point 4. Start engine and run at 1000 RPM. With the
transmission in neutral the flowmeter will show
K Transmission oil filter
the pump flow. Refer to Figure 22.
L Flowmeter
M Male adapter 4.1. A low reading indicates a worn pump or
N Female adapter blocked suction strainer. Refer to Figure 22.
P Banjo bolt 5. Again do step 4 and note gauge readings with
Q Fitting adapter engine running at 2000 RPM. Refer to Figure 22.
R Pressure test adapter 6. Stop engine and remove test adapters. Remove
the gearbox adapter and install the filter. Refer to
Pump flow (machines with direct mount Figure 22.
oil filter)
Converter in pressure
1. Stop the engine. Clean the area around the
transmission oil filter. Refer to Figure 22. Note that the converter in pressure is affected by
the transmission oil temperature, cooler circuit back
2. Remove the filter and the adapter installed to the
pressure and torque converter relief valve operation.
gearbox. Refer to Figure 22.
Before carrying out tests check the operation of the
3. Install one of the three alternative pump flow relief valve.
test adapters in place of the oil filter. The choice
of adapter is best determined by the ease of 1. Stop the engine, connect a pressure gauge of the
installation and/or accessibility. Refer to Figure specified limit to the converter inlet and converter
22. relief valve pressure test point. Refer to Figure
23.
3.1. Note that adapter type 'z' is installed as Pressure: 0 –20 bar ( 0.0 –289.9 psi)
standard on machines with a remote oil Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
filter. Refer to Figure 22.
3.2. Type 'x': Install the female adapter in the 2. Start engine and run at 1000 RPM. With the
gearbox case. Install the male adapter in transmission in neutral the pressure gauge will
the female adapter. Install the pressure test show the converter in pressure. Refer to Figure
adapter over the female and male adapter. 23.
Install the oil filter to clamp the pressure test 2.1. A low reading could indicate a worn pump,
adapter in place.Refer to Figure 22. a worn pump would also be evident during
3.3. Type 'y': With the component parts a pump flow test. Refer to Figure 23.
assembled, install and secure with banjo 2.2. A high pressure together with low flow could
bolt screwed into the gearbox and tightened be caused by a blocked oil cooler. Refer to
to the correct torque value. Refer to Figure Figure 23.
22.
2.3. Low pressure could be caused by a faulty
3.4. Type 'z': With the component parts pump or internal leakage. Refer to Figure
assembled, install and secure with fitting 23.
adapter screwed into the gearbox, and
tightened to the correct torque value. Refer 3. Stop the engine and remove the pressure test
to Figure 22. gauge. Refer to Figure 23.

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Figure 23. Converter in, converter relief valve pressure tests

S

C Converter inlet and converter relief valve S Load valve

pressure test point

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Converter relief (safety valve) pressure does not indicate a fault. If necessary reset the
load valve and perform the test again, carefully
The purpose of the torque converter relief valve is watch the pressure gauge. Refer to Figure 23.
to protect the torque converter from excessive oil
pressure. Excessive oil pressure can be generated 6. If the converter relief valve opens at a pressure
when the transmission oil temperature is below 50 higher than specified then the valve is faulty.
°C ( 121.9 °F) and/or the engine is run at over 2000 Refer to Figure 23.
RPM. 7. A low opening pressure indicates a leaking pump
to casing seal or a faulty converter relief valve.
In this event the relief valve opens and returns
Refer to Figure 23.
oil directly to the transmission sump, bypassing
the torque converter, cooler and clutch lubrication 8. Stop engine, remove test gauges and the load
circuits, protecting against damage due to excessive valve. Refer to Figure 23.
pressure.
9. Install hoses to their original position. Refer to
For this reason it is essential that the transmission Figure 23.
oil should be more than 50 °C ( 121.9 °F) and the
engine should run between idle and 1000 RPM when Bypassing the converter relief valve
you test the relief valve.
During some powershift pressure and oil flow tests
1. Connect a pressure gauge of the specified limit
it is advisable to temporarily bypass the converter
to the converter inlet and converter relief valve
relief valve. If the relief valve opens at the time of the
pressure test point. Refer to Figure 23.
following tests it will cause false results.
Pressure: 0 –20 bar ( 0.0 –289.9 psi)
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) • Converter out pressure/Oil cooler flow rate
• Converter in pressure
2. Install a load valve into the converter out line. • Lubrication pressure
Make sure the load valve is fully open before • Torque converter stall test
starting the test. Refer to Figure 23.
Before you bypass the torque converter relief valve
3. Do not allow the pressure to exceed more than make sure that the mainline pressure is correct and
the specified value, or else it can damage the that the transmission oil filter is fitted.
converter seals. Refer to Figure 23.
Pressure: 8.3 bar ( 120.3 psi) To temporarily bypass the relief valve (prevent the
valve from opening) proceed as follows:
4. Start the engine and run at 1000 RPM. With the
transmission in neutral, slowly screw down the 1. Stop the engine and remove the relief valve.
load valve and monitor the gauge reading which Refer to Figure 24.
should increase to the converter relief (safety)
valve pressure setting. Refer to Figure 23. 2. Carefully remove the spring. Refer to Figure 24.

5. The gauge pressure will fall, once the valve has 3. Obtain a suitable plug, drill and tap the centre
opened. This is normal relief valve operation and then install a locking bolt. Refer to Figure 24.

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Figure 24. Bypass the converter relief valve

U
T

T Spring U Locking bolt

V Spool

4. Install the plug assembly to the relief valve 2. Do not run the engine at more than 2000 RPM for
housing and tighten the bolt to hold the spool on more than the specified time. Refer to Figure 24.
its seat. Refer to Figure 24. Duration: 1 min
5. Do not damage the spool and its seat. Refer to
Figure 24. When the check is complete make sure to remove
the plug assembly and install the spring and cover/
The torque converter can be damaged when the plug.
converter relief valve is bypassed. To prevent the
torque converter from damage follow the below Converter out pressure and oil cooler
steps. flow rate
1. Before you start the engine make sure that Note that the converter out pressure and oil cooler
the transmission oil temperature is above the flow rate are affected by the torque converter relief
specified value. Refer to Figure 24. valve operation. Before you carry out the test check
Temperature: 50 °C ( 121.9 °F) the operation of the relief valve.

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1. Stop the engine. Connect a pressure gauge cooler flow rate. Make sure that the readings are
of the specified limit and flowmeter into the correct. Refer to Figure 25.
converter out line. Refer to Figure 25.
4.1. A high pressure together with low flow could
Pressure: 0 –20 bar ( 0.0 –289.9 psi) be caused by a blocked oil cooler. Low
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) pressure could be caused by a faulty pump
Special Tool: Flowmeter (Qty.: 1) or internal leakage. Refer to Figure 25.
2. The flowmeter may cause back pressure, so 5. Do the steps 3 and 4 with engine running at 2000
bypass the torque converter relief valve or else RPM and note gauge readings. Refer to Figure
it may open and cause false readings. Refer to 25.
Figure 25.
6. Stop the engine. Remove test gauges and install
3. Run the engine at 1000 RPM with transmission hoses to original position. Refer to Figure 25.
in neutral. Refer to Figure 25.
7. Make sure you remove the torque converter
4. The pressure gauge indicates the converter out relief valve by-pass assembly and install the
pressure and the flowmeter indicates the oil relief valve (ball, spring and cover/plug). Refer to
Figure 25.

Figure 25. Converter out, Lubrication pressure tests

W
L

AA

L Flowmeter W Pressure gauge

AA Pressure gauge connected to the return line
from the oil cooler

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Lubrication pressure park brake on. Therefore, so that we can

complete the test, move the park brake lever
Note that the lubrication pressure is affected by fractionally forward until the warning light is just
the torque converter relief valve operation and back extinguished; hold the lever in this position for the
pressure in the oil cooler circuit. Before you carry out duration of the test.
the test check the operation of the relief valve.
4. Do not move the lever too far forward, otherwise
1. Stop the engine, connect a suitable pressure the park brake will not be fully operational.
gauge into the return line from the oil cooler to Alternatively, disconnect the switch at the park
the transmission. Refer to Figure 25. brake.

2. Start the engine and run at 1000 rev/min. 5. Start engine and run at 1000 RPM, engage1st
With the transmission in neutral the pressure gear forward. Record the pressure reading.
gauge will indicate the lubrication pressure which Repeat the test for all gears in forward drive and
should be correct. Refer to Figure 25. record the pressure readings. Refer to Refer to
Table 26.
3. Do step 2 and note gauge readings with engine
running at 2000 RPM. If the pressure is high the 5.1. Readings should not vary between clutches
oil cooler may be blocked. Refer to Figure 25. by more than the specified value.
Pressure: 0.7 bar ( 10.1 psi)
4. Stop the engine and remove the pressure gauge.
5.2. In the table of examples shown, we can
Isolate a suspect clutch see that pressure is low when 2nd and 4th
gear forward is selected, indicating clutch
1. Stop the engine. Connect a pressure gauge of leakage. Refer to Table 26.
the specified to the mainline pressure test point. 5.3. From the table we can see that the forward
Refer to Figure 26. high clutch is used for selection of both 2nd
Pressure: 0 –20 bar ( 0.0 –289.9 psi) and 4th gear forward.
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1)
5.4. We know from the table that the mainshaft
2. Make sure that both sides of all four wheels are and layshaft clutches are working normally
chocked. Apply the foot brake and park brake. (1st and 3rd gear selection show normal
operating pressure). So we can assume
3. When fully engaged, the park brake electrically that the forward high clutch is leaking.
disconnects the transmission drive, this prevents
the machine from being driven with the 6. If necessary, do the above test again using
reverse clutch ratios.

Table 26.
Gear select Ratio clutch Mainshaft or layshaft Value (Examples Only)
clutch
1st Forward low Layshaft 9.65 bar ( 139.9 psi)
2nd Forward high Layshaft 8.62 bar ( 124.9 psi)
3rd Forward low Mainshaft 9.65 bar ( 139.9 psi)
4th Forward high Mainshaft 8.62 bar ( 124.9 psi)

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Figure 26.
A D

AB

A Mainline pressure (test point) D Forward high ratio clutch pressure (test point)
AB Layshaft clutch solenoid (3029)

Before you carry out individual clutch leakage tests, 4. Make sure that both sides of all four wheels are
we can confirm that the forward high clutch is leaking: chocked. Apply the foot brake and park brake.
Refer to Figure 26.
Individual clutch leakage test 5. When fully engaged, the park brake electrically
In the following procedures the forward high clutch disconnects the transmission drive, this prevents
is tested, therefore in step 2 a pressure gauge is the machine from being driven with the
connected to the forward high clutch test point. park brake on. Therefore, so that we can
complete the test, move the park brake lever
When you test the other suspect clutches, connect fractionally forward until the warning light is just
a gauge to the relevant suspect clutch test point. extinguished; hold the lever in this position for the
Because the forward high clutch is suspect, a gear duration of the test. Refer to Figure 26.
must be selected that will use the forward high clutch, 6. Do not move the lever too far forward, otherwise
in this instance 2nd gear forward. the park brake will not be fully operational.
Alternatively, disconnect the switch at the park
1. Stop the engine. Connect a pressure gauge of
brake. Refer to Figure 26.
the specified to the mainline pressure test point.
Refer to Figure 26. 7. Start engine and run at 1000 RPM, select 2nd
Pressure: 0 –20 bar ( 0.0 –289.9 psi) gear forward. Note the pressure readings on both
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) gauges, which should not vary more than the
specified value. If the difference on the gauges is
2. Connect a pressure gauge of the specified vale greater than the specified value do the following.
to the forward high ratio clutch test point. Refer Refer to Figure 26.
to Figure 26.
Pressure: 0.7 bar ( 10.1 psi)
Pressure: 0 –20 bar ( 0.0 –289.9 psi)
Special Tool: Pressure Gauge (0-40 Bar) (Qty.: 1) 7.1. Stop the engine and interchange the
gauges. Refer to Figure 26.
3. Remove the electrical connector from the
layshaft clutch solenoid. This will ensure that only 7.2. Start the engine and run at 1000 RPM,
the forward high clutch is energised when 2nd select 2nd gear forward. If the difference on
gear forward is selected. Refer to Figure 26. the gauges is still greater than the specified

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value then disassemble the forward high 7.3. If after interchanging the gauges, the
clutch. Refer to Figure 26. readings are different than the value
mentioned in step 7 then calibrate the
Pressure: 0.7 bar ( 10.1 psi)
gauges and again do the check. Refer to
Figure 26.

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Figure 27. Transmission Technical Data Checklist

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Disassemble and Assemble 2. Separate the front and rear case and remove the
clutch shafts.
3. Do not attempt to disassemble the gearbox
(For: PS764, PS766) further until it is safely positioned in a suitable
Special Tools work cradle.
Description Part No. Qty.
4. Separate the front case and remove the clutch
Gearbox Assembly 892/01082 1 shaft assemblies. Refer to (PIL 27-06).
Cradle
5. Remove the transfer gear.
Note: The Disassembly and Assembly procedures
given below illustrate and describe the 6x4 gearbox. Install
Procedures for the 4x4 version of the gearbox
are identical in most respects. Where there are 1. Use suitable lifting equipment and put the rear
differences, procedures are identified under the case of the gearbox in a work cradle.
heading 4x4 Gearbox.
Special Tool: Gearbox Assembly Cradle (Qty.: 1)
With the gearbox removed from the machine, place
1.1. Clamp the gearbox at the three clamping
suitable wooden blocks to securely support the
points on the rear case.
assembly. If the gearbox is installed with an integral
park brake the brake assembly must be removed 2. Do not attempt to assemble the gearbox further
before you disassemble the gearbox. Refer to (PIL until it is safely positioned in a suitable work
27-06). cradle.
Gearboxes compatible with a lock up torque 3. Install the transfer gear.
converter are installed with a control valve and
interconnecting pipe. These components must be 4. Install the clutch shaft assemblies and the front
removed before dismantling the gearbox. case. Refer to (PIL 27-06)
5. If applicable, install the layshaft cover as follows:
Disassemble Refer to Figure 29.
1. If installed, remove the layshaft cover. Refer to Figure 29.
Figure 28.
Figure 28.

B
A
B A Layshaft cover
A B Bolt 1
A Layshaft cover 5.1. Make sure that the case mating faces are
B Bolt 1 clean and not damaged.
1.1. Remove the bolts. 5.2. Apply a thin bead of sealant to the rear case
1.2. Remove the cover. and install the layshaft cover.

1.3. Note: Unless the cases are to be replaced, 5.3. Install the bolts 1.
or the gearbox oil has been contaminated it 5.4. Tighten the bolts 1 to the correct torque
is not necessary to remove the cover. value.

27 - 32 9823/1600-1 27 - 32
 27 - Driveline
06 - Semi-Automatic Gearbox
00 - General

Table 27. Torque Values

Item Description Nm
B Bolt 56

27 - 33 9823/1600-1 27 - 33
 27 - Driveline
06 - Semi-Automatic Gearbox
06 - Clutch - Reverse

06 - Clutch - Reverse Introduction

Introduction .................................................... 27-34 The clutch is a mechanical device that engages
Check (Condition) .......................................... 27-35 and disengages the transmission, from driving shaft
Remove and Install ....................................... 27-35 to driven shaft. The clutch is located between the
Disassemble and Assemble .......................... 27-36 engine and the gearbox, as disengaging it is required
to change gear.

The clutch is operated by a pedal using a hydraulic

or cable connection from the pedal to the clutch
mechanism.

The default state of the clutch is engaged, that is

the connection between the engine and gearbox is
always on unless the driver presses the pedal and
disengages it.

If the engine is running with the clutch engaged

and the transmission in neutral, the engine spins
the input shaft of the transmission, but no power
is transmitted to the wheels. Although the gearbox
does not stop rotating during a gear change, there
is no torque transmitted through it, thus less friction
between gears and their engagement gears.

27 - 34 9823/1600-1 27 - 34
 27 - Driveline
06 - Semi-Automatic Gearbox
06 - Clutch - Reverse

Check (Condition) Remove and Install

Carry out a visual inspection of the friction and The layshaft clutch, 2WD (Two Wheel Drive) / 4WD
counter plates: (Four Wheel Drive) clutch, reverse clutch, main shaft
clutch and forward / input clutch are all part of the
Counter plates main shaft assembly.

1. Light scoring or polishing is permissible, plates Refer to the main shaft remove and install procedure.
that are not flat, worn or heavily marked or scored Refer to (PIL 27-06-54).
must be replaced with a new set.

Friction plates
1. The cross hatching should be clearly visible,
plates that are not flat, have friction material
damage or scoring must be replaced with a new
set.
2. DO NOT mix old and new plates, if a plate is
damaged or worn install a complete new set.
3. Needle roller bearings should slide into position
freely, do not bend or distort the cage to install. If
the cage has been distorted install new bearings.
4. Take care when handling disc springs to avoid
marking or damage, which could result in stress
cracking. If in doubt install a new disc spring.

27 - 35 9823/1600-1 27 - 35
 27 - Driveline
06 - Semi-Automatic Gearbox
06 - Clutch - Reverse

Disassemble and Assemble

(For: PS764, PS766)

Refer to Clutch-Input, Disassembly and Assembly
(PIL 27-06-11).

27 - 36 9823/1600-1 27 - 36
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

07 - Clutch - 2WD/4WD Introduction

Introduction .................................................... 27-37 A clutch is a mechanical device that engages and
Component Identification ............................... 27-38 disengages drive, from driving shaft to driven shaft.
Check (Condition) .......................................... 27-44
Check (Pressure) .......................................... 27-44 Each gear on the gearbox has an associated clutch
which is operated using the applicable solenoid.
Remove and Install ....................................... 27-45
Disassemble and Assemble .......................... 27-49 When the solenoid is engaged fluid is applied to the
clutch to move it into position. When in position the
clutch connects the selected gear with the driven
shaft.

A combination of clutches is often used within the

gearbox to allow different gears to be engaged.

27 - 37 9823/1600-1 27 - 37
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

Component Identification

For: PS764, PS766 ................... Page 27-38

For: PS764, PS766 ................... Page 27-39
For: PS764, PS766 ................... Page 27-41

(For: PS764, PS766)

Figure 30. Pressure ON

G
F
E

F
D
C

M
L

K
J
H U
S

Q
P
N
A

A Bearing 1 B Piston ring seal

C Bearing 2 D Thrust washer 1
E 4WD (Four Wheel Drive)gear and splined hub F Needle roller bearing
G Thrust washer 2 H Circlip 1
J Shim K Pressure end plate
L Friction plate M Counter plate
N Circlip 2 P Spring retaining plate
Q Piston spring R Oil baffle
S Piston T O-ring 1 (Piston)
U O-ring 2 (Shaft)

27 - 38 9823/1600-1 27 - 38
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

(For: PS764, PS766)

Figure 31. S1 Spring ON

E F
L
F
D
C G N
M

U
H2

K
J

S
T
H1
Y
R

W
V

A Bearing 1 B Piston ring seal

C Bearing 2 D Thrust washer
E 4WD gear F Needle roller bearing
G Circlip 1 H1 Disc spring 1
H2 Disc spring 1 J Pressure end plate
K Shim L Friction and counter plates
M Circlip 2 N Support washer
P Clutch drum Q Actuating sleeve
R Disc spring 2 S Piston
T Spring steel ring U O-ring 1
V O-ring 2 W Piston housing
X Shaft Y Spacer

27 - 39 9823/1600-1 27 - 39
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

Figure 32. S2 Spring ON

8

6
4
12
5
3 7
2

11
10
9B 23

17

9A

18
19

20

21

22
13
14

15
16

1 Piston ring seal 2 Bearing 1

3 Thrust washer 1 4 4WD gear
5 Needle roller bearing 1 6 Needle roller bearing 2
7 Thrust washer 2 8 Circlip
9A Disc spring 1 9B Disc spring 1
10 Pressure end plate 11 Shim(s)
12 Friction plates and counter plates 13 Bearing 2
14 Thrust washer 3 15 Piston housing
16 O-ring 1 17 O-ring 2
18 Piston 19 Spring steel ring
20 Disc spring 2 21 Actuating sleeve
22 Clutch drum 23 Shaft

27 - 40 9823/1600-1 27 - 40
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

(For: PS764, PS766)

Figure 33. S1 - 4WD Spring ON

U
M
L
F

E
C
B
A

Q
G

S
H
P
T
N W
V
J1

J2

A Piston ring seal B Taper roller bearing 1

C Thrust washer 1 D Gear and splined hub
E Needle roller bearings F Thick thrust washer
G Taper roller bearing 2 H Locknut
J1 Disc spring J2 Disc spring
K Friction and counter plates retaining circlip L Shims
M Pressure end plate N Friction plates
P Counter plates Q Pressure end plate

27 - 41 9823/1600-1 27 - 41
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

R Piston S O-ring 1
T O-ring 2 U O-ring 3
V Capscrew W Reaction pin

Figure 34. S2 - 4WD Spring ON

8

6
4
12
5
3 7
2

11
10
9B 23

17

9A

18
19

20

21

22
13
14

15
16

1 Piston ring seal 2 Bearing 1

3 Thrust washer 1 4 4WD gear
5 Needle roller bearing 1 6 Needle roller bearing 2
7 Thrust washer 2 8 Circlip
9A Disc spring 1 9B Disc spring 1
10 Pressure end plate 11 Shim(s)
12 Friction plates and counter plates 13 Bearing 2
14 Thrust washer 3 15 Piston housing
16 O-ring 1 17 O-ring 2
18 Piston 19 Spring steel ring
20 Disc spring 2 21 Actuating sleeve

27 - 42 9823/1600-1 27 - 42
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

22 Clutch drum 23 Shaft

Figure 35. S3 - 4WD Spring ON

8

6
4
12
5
3 7
2

11
10
9B 23

17

9A

18
19

20

21

22
13
14

15
16

1 Piston ring seal 2 Bearing 1

3 Thrust washer 1 4 4WD gear
5 Needle roller bearing 1 6 Needle roller bearing 2
7 Thrust washer 2 8 Circlip
9 Disc spring 1 10 Pressure end plate
11 Shim(s) 12 Friction plates and counter plates
13 Bearing 2 14 Thrust washer 3
15 Piston housing 16 O-ring 1
17 O-ring 2 18 Piston
19 Spring steel ring 20 Disc spring 2
21 Actuating sleeve 22 Clutch drum
23 Shaft

27 - 43 9823/1600-1 27 - 43
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

Check (Condition) Check (Pressure)

Do a visual check of the friction and counter plates (For: PS764, PS766, Spring ON)
and gears:
Special Tools
Counter plates Description Part No. Qty.
Hand Pump Pressure 892/00223 1
1. Light scoring or polishing is permissible, plates Test
that are not flat, worn or heavily marked or scored Pressure Test Adaptor 993/59300 1
must be replaced with a new one.
1. Assemble the 2 and 4 wheel drive clutch. Refer to
Friction plates the relevant Clutch- Disassemble and Assemble
procedure (PIL 27-06).
1. The lubrication slots should be clearly visible,
plates that are not flat, have friction material 2. Check the clutch pack end float and adjust
damage or scoring must be replaced with a new as required. Refer to the relevant Clutch -
one. Disassemble and Assemble procedure (PIL
27-06).
2. Do not change individual plates, if a plate is
damaged or worn install a complete new set. 3. Use the service tool (993/59300), insert the
adaptor into the oil gallery in the end of the 2
3. Needle roller bearings should slide into position and 4 wheel drive clutch shaft as shown. Hold the
freely, do not bend or distort the cage to install. If adaptor in position with clamp.
the cage has been distorted install new bearings.
Special Tool: Pressure Test Adaptor (Qty.: 1)
The piston consists of a small check valve. Visually
check the piston to make sure that the ball is in 4. Use the hand pump (892/00223) to pressurise
place and that the seat is free from contamination. the clutch assembly until the gear can be turned
If necessary clean the valve by blowing through with by hand. Note the pressure gauge reading. Do
an air line. Do not use a wire rod (or screwdriver) as not exceed the given value.
it can damage the valve seat. Pressure: 13.8 bar ( 200.0 psi)
Special Tool: Hand Pump Pressure Test (Qty.: 1)
Gears
5. If the pressure gauge reading is between
1. Check the gear teeth for wear, cracking or the given values, then the clutch is operating
damage. correctly and can be installed in the gearbox.
Pressure: 8.6 –9.3 bar ( 124.6 –134.8 psi)
6. If the pressure gauge reading is above the
given value, then check the clutch for assembly
defects, especially the clutch pack end float (the
shim may not be to the correct thickness). Re-
test after checking and rectify assembly defects.
Pressure: 9.3 bar ( 134.8 psi)

27 - 44 9823/1600-1 27 - 44
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

Figure 36. Remove and Install

(For: PS764, PS766)

Special Tools
Description Part No. Qty.
Drive Coupling 892/00812 1
Spanner

Remove
1. Remove the 4WD clutch assembly as follows:
Refer to Figure 37.
Figure 37.
B

D C

H
E
A Adaptor (Part of 993/59300)
B Clamp (Part of 993/59300) F

A Output yoke
B Bolt 1 (If applicable)
C Thick washer (If Bolt 1 is installed)
D Nut
E Bolt 2
F Cover
G O-ring (If installed)
H Oil seal
J 4WD clutch and shaft assembly
1.1. Hold the output yoke with the tool.
Special Tool: Drive Coupling Spanner (Qty.:
1)

27 - 45 9823/1600-1 27 - 45
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

1.2. Either remove the nut or the bolt1 along 1.2. Put the clutch and shaft assembly in the
with the thick washer. The nut or bolt is very housing.
tight and the help of a assistant would be
1.3. Make sure that the front and 4WD case
required.
mating faces are clean and not damaged.
1.3. Remove the yoke
1.4. If applicable install the O-ring to the front
1.4. Remove the bolts 2 (x8) and lift off the cover. case. The O-ring deforms to get positioned
in the recess.
1.5. Make sure to remove the bearing outer cup
from inside the cover. 1.5. For gearbox variants installed with an O-
ring apply a bead of Loctite 509 of the
1.6. If installed, remove the o-ring.
specified thickness to the front case at the
1.7. Remove the output shaft oil seal. Take care locations shown. Refer to Figure 39.
not to damage the seal housing. Dimension: 3 mm
1.8. Lift the 4WD clutch and shaft assembly from
the housing. Figure 39.

1.9. Remove the inner bearing outer cup from

the case. P G
2. Remove the torque converter relief valve as
P
follows: Refer to Figure 38.
Figure 38.
K
L
M P
N

G O-ring
P Loctite 509
1.6. For gearbox variants not installed with O-
ring apply a bead of Loctite 509 of the
specified thickness on the front case at the
locations shown. Refer to Figure 40.
Dimension: 3 mm
K Plug
L Sealing washer
M Spring
N Poppet
2.1. Remove the plug.
2.2. Remove the sealing washer and the spring.
2.3. Remove the poppet.

Install
1. Install the 4WD clutch assembly as follows: Refer
to Figure 41.
1.1. Make sure that the inner bearing outer cup
is correctly installed in the front case.

27 - 46 9823/1600-1 27 - 46
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

Figure 40. Figure 41.

B
P
D C
P
A

H
P E

G
P

P Loctite509
J
1.7. Note that the bead is applied near the inner
or outer edge of the flange as applicable at
positions shown.
1.8. Make sure that the outer bearing outer cup
is correctly installed inside the cover.
1.9. Install the cover with the bolts 2 (x8).
1.10. Tighten the bolts 2 to the correct value.

A Output yoke
B Bolt 1 (If applicable)
C Thick washer (If Bolt 3 is installed)
D Nut
E Bolt 2
F Cover
G O-ring 3 (If installed)
H Oil seal
J 4WD clutch and shaft assembly
2. Measure the 4WD clutch shaft end float. as
follows:
2.1. The end float will be within limits provided
the components are installed correctly.
Rotate the shaft by hand, it should rotate
smoothly.
2.2. Install a bolt to the threaded hole in the end
of the shaft.
2.3. Pull up the bolt a to detect excessive end
float.
2.4. The end float must be within the range
specified.
Dimension: 0.01 –0.16 mm
3. Continue the installation of the 4WD clutch
assembly as follows:

27 - 47 9823/1600-1 27 - 47
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

3.1. Install a new oil seal. Make sure that the

seal is positioned correctly in the housing.
3.2. Install the output yoke.
3.3. As applicable install either the thick washer
and bolt 1 or the stake nut.
3.4. Hold the yoke with the tool.
Special Tool: Drive Coupling Spanner (Qty.:
1)
3.5. Tighten the bolt or nut to the correct torque
value.
3.6. If the stake nut is installed, then stake the
nut with a square ended staking tool.
4. Install the torque converter relief valve as follows:
Refer to Figure 42.
Figure 42.
K
L
M
N

K Plug
L Sealing washer
M Spring
N Poppet
4.1. Install the poppet and the spring.
4.2. Use a new sealing washer and install the
plug.
4.3. Tighten the plug to the correct torque value.

Table 28. Torque Values

Item Description Nm
B Bolt 1 400
D Nut 300
E Bolt 2 56
K Plug 56

27 - 48 9823/1600-1 27 - 48
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

Disassemble and Assemble

For: PS764, PS766, Pressure ON

................................................... Page 27-49
For: PS764, PS766 ................... Page 27-51

(For: PS764, PS766, Pressure ON)

Special Tools
Description Part No. Qty.
Hand Pump Pressure 892/00223 1
Test

Disassemble

Figure 43.
G
F
E

F
D
C

M
L

K
J
H U
S

Q
P
N
A

A Bearing 1 B Piston ring seal

C Bearing 2 D Thrust washer 1
E 4WD gear and splined hub F Needle roller bearing
G Thrust washer 2 H Circlip 1

27 - 49 9823/1600-1 27 - 49
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

J Shim K Pressure end plate

L Friction plate M Counter plate
N Circlip 2 P Spring retaining plate
Q Piston spring R Oil baffle
S Piston T O-ring 1 (Piston)
U O-ring 2 (Shaft)

1. Remove the bearing 1, only if it is required to be 11. Turn the assembly over and knock the clutch
replaced. shaft on a piece of aluminium (or wood) to loosen
the piston.
2. Carefully remove the piston ring seal.
11.1. If the piston does not loosen, then hand
2.1. Note: If the piston ring seal is damaged pump air down the shaft oil inlet hole.
or excessively worn then check for burrs
or damage on shaft grooves. If necessary Special Tool: Hand Pump Pressure Test
remove burrs with a fine grade abrasion (Qty.: 1)
paper and oil. Figure 45.
3. With a puller or press, remove the 4WD gear and
splined hub, together with its bearing 2, needle
roller bearing and thrust washer 1.
4. Remove the thrust washer 2.
4.1. Note the thrust washer 1 and thrust washer
2 are not interchangeable.
5. Remove the circlip 1 that retains the friction and
counter plates.
6. Remove the pressure end plate and shim (If
applicable).
7. Remove the friction plates and the counter
plates.
12. Remove the piston.
7.1. Keep them together in sets, do not mix the
plates with those from other clutches. 13. Remove and discard the piston O-ring 1.

8. Put the clutch assembly in a suitable press. 14. Remove and discard the shaft O-ring 2.

8.1. With a cut away tube compress the piston Assemble

spring and remove the circlip 2.
1. Install the new O-ring 1 onto the piston.
Figure 44.
2. Install the new O-ring 2 onto the shaft.
3. Lubricate the piston with oil and press fully into
the bore of the clutch housing.
4. Install the oil baffle and piston spring. Make sure
that the spring is positioned properly in the piston.
5. Install the spring retaining plate.
6. Compress the spring with a cut away tube and
install the circlip 2.
7. Install one counter plate followed by one friction
plate.
7.1. Continue to install alternate counter and
9. Lift off the spring retaining plate. friction plates, finishing with a friction plate.

10. Remove the spring and oil baffle.

27 - 50 9823/1600-1 27 - 50
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

8. Install the pressure end plate. Make sure the Consumables

chamfered face of the pressure end plate faces Description Part No. Size
the clutch pack. JCB Threadlocker 4101/0250 0.01 L
9. Make sure that the teeth are not aligned with the and Sealer (Medium 4101/0251 0.05 L
lubrication slots in the housing. Strength)

10. Do not install the shim at this stage. This range of gearboxes can be installed with one of
three clutch types, all are 4WD (Four Wheel Drive)
11. Install the friction and counter plate retaining Spring ON.
circlip 1.
12. With a DTI (Dial Test Indicator) measure the end
Disassembly
float of the pressure end plate. The value should 1. Carefully remove the piston ring seal from the
be within the specified range. shaft.
Dimension: 1.9 –2.5 mm
1.1. If the piston ring seal is damaged or
Figure 46. excessively worn then check for burrs or
damage on the shaft grooves. If necessary
remove burrs with a fine grade abrasion
paper and oil.
2. Use a suitable puller or press to remove the 4WD
gear and splined hub together with its taper roller
bearing 1, needle roller bearing and the thrust
washer 1.
2.1. Remove the thick thrust washer.
2.2. Note, the thick thrust washer and thrust
washer1 are not interchangeable.
3. Use a suitable puller or press to remove the taper
13. If it is necessary to adjust the end float to bring it roller bearing 2.
within tolerance, there is a choice of installing a
6.0mm (0.23in) or 6.5mm (0.25in) thick pressure 4. Use an adaptor spanner and a 1/2" square drive
end plate, with either a shim or an extra counter socket to remove the locknut.
plate between the retaining circlip 1 and the Special Tool: Adaptor Spanner (Qty.: 1)
pressure end plate.
5. Use the 4WD output yoke secured in a vice as
14. Use an air line to check the operation of the a holding fixture, to support the clutch assembly
clutch. and prevent it from rotation when torque is
applied.
15. Install the thrust washer 2.
6. Lift off the disc springs.
16. Carefully align the teeth of the clutch plates with
a thin rod (or screwdriver) and install the 4WD 7. Turn the assembly over and remove the friction
gear and splined hub, needle roller bearings and and counter plates retaining circlip.
thrust washer 1.
8. Remove the pressure end plate 1 and shims, if
17. Apply gearbox oil on the clutch end bearing 2 and installed.
press the bearing onto the shaft to seat on the
thrust washer 1. 9. Remove the friction plates and the counter
plates.
18. Install the new piston ring seals.
9.1. Keep them together in sets, do not mix the
(For: PS764, PS766) plates with those from other clutches.

Special Tools 10. Remove the pressure end plate 2.

Description Part No. Qty.
11. Turn the assembly over and knock the clutch
Hand Pump Pressure 892/00223 1 shaft on a piece of aluminium (or wood) to loosen
Test the piston.
Pressure Test Adaptor 993/59300 1
Adaptor Spanner 998/10738 1

27 - 51 9823/1600-1 27 - 51
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

11.1. Match mark the piston and the clutch 11.2. If the piston does not loosen, then hand
housing, to make sure that the piston is pump air down the shaft oil inlet hole.
assembled in the same orientation when Special Tool: Hand Pump Pressure Test
they are assembled again. (Qty.: 1)
Figure 47. 12. Remove the piston.
13. Remove and discard the O-ring 1 and O-ring 2
from the piston.
14. Remove and discard the O-ring 3 from the shaft.
15. If it is necessary to replace, remove the
capscrews and the reaction pins.

27 - 52 9823/1600-1 27 - 52
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

Figure 48. S1 - 4WD Spring ON

U
M
L
F

E
C
B
A

Q
G

S
H
P
T
N W
V
J1

J2

A Piston ring seal B Taper roller bearing 1

C Thrust washer 1 D Gear and splined hub
E Needle roller bearings F Thick thrust washer
G Taper roller bearing 2 H Locknut
J1 Disc spring J2 Disc spring
K Friction and counter plates retaining circlip L Shims
M Pressure end plate N Friction plates
P Counter plates Q Pressure end plate
R Piston S O-ring 1
T O-ring 2 U O-ring 3

27 - 53 9823/1600-1 27 - 53
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

V Capscrew W Reaction pin

Figure 49. S2 - 4WD Spring ON

8

6
4
12
5
3 7
2

11
10
9B 23

17

9A

18
19

20

21

22
13
14

15
16

1 Piston ring seal 2 Bearing 1

3 Thrust washer 1 4 4WD gear
5 Needle roller bearing 1 6 Needle roller bearing 2
7 Thrust washer 2 8 Circlip
9A Disc spring 1 9B Disc spring 1
10 Pressure end plate 11 Shim(s)
12 Friction plates and counter plates 13 Bearing 2
14 Thrust washer 3 15 Piston housing
16 O-ring 1 17 O-ring 2
18 Piston 19 Spring steel ring
20 Disc spring 2 21 Actuating sleeve
22 Clutch drum 23 Shaft

27 - 54 9823/1600-1 27 - 54
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

Figure 50. S3 - 4WD Spring ON

8

6
4
12
5
3 7
2

11
10
9B 23

17

9A

18
19

20

21

22
13
14

15
16

1 Piston ring seal 2 Bearing 1

3 Thrust washer 1 4 4WD gear
5 Needle roller bearing 1 6 Needle roller bearing 2
7 Thrust washer 2 8 Circlip
9 Disc spring 1 10 Pressure end plate
11 Shim(s) 12 Friction plates and counter plates
13 Bearing 2 14 Thrust washer 3
15 Piston housing 16 O-ring 1
17 O-ring 2 18 Piston
19 Spring steel ring 20 Disc spring 2
21 Actuating sleeve 22 Clutch drum
23 Shaft

27 - 55 9823/1600-1 27 - 55
 27 - Driveline
06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

Assembly retaining circlip and the pressure end plate

2.
1. Assemble the reaction pins.
Figure 51.
1.1. If removed then install the reaction pins to
the piston. do the steps below to make sure
that the pins are correctly aligned.
1.2. Put the piston into the bore of the clutch
housing. Do not install any O-rings at this
stage.
1.3. Install each reaction pin in turn from the
opposite end of the housing and secure to
the piston with a capscrew.
1.4. Apply JCB Threadlocker and Sealer to the
threads of the capscrews before you install
them.
Consumable: JCB Threadlocker and Sealer 7. Install the thick thrust washer.
(Medium Strength)
8. Carefully use a thin rod (or screwdriver) to align
1.5. When all four reaction pins are installed, the teeth of the clutch plates.
tighten the capscrews to the specified
torque value. 8.1. Install the 4WD gear, splined hub and the
needle roller bearings.
Torque: 10 –12 N·m
1.6. Match mark the piston and the clutch 9. Install the thrust washer1.
housing to make sure that the piston is 9.1. Apply gearbox oil to the taper roller bearing
assembled in the same orientation. 2 and press the bearing onto the shaft to
1.7. Temporarily remove the piston from the seat on the thrust washer 1.
clutch housing and assemble the clutch
pack. 10. Turn the assembly over and install a new O-ring
3 to the shaft.
2. Install the pressure end plate 2.
10.1. Install a new O-ring 1 and O-ring 2 to the
3. Install one counter plate followed by one friction piston.
plate. 10.2. Lubricate the piston with gearbox oil and
3.1. Continue to install alternate counter and press fully into the bore of the clutch
friction plates, finishing with a friction plate. housing (note the match marks made at
the time of disassembly).
4. Install the pressure end plate 1 but do not install
the shim at this stage. 11. Install the first two disc springs with their concave
sides uppermost (there are four disc springs,
4.1. Make sure that the chamfered face of the which are identical).
pressure end plate faces the clutch pack.
11.1. Place the other two disc springs with their
4.2. Make sure the teeth are not aligned with the concave sides down, on top of the first two
lubrication slots in the housing. as shown.
5. Install the friction and counter plates retaining 12. Use an adaptor spanner and a 1/2" square drive
circlip. socket to install the locknut and tighten the nut to
the correct torque value.
6. Use a DTI to measure the end float of the
pressure end plate. It should be within the Special Tool: Adaptor Spanner (Qty.: 1)
specified limit.
12.1. Note that the locknut is assembled dry
Dimension: 4 –5 mm with no thread lockers or sealant on the
threads.
6.1. If it is necessary to adjust the end float to
bring it within the specified limit mentioned 13. Use the 4WD output yoke secured in a vice as
in step6, Install a 6.0mm (0.23in) or 6.5mm a holding fixture, to support the clutch assembly
(0.25in) pressure end plate1 together with a and prevent it from rotation when torque is
shim or an extra counter plate, between the applied.

27 - 56 9823/1600-1 27 - 56
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06 - Semi-Automatic Gearbox
07 - Clutch - 2WD/4WD

14. Use the pressure test adaptor and clamp

assembly to check the operation of the clutch
assembly.
Special Tool: Pressure Test Adaptor (Qty.: 1)
14.1. Make sure that the clutch fully disengages
at the specified working pressure.
Pressure: 13 bar ( 188.4 psi)
15. Apply gearbox oil to the taper roller bearing 2 and
press the bearing onto the shaft.
16. Install the piston ring seal.

Table 29. Torque Values

Item Description Nm
H Locknut 300

27 - 57 9823/1600-1 27 - 57
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06 - Semi-Automatic Gearbox
08 - Clutch - Layshaft

08 - Clutch - Layshaft Introduction

Introduction .................................................... 27-58 A clutch is a mechanical device that engages and
Component Identification ............................... 27-59 disengages drive, from driving shaft to driven shaft.
Check (Condition) .......................................... 27-61
Calibrate ........................................................ 27-62 Each gear on the gearbox has an associated clutch
which is operated using the applicable solenoid.
Remove and Install ....................................... 27-65
Disassemble and Assemble .......................... 27-66 When the solenoid is engaged fluid is applied to the
clutch to move it into position. When in position the
clutch connects the selected gear with the driven
shaft.

A combination of clutches is often used within the

gearbox to allow different gears to be engaged.

27 - 58 9823/1600-1 27 - 58
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06 - Semi-Automatic Gearbox
08 - Clutch - Layshaft

Component Identification

(For: PS764, PS766)

Figure 52.

L
J2
J1

F
K
H S
C
A

G
D
B

M
R

U
T

X Y Z
V W

27 - 59 9823/1600-1 27 - 59
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06 - Semi-Automatic Gearbox
08 - Clutch - Layshaft

Table 30.
Item Description
A Piston ring seals
B Taper roller bearing 1
C Circlip 1
D 4 wheel drive transfer
gear
E Gear and splined hub
F Thin thrust washers 1
G Thrust bearing 1
H Needle roller bearings
J1 Thin thrust washer 2
J2 Thin thrust washer 3
K Thrust bearing 2
L Thick thrust washer
M Taper roller bearing 2
N Friction and counter
plates retaining circlip
P Pressure end plate
Q Shim
R Friction plates
S Counter plates
T Circlip 2
U Spring retaining plate
V Spring
W Oil baffle
X Piston
Y O-ring 1
Z O-ring 2

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06 - Semi-Automatic Gearbox
08 - Clutch - Layshaft

Check (Condition)

Do a visual check of the friction and counter plates:

Counter plates
1. Light scoring or polishing is permissible, plates
that are not flat, worn or heavily marked or scored
must be replaced with a new one.

Friction plates
1. The cross hatching should be clearly visible,
plates that are not flat, have friction material
damage or scoring must be replaced with a new
one.
2. Do not change individual plates, if a plate is
damaged or worn install a complete new set.
3. Needle roller bearings should slide into position
freely, do not bend or distort the cage to install. If
the cage has been distorted install new bearings.

The piston consists of a small check valve. Visually

check the piston to make sure that the ball is in
place and that the seat is free from contamination.
If necessary clean the valve by blowing through with
an air line. Do not use a wire rod (or screwdriver) as
it can damage the valve seat.

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06 - Semi-Automatic Gearbox
08 - Clutch - Layshaft

Calibrate

.............................................. Page 27- Later clutch assemblies feature an additional thin

For: PS764, PS766 ................... Page 27-62 thrust washer. If any of the components listed below
are to be replaced, the end float of gear must be
measured and reset as required:
End float measurement
• Shaft assembly
1. Use a DTI (Dial Test Indicator) to measure the
• Gear and plate carrier assembly
end float of the pressure end plate.
• Thin thrust washers1
2. The end float should be within the specified limit. • Thin thrust washer2 and thin thrust washer3
• 4 wheel drive (WD) transfer gear or spacer as
Dimension: 1.9 –2.5 mm applicable
Figure 53. Measure the end float as follows:

1. Temporarily install thick thrust washer, thin

thrust washer3, thrust bearing2 and thin thrust
washer2.
2. Install the needle roller bearing.
A
3. Temporarily install the gear and plate carrier
assembly.
4. Install the thin thrust washer1 and thrust bearing1
followed by the remaining thrust washer1.
5. Temporarily install the 4WD transfer gear 4 onto
the layshaft spline. Make sure that the gear is
installed in the correct orientation.
5.1. 2 wheel drive machines have a spacer
installed instead of a gear.
6. Install the circlip1.

A DTI 7. Make sure that the 4 wheel drive gear (or spacer)
is fully seated against circlip1.
3. If the end float is more than the specified value
then install a 6.0mm (0.23in) or 6.5mm (0.25in) 8. Measure the end float of gear.
thick pressure end plate, with either a shim or an
extra counter plate between the retaining circlip 9. The end float should be within the specified
and the pressure end plate. range.
Dimension: 0.01 –0.15 mm
4. Use an air line to check the operation of the
clutch. 10. If the end float is to be adjusted select a suitable
thrust washer from the spacer kit and again
(For: PS764, PS766) assemble the components given in steps 1 to 6.
Special Tools Special Tool: Thrust Washer Kit (Qty.: 1)
Description Part No. Qty. 11. Measure the end float again and assemble the
Thrust Washer Kit 823/10420 1 clutch assembly.

End Float Setting - Plate Carrier and Gear 12. Make sure you install the correct thick thrust
washer on final assembly.
Note: The following procedure is only applicable to
clutch assemblies fitted with thin thrust washer3.

27 - 62 9823/1600-1 27 - 62
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06 - Semi-Automatic Gearbox
08 - Clutch - Layshaft

Figure 54.
L
J2
J1

F
K
H S
C
A

G
D
B

M
R

U
T

X Y Z
V W

A Piston ring seals B Taper roller bearing1

C Circlip1 D 4 wheel drive transfer gear
E Gear and splined hub F Thin thrust washers1
G Thrust bearing1 H Needle roller bearings
J1 Thin thrust washer2 J2 Thin thrust washer3
K Thrust bearing2 L Thick thrust washer
M Taper roller bearing2 N Friction and counter plates retaining circlip
P Pressure end plate Q Shim

27 - 63 9823/1600-1 27 - 63
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06 - Semi-Automatic Gearbox
08 - Clutch - Layshaft

R Friction plates S Counter plates

T Circlip2 U Spring retaining plate
V Spring W Oil baffle
X Piston Y O-ring1
Z O-ring2

27 - 64 9823/1600-1 27 - 64
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06 - Semi-Automatic Gearbox
08 - Clutch - Layshaft

Remove and Install

The layshaft clutch, 2WD (Two Wheel Drive) / 4WD

(Four Wheel Drive) clutch, reverse clutch, mainshaft
clutch and forward / input clutch are all part of the
mainshaft assembly.

Refer to the mainshaft remove and install procedure.

Refer to (PIL 27-06-54).

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06 - Semi-Automatic Gearbox
08 - Clutch - Layshaft

Disassemble and Assemble

(For: PS764, PS766) 9. Remove the pressure end plate and shim, if
installed.
Special Tools
Description Part No. Qty. 10. Remove the friction plates and the counter
Hand Pump Pressure 892/00223 1 plates.
Test
10.1. Keep them together in sets, do not mix the
plates with those from other clutches.
The illustration shows a main shaft assembly for a 6
speed gearbox. The main shaft assembly for 4 speed 11. Put the clutch assembly in a suitable press.
gearboxes has some small differences. Procedures
are applicable for both 4 and 6 speed variants. 11.1. With a cut away tube compress the piston
spring and then remove the circlip 2.
Disassembly Figure 55.
1. Carefully remove the piston ring seals.
1.1. If the piston ring seals are excessively worn
then check for burrs or damage on the shaft
grooves. If necessary remove burrs with a
fine grade abrasion paper and oil.
2. Remove the taper roller bearing 1 with a suitable
puller and press.
3. Remove the circlip 1 and remove the 4 wheel
drive(4WD) transfer gear.
3.1. Make a note in which orientation the gear is
installed for assembly.
3.2. The 2 wheel drive (2WD) machines have a
spacer installed instead of a gear. 12. Lift off the spring retaining plate.
4. Remove the gear and the splined hub together 13. Remove the spring and oil baffle.
with the thin thrust washer1 and thrust bearing1.
14. Turn the assembly over and knock the clutch
5. Remove the two needle roller bearing shaft on a piece of aluminium (or wood) to loosen
assemblies. the piston.
5.1. 4-speed transmissions have only one 14.1. If the piston does not loosen, then hand
needle roller bearing installed. pump air down the shaft oil inlet hole.
6. Remove the thin thrust washer 2, thrust bearing Special Tool: Hand Pump Pressure Test
2, thin thrust washer 3 (if installed) and thick (Qty.: 1)
thrust washer 1.
Figure 56.
7. Use a puller to remove the taper roller bearing 2.
7.1. It must be discarded and replaced.
7.2. This bearing would not normally be
removed unless it was damaged.
7.3. If a collet tool is not available, then it
is permissible to use a standard bearing
puller, although it can damage the bearing
cage which will require a new bearing.
8. Remove the friction and counter plates retaining
circlip.

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06 - Semi-Automatic Gearbox
08 - Clutch - Layshaft

15. Remove the piston. 17. Remove and discard the shaft O-ring 2.
16. Remove and discard the piston O-ring 1.

Figure 57.

L
J2
J1

F
K
H S
C
A

G
D
B

M
R

U
T

X Y Z
V W

27 - 67 9823/1600-1 27 - 67
 27 - Driveline
06 - Semi-Automatic Gearbox
08 - Clutch - Layshaft

Figure 58.

Table 31.
Item Description
A Piston ring seals
B Taper roller bearing 1
C Circlip 1
D 4 wheel drive transfer
gear
E Gear and splined hub
F Thin thrust washers 1
G Thrust bearing 1
H Needle roller bearings
J1 Thin thrust washer 2
J2 Thin thrust washer 3
7. Install one counter plate followed by one friction
K Thrust bearing 2 plate.
L Thick thrust washer
M Taper roller bearing 2 7.1. Continue to install alternate counter and
friction plates, finishing with a friction plate.
N Friction and counter
plates retaining circlip 8. Install the pressure end plate. Make sure that the
P Pressure end plate chamfered face of the pressure end plate faces
Q Shim the clutch pack.
R Friction plates 9. Make sure that the teeth are not aligned with the
S Counter plates lubrication slots in the housing.
T Circlip 2
10. A spring disc is not installed in this clutch pack.
U Spring retaining plate
V Spring 11. Do not install the shim at this stage.
W Oil baffle 12. Install the friction and counter plate retaining
X Piston circlip.
Y O-ring 1
13. Use a DTI (Dial Test Indicator) to measure the
Z O-ring 2
end float of the pressure end plate. The value
should be within the specified range.
Assembly
Dimension: 1.9 –2.5 mm
1. Install the new O-ring 1 onto the piston.
Figure 59.
2. Install the new O-ring 2 onto the shaft.
3. Lubricate the piston with oil and press fully into
the bore of the clutch housing.
4. Install the oil baffle and piston spring. Make
sure that the spring is positioned correctly in the
piston.
5. Install the spring retaining plate.
6. Compress the spring with a cut away tube and
install the circlip 2.

14. If it is necessary to adjust the end float to

bring it within tolerance, there is a choice of
installing a 6.0mm (0.23in) or 6.5mm (0.25in)
thick pressure end plate, with either a shim or an
extra counter plate between the retaining circlip
and the pressure end plate.

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06 - Semi-Automatic Gearbox
08 - Clutch - Layshaft

15. Use an airline to check the operation of the

clutch.
16. Install the thick thrust washer 1, thin thrust
washer 3, thrust bearing 2 and the thin thrust
washer 2.
17. Install the two needle roller bearing assemblies.
17.1. 4-speed transmissions have only one
needle roller bearing installed.
18. Carefully align the teeth of the clutch plates using
a thin rod (or screwdriver) and install the gear and
splined hub.
19. Install the thin thrust washer 1 and thrust bearing
1.
20. Install the 4 wheel drive transfer gear onto
the layshaft spline. Make sure that the gear is
installed in the correct orientation.
20.1. 2 wheel drive machines have a spacer
installed instead of a gear.
20.2. Install the circlip 1.
21. Apply gearbox oil on the taper roller bearing
1 and taper roller bearing 2 then push both
bearings onto the shaft.
22. Install new piston ring seals.

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06 - Semi-Automatic Gearbox
09 - Clutch - Main Shaft

09 - Clutch - Main Shaft Introduction

Introduction .................................................... 27-70 A clutch is a mechanical device that engages and
Component Identification ............................... 27-71 disengages drive, from driving shaft to driven shaft.
Check (Condition) .......................................... 27-73
Remove and Install ....................................... 27-73 Each gear on the gearbox has an associated clutch
which is operated using the applicable solenoid.
Disassemble and Assemble .......................... 27-74
When the solenoid is engaged fluid is applied to the
clutch to move it into position. When in position the
clutch connects the selected gear with the driven
shaft.

A combination of clutches is often used within the

gearbox to allow different gears to be engaged.

27 - 70 9823/1600-1 27 - 70
 27 - Driveline
06 - Semi-Automatic Gearbox
09 - Clutch - Main Shaft

Component Identification

(For: PS764, PS766)

Figure 60.

D
C

L
B M1
N
S
P

A Q
V R
T
M2
J

E
F
G
H

A Piston ring seals B Taper roller bearing 1

C Gear 1 D Gear 2
E Taper roller bearing 2 F Circlip 1
G Pressure end plate H Shim

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06 - Semi-Automatic Gearbox
09 - Clutch - Main Shaft

J Friction plate K Counter plate

L Circlip 2 M1 Spring retaining plate (6 speed gearbox)
M2 Spring retaining plate (4 speed gearbox) N Spring
P Oil baffle Q Piston
R Piston O-ring S Shaft O-ring
T Circlip 3 U Clutch housing
V O-ring 1

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06 - Semi-Automatic Gearbox
09 - Clutch - Main Shaft

Check (Condition) Remove and Install

Do a visual check of the friction and counter plates: The layshaft clutch, 2WD / 4WD clutch, reverse
clutch, mainshaft clutch and forward / input clutch are
Counter plates all part of the mainshaft assembly.

1. Light scoring or polishing is permissible, plates Refer to the mainshaft remove and install procedure.
that are not flat, worn or heavily marked or scored Refer to (PIL 27-06-54).
must be replaced with a new one.

Friction plates
1. The cross hatching should be clearly visible,
plates that are not flat, have friction material
damage or scoring must be replaced with a new
one.
2. Do not change individual plates, if a plate is
damaged or worn install a complete new set.
3. Needle roller bearings should slide into position
freely, do not bend or distort the cage to install. If
the cage has been distorted install new bearings.

The piston consists of a small check valve. Visually

check the piston to make sure that the ball is in
place and that the seat is free from contamination.
If necessary clean the valve by blowing through with
an air line. Do not use a wire rod (or screwdriver) as
it can damage the valve seat.

27 - 73 9823/1600-1 27 - 73
 27 - Driveline
06 - Semi-Automatic Gearbox
09 - Clutch - Main Shaft

Disassemble and Assemble

(For: PS764, PS766) The illustration shows a main shaft assembly for a 6
speed gearbox. The main shaft assembly for 4 speed
Special Tools gearboxes has some small differences. Procedures
Description Part No. Qty. are applicable for both 4 and 6 speed variants.
Hand Pump Pressure 892/00223 1
Test

27 - 74 9823/1600-1 27 - 74
 27 - Driveline
06 - Semi-Automatic Gearbox
09 - Clutch - Main Shaft

Disassemble

Figure 61.

D
C

L
B M1
N
S
P

A Q
V R
T
M2
J

E
F
G
H

A Piston ring seals B Taper roller bearing 1

C Gear 1 D Gear 2
E Taper roller bearing 2 F Circlip 1
G Pressure end plate H Shim
J Friction plate K Counter plate
L Circlip 2 M1 Spring retaining plate (6 speed gearbox)
M2 Spring retaining plate (4 speed gearbox) N Spring

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06 - Semi-Automatic Gearbox
09 - Clutch - Main Shaft

P Oil baffle Q Piston

R Piston O-ring S Shaft O-ring
T Circlip 3 U Clutch housing
V O-ring 1

1. Carefully remove the piston ring seals. 11. Turn the assembly over and knock the clutch
shaft on a piece of aluminium (or wood) to loosen
1.1. If the piston ring seals are excessively worn the piston.
then check for burrs or damage on shaft
grooves. If necessary remove burrs with a 11.1. If the piston does not loosen, then hand
fine grade abrasion paper and oil. pump air down the shaft oil inlet hole.
2. Use a puller or press to remove the taper roller Special Tool: Hand Pump Pressure Test
bearing 1. (Qty.: 1)

3. Remove gear 1 and gear 2. Before removal make Figure 63.

a record of the orientation of the gears.
4. From the opposite end of the shaft remove the
taper roller bearing 2 with a suitable puller.
5. Remove the circlip 1 that retains the friction and
counter plates.
6. Remove the pressure end plate and the shims (If
applicable).
7. Remove the friction plates and counter plates.
7.1. Keep them together in sets, do not mix the
plates with those from other clutches.

CAUTION! The spring (or springs) apply

considerable force. Make sure you take care to 12. Remove the piston.
avoid damage or injury.
13. Remove and discard the piston O-ring.
8. Put the clutch assembly in a suitable press.
14. Remove and discard the shaft O-ring.
8.1. With a cut away tube compress the piston
15. Remove the circlip 3 and the remove the clutch
spring and remove the circlip 2.
housing from the shaft.
Figure 62.
16. Remove and discard the O-ring 1.

Assemble
1. Install the new O-ring 1.
2. Press the clutch housing onto the shaft spline
and install the circlip 3.
3. Install the new piston and shaft O-rings.
4. Lubricate the piston with oil and press fully into
the bore of the clutch housing.
5. Install the oil baffle and piston spring. Make sure
that the spring seats in the piston correctly.
6. Install the spring retaining plate. The 4 speed
9. Remove the spring retaining plate. The 4 speed transmissions have a different shaped spring
transmissions have a different shaped spring retaining plate installed.
retaining plate installed.
7. Compress the spring with a cut away tube and
10. Remove the spring and oil baffle. install the circlip 2.

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06 - Semi-Automatic Gearbox
09 - Clutch - Main Shaft

8. Install one counter plate followed by one friction

plate.
8.1. Continue to install alternate counter and
friction plates, finishing with a friction plate.
9. Install the pressure end plate. Make sure that the
chamfered face of the pressure end plate faces
the clutch pack.
10. Make sure that the teeth are not aligned with the
lubrication slots in the housing.
11. Do not install the shim at this stage.
12. Install the friction and counter plate retaining
circlip 1.
13. Use a DTI (Dial Test Indicator) to measure the
end float of the pressure end plate. The value
should be within the specified range.
Length/Dimension/Distance: 1.9 –2.5 mm
Figure 64.

14. If it is necessary to adjust the end float to bring it

within tolerance, there is a choice of installing a
6.0mm (0.23in) or 6.5mm (0.25in) thick pressure
end plate, with either a shim or an extra counter
plate between the retaining circlip 1 and the
pressure end plate.
15. Use an air line to check the operation of the
clutch.
16. Apply gearbox oil onto the taper roller bearing 2
and press the bearing onto the shaft.
17. At the opposite end of the shaft press gear 1 and
gear 2 onto the shaft spline.
18. Make sure that the gears are installed in their
correct orientation.
19. Apply gearbox oil onto the taper roller bearing 1
and press the bearing onto the shaft.
20. Install new piston ring seals.

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06 - Semi-Automatic Gearbox
10 - Clutch - 6 Speed

10 - Clutch - 6 Speed Introduction

Introduction .................................................... 27-78 A clutch is a mechanical device that engages and
Component Identification ............................... 27-79 disengages drive, from driving shaft to driven shaft.
Check (Condition) .......................................... 27-81
Disassemble and Assemble .......................... 27-82 Each gear on the gearbox has an associated clutch
which is operated using the applicable solenoid.

When the solenoid is engaged fluid is applied to the

clutch to move it into position. When in position the
clutch connects the selected gear with the driven
shaft.

A combination of clutches is often used within the

gearbox to allow different gears to be engaged.

27 - 78 9823/1600-1 27 - 78
 27 - Driveline
06 - Semi-Automatic Gearbox
10 - Clutch - 6 Speed

Component Identification

Figure 65.

AA

C N
Q
P
B

A
R

S
U
V

A
D
F
G
H
L
J
M

E
K

A Piston ring seal B Taper roller bearing

C Gear 1 D Clutch end bearing
E Splined hub F Thick thrust washer 1
G Thrust bearing 1 H Thin thrust washer 1
J Needle roller bearing K Thin thrust washer 2

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06 - Semi-Automatic Gearbox
10 - Clutch - 6 Speed

L Thrust bearing 2 M Thick thrust washer 2

N Circlip 1 P Pressure end plate
Q Shim R Friction plates
S Counter plates T Disc spring
U Circlip 2 V Spring retaining plate
W Spring X Oil baffle
Y Piston Z Piston O-ring
AA Shaft O-ring

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 27 - Driveline
06 - Semi-Automatic Gearbox
10 - Clutch - 6 Speed

Check (Condition)

Do a visual check of the friction and counter plates:

Counter Plates
1. Counter plates- light scoring or polishing is
permissible, plates that are not flat, worn or
heavily marked or scored must be replaced with
a new one.

Friction Plates
1. The cross hatching should be clearly visible,
plates that are not flat, have friction material
damage or scoring must be replaced with a new
one.
2. Do not change individual plates, if a plate is
damaged or worn install a complete new set.
3. Needle roller bearings should slide into position
freely, do not bend or distort the cage to install. If
the cage has been distorted install new bearings.

The piston consists of a small check valve. Visually

check the piston to make sure that the ball is in
place and that the seat is free from contamination.
If necessary clean the valve by blowing through with
an air line. Do not use a wire rod (or screwdriver) as
it can damage the valve seat.

27 - 81 9823/1600-1 27 - 81
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06 - Semi-Automatic Gearbox
10 - Clutch - 6 Speed

Disassemble and Assemble

Disassembly 11. Remove the friction plates and the counter

plates. Keep them together in a set.
1. Carefully remove the piston ring seals from each
end of the shaft. 12. Do not mix the plates with those from other
clutches assemblies.
2. If the piston ring seals are excessively worn
then check for burrs or damage on the shaft 13. Remove the disc spring.
grooves. If necessary remove burrs with a fine
grade abrasion paper and oil. 14. Put the clutch assembly in a suitable press to
compress the piston spring, then remove the
3. Use a collet tool to push and remove the taper circlip 2.
roller bearing.
15. Lift off the spring retaining plate.
4. Remove the gear and make a note of, in which
orientation the gear is installed. 16. Remove the spring and the oil baffle.

5. Use a puller to remove the clutch end bearing 17. Turn the assembly over and hit the clutch shaft
from the opposite end. gently on a piece of aluminium (or wooden) block
to loosen the piston.
6. Remove the gear and the splined hub together
with the thick thrust washer 1, thin thrust washer 18. If the piston does not loosen when you hit the
1 and the thrust bearing 1. clutch shaft then hand pump air down the shaft
oil inlet hole.
7. Remove the needle roller bearing.
19. Remove the piston.
8. Remove the thin thrust washer 2, thrust bearing
2 and the thick thrust washer 2. 20. Remove the piston O-ring and the shaft O-ring.

9. Remove the friction and the counter plate Before you assemble the clutch assembly check
retaining circlip 1. the condition of the clutch assembly. Refer to
Semi- Automatic Gearbox, Clutch- 6 Speed, Check
10. If installed, remove the pressure end plate and Condition (PIL 27-06-10).
shims.

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06 - Semi-Automatic Gearbox
10 - Clutch - 6 Speed

Figure 66.

AA

C N
Q
P
B

A
R

S
U
V

A
D
F
G
H
L
J
M

E
K

A Piston ring seal B Tapper roller bearing

C Gear 1 D Clutch end bearing
E Splined hub F Thick thrust washer 1
G Thrust bearing 1 H Thin thrust washer 1
J Needle roller bearing K Thin thrust washer 2
L Thrust bearing 2 M Thick thrust washer 2
N Circlip 1 P Pressure end plate
Q Shim R Friction plates

27 - 83 9823/1600-1 27 - 83
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06 - Semi-Automatic Gearbox
10 - Clutch - 6 Speed

S Counter plates T Disc spring

U Circlip 2 V Spring retaining plate
W Spring X Oil baffle
Y Piston Z Piston O-ring
AA Shaft O-ring

27 - 84 9823/1600-1 27 - 84
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06 - Semi-Automatic Gearbox
10 - Clutch - 6 Speed

Assembly 16. Use an air line to check the operation of the

clutch.
1. Install both the piston O-ring and the shaft O-ring.
17. Install the thick thrust washer 2, thrust bearing 2,
2. Lubricate the piston with hydraulic oil and push and the thin thrust washer 2.
fully into the bore of the clutch housing.
18. Install the needle roller bearing.
3. Install the oil baffle and the piston spring. Make
sure that the spring seats in the piston. 19. Carefully use a thin rod (or screwdriver) to align
the teeth of the clutch plates.
4. Install the spring retaining plate.
20. Install the gear and splined hub.
5. Compress the spring and install the circlip 2.
21. Install the thin thrust washer 1, thrust bearing 1
6. If applicable, install the disc spring assembly. and the thick thrust washer 1.
7. Make sure that the disc spring is installed with 22. Smear the clutch end bearing with gearbox oil
the teeth facing towards the clutch pack. and push the bearing onto the shaft.
8. Make sure that the teeth are not aligned with the 23. At the opposite end, push the gear onto the shaft
lubrication slots in the housing. spline. Make sure that the gear is installed in the
correct orientation.
9. Install the counter plates and friction plates
alternately, starting with a counter plate and finish 24. Smear the tapper roller bearing with gearbox oil
with a friction plate. and push the bearing onto the shaft.
10. Install the pressure end plate. Do not install the 25. Install new piston ring seals at each end of the
shims at this stage. shaft.
11. Make sure that the chamfered face is installed, Refer to: PIL 27-06-45.
facing the clutch pack.
12. Make sure that the teeth are not aligned with the
lubrication slots in the housing.
13. Install the clutch friction and counter plate
retaining circlip 1.
14. Use a DTI (Dial Test Indicator) to measure the
end float of the pressure end plate and it should
be within the specified limit.
Dimension: 1.9 –2.5 mm
Figure 67.

15. If it is necessary to adjust the end float to bring

it within specified limit mentioned in step 14,
Install a 6.0mm (0.23in) or 6.5mm (0.25in) thick
pressure end plate together with a shim or an
extra counter plate, between the retaining circlip
and the pressure end plate.

27 - 85 9823/1600-1 27 - 85
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06 - Semi-Automatic Gearbox
11 - Clutch - Forward (Input)

11 - Clutch - Forward (Input) Introduction

Introduction .................................................... 27-86 A clutch is a mechanical device that engages and
Component Identification ............................... 27-87 disengages drive, from driving shaft to driven shaft.
Clean ............................................................. 27-89
Check (Condition) .......................................... 27-89 Each gear on the gearbox has an associated clutch
which is operated using the applicable solenoid.
Remove and Install ....................................... 27-90
Disassemble and Assemble .......................... 27-91 When the solenoid is engaged fluid is applied to the
clutch to move it into position. When in position the
clutch connects the selected gear with the driven
shaft.

A combination of clutches is often used within the

gearbox to allow different gears to be engaged.

27 - 86 9823/1600-1 27 - 86
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06 - Semi-Automatic Gearbox
11 - Clutch - Forward (Input)

Component Identification

(For: PS764, PS766)

Figure 68.

L
J X Y
W

C E
A

P
H
A K

G F V
D U
T R
S
A B
R
N

S
Y T
U
V H
J
Q P
W
M

L
M
N
Q Z

AB

AA
AC
AF
AD
AE

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06 - Semi-Automatic Gearbox
11 - Clutch - Forward (Input)

Table 32.
Item Description
A Piston ring seal 1 (For-
ward and reverse clutch
only)
B Clutch end bearing 1
C Gear
D Thrust bearing 1
E Thin thrust washer 1
F Gear and splined hub 1
G Needle roller bearing 1
H Thick thrust washer 1
J Thrust bearing 2
K Thin thrust washer 2
L Friction and counter
plate retaining circlip
M Shim
N Pressure end plate
P Friction plates
Q Counter plates
R Disc spring assembly
S Circlip 2
T Spring retaining plate
U Spring
V Oil baffle
W Piston
X Piston O-ring
Y Shaft O-ring
Z Piston ring seal 2
AA Clutch end bearing 2
AB Thick thrust washer 2
AC Thrust bearing 3
AD Thin thrust washer 3
AE Gear and splined hub 2
AF Needle roller bearing 2

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06 - Semi-Automatic Gearbox
11 - Clutch - Forward (Input)

Clean Check (Condition)

Consumables
Description Part No. Size Carry out a visual inspection of the friction and
Surface Cleaning Fluid 4103/1204 1L counter plates:

1. Carefully remove all traces of gasket or gasket Counter plates

compound from the front and rear case mating
faces. 1. Light scoring or polishing is permissible, plates
that are not flat, worn or heavily marked or scored
1.1. Use a gasket removal product such as must be replaced with a new set.
Loctite Chisel when you remove the gasket
compound. Friction plates
1.2. Make sure that the mating faces are not 1. The cross hatching should be clearly visible,
damaged. plates that are not flat, have friction material
1.3. Clean the mating faces with a fine damage or scoring must be replaced with a new
carborundum paper. set.
1.4. Use a solvent cleaner and a clean cloth to 2. DO NOT mix old and new plates, if a plate is
finally remove all traces of oil or debris. damaged or worn install a complete new set.
Consumable: Surface Cleaning Fluid 3. Needle roller bearings should slide into position
2. Use a suitable degreasing agent to clean the freely, do not bend or distort the cage to install. If
inside of the case. the cage has been distorted install new bearings.
4. Take care when handling disc springs to avoid
marking or damage, which could result in stress
cracking. If in doubt install a new disc spring.

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06 - Semi-Automatic Gearbox
11 - Clutch - Forward (Input)

Remove and Install

The layshaft clutch, 2WD / 4WD clutch, reverse

clutch, mainshaft clutch and forward / input clutch are
all part of the mainshaft assembly.

Refer to the mainshaft remove and install procedure.

Refer to (PIL 27-06-54).

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06 - Semi-Automatic Gearbox
11 - Clutch - Forward (Input)

Disassemble and Assemble

(For: PS764, PS766) Figure 69.

Special Tools
Description Part No. Qty.
Hand Pump Pressure 892/00223 1
Test

This procedure is the same for the input and reverse

clutch assemblies. If there are any differences it will
be identified in the procedure.

Disassembly
The illustrations show a reverse clutch assembly for
a 6 speed gearbox. 4 speed gearbox clutches have
fewer friction and counter plates. Procedures are
applicable for both 4 and 6 speed variants.
11. Lift off the spring retaining plate.
1. Carefully remove the piston ring seals 1.
12. Remove the spring and the oil baffle.
1.1. If the piston ring seals are excessively worn
then check for burrs or damage on the shaft 13. Turn the assembly over and knock the clutch
grooves. If necessary remove burrs with a shaft on a piece of aluminium (or wood) to loosen
fine grade abrasion paper and oil. the piston.

1.2. The input shaft does not have piston ring 13.1. If the piston does not loosen, then hand
seals installed at this end of the shaft. pump air down the shaft oil inlet hole.

2. Use a suitable puller and press to remove the Special Tool: Hand Pump Pressure Test
clutch end bearing 1 and the gear. (Qty.: 1)

3. Remove the thrust bearing 1 and thin thrust Figure 70.

washer 1.
4. Remove the gear and splined hub 1 assembly
with the needle roller bearing 1.
5. Remove the thrust bearing 2, thick thrust washer
1 and thin thrust washer 2.
6. Remove the friction and counter plates retaining
circlip.
7. If installed, remove the pressure end plate and
shim.
8. Remove the friction plates and counter plates.
8.1. Keep them together in sets, do not mix the
plates with those from other clutches. 14. Remove the piston.

9. If installed, remove the disc spring assembly. 15. Remove and discard the piston O-ring 1.

10. Put the clutch assembly in a suitable press. 16. Remove and discard the shaft O-ring 2.

10.1. With a cut away tube compress the piston 17. To disassemble the opposite clutch, carefully
spring and then remove the circlip 2. remove the piston ring seals 2.
17.1. The input shaft has four piston ring seals
installed at this end of the shaft.

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06 - Semi-Automatic Gearbox
11 - Clutch - Forward (Input)

18. Loosen the clutch end bearing 2 and use a 20. Remove the gear and splined hub 2 assembly
suitable puller to remove it. with the needle roller bearing 2.
19. Remove the thrust bearing 3, thick thrust washer 21. Do the steps 5 to 16 to disassemble the opposite
2 and thin thrust washer 3. side clutch assembly.

Figure 71.

L
J X Y
W

C E
A

P
H
A K

G F V
D U
T R
S
A B
R
N

S
Y T
U
V H
J
Q P
W
M

L
M
N
Q Z

AB

AA
AC
AF
AD
AE

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06 - Semi-Automatic Gearbox
11 - Clutch - Forward (Input)

7.1. Make sure that the disc spring is installed

Table 33. with the teeth towards the clutch pack.
Item Description 7.2. Make sure that the teeth are not aligned with
A Piston ring seal1 (For- the lubrication slots in the housing.
ward and reverse clutch
only) 7.3. In PS760 variant no disc spring is installed.
B Clutch end bearing 1 8. Install one counter plate followed by one friction
C Gear plate.
D Thrust bearing 1 8.1. Continue to install alternate counter and
E Thin thrust washer 1 friction plates, finishing with a friction plate.
F Gear and splined hub 1
G Needle roller bearing 1 9. Install the pressure end plate. Make sure the
chamfered face of the pressure end plate faces
H Thick thrust washer 1 the clutch pack.
J Thrust bearing 2
K Thin thrust washer 2 10. Make sure that the teeth are not aligned with the
lubrication slots in the housing.
L Friction and counter
plate retaining circlip 11. Do not install the shim at this stage.
M Shim
12. Install the friction and counter plate retaining
N Pressure end plate
circlip.
P Friction plates
Q Counter plates 13. Use a DTI (Dial Test Indicator) to measure the
R Disc spring assembly end float of the pressure end plate. For PS760
variant the value should be within the specified
S Circlip 1 range.
T Spring retaining plate
Dimension: 1.9 –2.5 mm
U Spring
V Oil baffle Figure 72.
W Piston
X Piston O-ring
Y Shaft O-ring
Z Piston ring seal 2
AA Clutch end bearing 2
AB Thick thrust washer 2
AC Thrust bearing 3
AD Thin thrust washer 3
AE Gear and splined hub 2
AF Needle roller bearing 2

Assembly 14. If it is necessary to adjust the end float to

bring it within tolerance, then you can choose
1. Install the new piston O-ring onto the piston. either 6.0mm (0.23in) or 6.5mm (0.25in) thick
pressure end plate, with either a shim or an extra
2. Install the new shaft O-ring onto the shaft. counter plate between the retaining circlip and
3. Lubricate the piston with oil and push fully into the pressure end plate.
the bore of the clutch housing. 15. Use an airline to check the operation of the
4. Install the oil baffle and the piston spring. Make clutch.
sure that the spring is positioned properly in the 16. Install the thick thrust washer 1, thin thrust
piston. washer 2, and the thrust bearing 2.
5. Install the spring retaining plate. 17. Use a thin rod (or screwdriver) to carefully align
6. Compress the spring with a cut away tube and the teeth of the clutch plates and install the gear
secure with circlip 2. and splined hub 1.

7. Install the disc spring assembly. 18. Install the needle roller bearing 1.

27 - 93 9823/1600-1 27 - 93
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06 - Semi-Automatic Gearbox
11 - Clutch - Forward (Input)

19. Install the thrust bearing 1 and thin thrust washer

1.
20. Apply gearbox oil on the clutch end bearing then
push the gear and the clutch end bearing 1 onto
the shaft.
21. Install the piston ring seals 1.
21.1. The input shaft does not have piston ring
seals installed at this end of the shaft.
22. To assemble the opposite side clutch do the
steps 1 to 15 again.
23. Use a thin rod (or screwdriver) to carefully align
the teeth of the clutch plates and install the gear
and splined hub 2.
24. Install the needle roller bearing 2.
25. Install the thrust bearing 3, thick thrust washer 2,
and thin thrust washer 3.
26. Apply gearbox oil on the clutch end bearing then
push the gear and the clutch end bearing 2 onto
the shaft.
27. Install the piston ring seals 2.
27.1. The input shaft has four piston ring seals
installed at this end of the shaft.

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06 - Semi-Automatic Gearbox
15 - Solenoid Control Valve

15 - Solenoid Control Valve Introduction

Introduction .................................................... 27-95 The solenoid control valves provides the switching
Component Identification .......................... 27- for forward drive and reverse drive to select the
Check (Condition) .......................................... 27-96 direction of travel.
Remove and Install ....................................... 27-96
On some transmission systems the solenoid control
valves are also used for gear selection and 2WD
(Two Wheel Drive) / 4WD (Four Wheel Drive)
selection.

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06 - Semi-Automatic Gearbox
15 - Solenoid Control Valve

Check (Condition) Remove and Install

If damage to any component or distortion of the (For: PS764, PS766)

spool is evident the complete valve assembly must
be renewed. Great care should be taken when
dismantling and assembling the valve to avoid the Remove
following: 1. Put tags on the electrical harness connectors.
• Contamination 2. Disconnect the connectors from the solenoids.
• Damage to spools
• Damage to seal grooves 3. Clean the area around the solenoid valve block.
Do not allow particles of dirt to fall into the
Any of the above may result in possible problems gearbox.
with the operation of the valve.
4. Remove the socket head cap screws along with
the washers and lift off the valve block assembly.
5. Do not use a screwdriver to lift the valve block,
the sealing faces will get damaged.
5.1. If it is difficult to remove the valve block,
lightly tap the manifold block with a soft
faced hammer.
6. If any of the individual solenoid valve cartridges
are to be removed, take care not to grip the unit
by its electrical connector block. The connector
block is not designed as a leverage point.
7. Remove and discard the valve block sealing
gasket.
7.1. The gasket may disintegrate on removal,
make sure that all traces are removed and
discarded.
Figure 73.

D
C

A Capscrews
B Solenoid valve block
C Valve cartridge
D Valve cartridge connector block

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06 - Semi-Automatic Gearbox
15 - Solenoid Control Valve

Install
1. Install two guide studs at the valve interface on
the front case.
2. Install a new valve block sealing gasket. Care is
needed as the gasket is thin.
Figure 74.

7A17
/10
813

E Gasket
3. Put the valve block in position against the front
case.
4. Install the socket head capscrews and the
washers.
5. Progressively tighten the screws to the correct
torque value.
6. If any of the individual solenoid valve cartridges
are to be replaced, take care not to grip the unit
by its electrical connector block. The connector
block is not designed as a leverage point.
7. Install the electrical harness connectors to the
solenoid valve cartridge connector block.

Table 34. Torque Values

Item Nm
A 35

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06 - Semi-Automatic Gearbox
18 - Pressure Relief Valve

18 - Pressure Relief Valve

Introduction

The pressure relief valve is a type of valve used to

control or limit the pressure which can build up due
to a fault in the system.

The pressure is relieved by allowing the pressurised

fluid to flow from an auxiliary passage out of the
system. The relief valve is designed to open at
a predetermined set pressure to protect pressure
vessels from being subjected to pressures that
exceed their design limits.

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06 - Semi-Automatic Gearbox
24 - Oil Pump

24 - Oil Pump Check (Condition)

Check (Condition) .......................................... 27-99
Remove and Install ..................................... 27-100
(For: PS764, PS766)

Check (Condition)
A pump which is damaged or worn can cause
damage to the gearbox.

1. Remove the screws and then remove the pump

body.
2. Carefully check for any signs of wear or damage
on the gear teeth, white metal bearing and gear
mating faces. If any signs of wear or damage is
visible then you must replace the pump with a
new one.
3. Carefully remove and discard the oil seal.
Figure 75.

A
B

C
A Screw
B Oil seal
C Pump housing
4. Make sure that the seal housing is not damaged.
5. Install a new seal.
6. Install the seal the correct way around. Push the
seal flush with the front of the housing.
7. Assemble the pump again.
8. Make sure that the pump and the mating face on
the gearbox front cover is clean and free from
surface damage.

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06 - Semi-Automatic Gearbox
24 - Oil Pump

Remove and Install Consumable: JCB Threadlocker and Sealer

(Medium Strength)
5. Install the bolts together with the new sealing
(For: PS764, PS766) washers.
Consumables
Description Part No. Size 6. Progressively tighten the bolts to the correct
torque value.
JCB Threadlocker 4101/0250 0.01 L
and Sealer (Medium 4101/0251 0.05 L 7. Put some clean, new, oil into the pump at the
Strength) location shown.

Remove Table 35. Torque Values

Item Nm
1. Clean the area around the pump. Do not allow
A 28
any dirt or contamination to fall into the gearbox.
2. Remove the fixing bolts and lift the pump
assembly off the input shaft.
3. Remove the sealing washers and the pump
sealing ring.
4. Discard the washers and sealing ring.
Figure 76.

B A
F

D
E

A Bolt
B Oil pump
C Sealing washer
D Input shaft
E Sealing ring
F Oil filling location

Install
1. If the existing pump is to be installed then inspect
the pump for damage.
2. Install a new sealing ring.
3. Install the pump over the input shaft. Make sure
that the bolt holes are aligned.
4. Apply sealant to the threads of the bolts.

27 - 100 9823/1600-1 27 - 100

 27 - Driveline
06 - Semi-Automatic Gearbox
39 - Filter

39 - Filter Introduction
Introduction .................................................. 27-101 The transmission filter is designed to filter all the
Remove and Install ..................................... 27-102 contamination that is generated through use to
the required level of cleanliness. The filter must
be serviced to the requirements of the machine
maintenance schedules.

27 - 101 9823/1600-1 27 - 101

 27 - Driveline
06 - Semi-Automatic Gearbox
39 - Filter

Remove and Install Assemble

1. Smear the seal with transmission oil.
(For: PS764, PS766) Consumable: JCB Transmission Fluid EP SAE
Special Tools 30
Description Part No. Qty. 2. Screw the filter on until it just contacts the filter
Oil Filter Removal Tool 892/00292 1 head.

Consumables 3. Turn the filter at least another 3/4 of a turn.

Description Part No. Size
JCB Transmission Fluid 4000/2601 5L
EP SAE 30 4000/2605 20 L
4000/2603 200 L

For draining the gearbox, refer to Gearbox, Drain and

Fill (PIL 27-06).

Remove
1. Clean the area around the filter. Do not allow
particles of grit to fall into the gearbox.
2. If required, use a strap wrench to loosen the oil
filter.
Special Tool: Oil Filter Removal Tool (Qty.: 1)
3. Remove and discard the filter.
Figure 77.

A Gearbox filter
B Seal

27 - 102 9823/1600-1 27 - 102

 27 - Driveline
06 - Semi-Automatic Gearbox
40 - Suction Strainer

40 - Suction Strainer Introduction

Introduction .................................................. 27-103 The suction strainer is a component used for trapping
Remove and Install ..................................... 27-104 large and coarse particles entering the transmission
system.

27 - 103 9823/1600-1 27 - 103

 27 - Driveline
06 - Semi-Automatic Gearbox
40 - Suction Strainer

Remove and Install Table 36. Torque Values

Item Nm
Consumables
Description Part No. Size B 12
JCB Threadlocker 4101/0250 0.01 L
and Sealer (Medium 4101/0251 0.05 L
Strength)

Remove
1. Clean the area around the strainer. Do not allow
particles of grit to fall into the gearbox.
2. Place a container, of suitable size beneath the
suction strainer. Remove the bolts. Remove the
strainer and the gasket. Allow the oil to drain into
the container. Be aware that the oil may be hot.
Refer to Gearbox, Drain and Fill (PIL 27-06).
3. Clean the strainer with a suitable solvent. Follow
the solvent manufacturer's instructions on safety.
Figure 78.

A Strainer
B Bolts
D Gasket

Install
1. Install the strainer and a new gasket.
2. Apply JCB Threadlocker and Sealer to the
threads of the bolts. Tighten the bolts to the
correct torque value.
Consumable: JCB Threadlocker and Sealer
(Medium Strength)

27 - 104 9823/1600-1 27 - 104

 27 - Driveline
06 - Semi-Automatic Gearbox
45 - Piston Ring Seal

45 - Piston Ring Seal Introduction

Introduction .................................................. 27-105 A piston ring is a split ring that fits into a groove on
Remove and Install ..................................... 27-106 the outer diameter of a piston

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 27 - Driveline
06 - Semi-Automatic Gearbox
45 - Piston Ring Seal

Remove and Install

Remove
1. Refer to the relevant Clutch - Disassemble and
Assemble procedure (PIL 27-06).

Install
1. Wind the PTFE (Polytetrafluoroethylene) piston
ring seal around your finger as shown, so that the
seal forms a coil.
Figure 79.

2. Lubricate the seal and then install the seal to the

shaft. Make sure that the seal sits below or flush
with the outer diameter of the shaft. If necessary,
use finger pressure as shown to make the seal
flush with the shaft.
Figure 80.

3. If the seal is not set below or flush with the outer

diameter of the shaft, then the seal will cut when
the shaft is installed to its mating component.

27 - 106 9823/1600-1 27 - 106

 27 - Driveline
06 - Semi-Automatic Gearbox
47 - Oil Seal

47 - Oil Seal Introduction

Introduction .................................................. 27-107 Oil seals close spaces between components in
Remove and Install ..................................... 27-108 mechanical systems, they are designed to:

• Prevent lubricant escape

• Prevent harmful contaminants from entering a
system
• Prevent corrosive moisture from entering a
system
• Prevent mixture of two different mediums e.g.
lubricating oil and water.

27 - 107 9823/1600-1 27 - 107

 27 - Driveline
06 - Semi-Automatic Gearbox
47 - Oil Seal

Remove and Install Install

1. Make sure that the oil seal interface on the yoke
Remove is clean and free from wear or damage.

1. Bend back the stake nut locking ring. 2. Install a new oil seal. Locate the seal in the
position shown, the seal does not locate to the
2. Remove the yoke and the washer, refer to back of the housing.
Gearbox, Yoke- Remove and Install (27-06-95).
3. Lubricate the lips of the oil seal.
3. Remove the oil seal. Do not damage the seal
housing. 4. Install the yoke, refer to Gearbox, Yoke- Remove
and Install (27-06-95).
Figure 81.
5. Install a NEW stake nut. Tighten to the correct
torque value.
6. Stake the nut to the shaft using a square ended
staking tool, as shown.

Table 37. Torque Values

Item Nm
B 400

A Yoke
B Stake nut
C Oil seal
D Oil seal interface
E Washer
F Locking ring

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06 - Semi-Automatic Gearbox
52 - Driveshaft

52 - Driveshaft Introduction
Introduction .................................................. 27-109 The driveshaft is a mechanical component for
Remove and Install ..................................... 27-110 transmitting torque and rotation, it is used to connect
other components of the driveline that cannot be
connected directly because of the distance or the
need to allow for relative movement between them.

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 27 - Driveline
06 - Semi-Automatic Gearbox
52 - Driveshaft

Remove and Install

(For: PS764, PS766) 1.2. Draw the pump away from the gearbox,
disengage the drive shaft.
Remove 1.3. Lift the pump clear.
1. If the main hydraulic pump has not already been 2. Remove the circlip and the bearing.
removed proceed as follows:
3. Remove the driveshaft.
1.1. Support the pump, and remove the bolts.
4. Remove the sealing ring from the shaft.

Figure 82.

A
A

B E
F
C

A Bolts B Pump
C Circlip D Ball bearing
E Driveshaft F Sealing ring

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 27 - Driveline
06 - Semi-Automatic Gearbox
52 - Driveshaft

Install
1. Install a new sealing ring to the shaft.
2. Apply clean oil to the sealing ring and install the
shaft inside the gearbox.
3. Apply clean oil to the ball bearing.
4. Install the bearing followed by the circlip.
5. Install the pump as follows:
5.1. Engage the pump with the driveshaft.
5.2. Support the pump and install the bolts.

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06 - Semi-Automatic Gearbox
54 - Main Shaft

54 - Main Shaft Introduction

Introduction .................................................. 27-112 The main shaft receives its power from the engine
Check (Condition) ........................................ 27-113 and transmits the power to other components in the
gearbox.

Refer to Driveline, Semi-Automatic Gearbox, Output

Shaft, Introduction (PIL 27-06-58).

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 27 - Driveline
06 - Semi-Automatic Gearbox
54 - Main Shaft

Check (Condition)
1. Carefully inspect all gears, bearings and shafts
for signs of excessive wear or damage. If wear
or damage is evident, the components must be
renewed.
2. Make sure that all oil way cross drillings are clear
and free from debris. Blocked oil ways are a
common cause of bearing failure. If necessary
use an air line to blow through the oil ways.

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06 - Semi-Automatic Gearbox
56 - Layshaft

56 - Layshaft

Introduction

The layshaft is an intermediate shaft within a gearbox

that carries gears, but does not transfer the primary
drive of the gearbox either in or out of the gearbox.

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06 - Semi-Automatic Gearbox
57 - Input Shaft

57 - Input Shaft

Introduction

Refer to Driveline, Semi-Automatic Gearbox, Output

Shaft, Introduction (PIL 27-06-58).

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06 - Semi-Automatic Gearbox
58 - Output Shaft

58 - Output Shaft Introduction

Introduction .................................................. 27-116 In the gearbox, the input and output shafts lie along
Calibrate ...................................................... 27-117 the same line, and are sometimes combined into a
Remove and Install ..................................... 27-118 single shaft within the gearbox. This single shaft is
called the main shaft.

The input and output ends of this combined shaft

rotate independently, at different speeds, which is
possible because one piece slides into a hollow bore
in the other piece, where it is supported by a bearing.
Sometimes the term main shaft refers to just the input
shaft or just the output shaft, rather than the entire
assembly.

In many gearboxes the input and output components

of the main shaft can be locked together to create a
1:1 gear ratio, causing the power flow to bypass the
layshaft. The main shaft then behaves like a single,
solid shaft: a situation referred to as direct drive.

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06 - Semi-Automatic Gearbox
58 - Output Shaft

Calibrate

(For: PS764, PS766)

Refer to the individual Remove and Install tasks of
the Output Shaft for the calibration procedure.

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06 - Semi-Automatic Gearbox
58 - Output Shaft

Remove and Install

(For: PS764, PS766) bearings together with their respective outer

cups in their original relationships.
Special Tools
Description Part No. Qty. 9.2. Put tags on the bearings to make sure that
assembly of them in their original positions.
Drive Coupling 892/00812 1
Spanner 9.3. If any of the two bearings is worn or
Transfer Gear 892/01083 1 damaged, both the bearings must be
Assembly Tool replaced and a new solid spacer be
selected and installed.
Bearing Assembly Tool 892/01084 1
10. Remove the layshaft bearing outer cup from the
Before Removal rear case.

1. Remove the front case and the clutch shafts. Figure 83.

Remove
1. Remove the pressure maintenance valve as
follows:
R
1.1. Remove the plug.
1.2. Remove the spring and valve spool from the
rear case.
2. If required, remove the speed sensor as follows:
2.1. Remove the bolt 1.
2.2. Remove the sensor and its O-ring from the
rear case.
3. Hold the output yoke with the service tool.
Special Tool: Drive Coupling Spanner (Qty.: 1)
R Layshaft bearing outer cup
4. Remove the bolt 2 and the thick washer.
4.1. The bolt is very tight, the help of an assistant
will be required.
5. Remove the yoke.
6. Remove and discard the oil seal. Make sure that
you do not damage the seal housing.
7. Support the transfer gear shaft assembly and
remove the gear from inside the rear case.
8. The gear assembly will come down along with
the following components:
8.1. Inner taper roller bearing.
8.2. Inner taper bearing outer cup.
8.3. Solid spacer.
9. Remove the outer taper rolling bearing and the
outer bearing outer cup.
9.1. Note: If the inner and outer taper roller
bearings are to be used again, keep the

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 27 - Driveline
06 - Semi-Automatic Gearbox
58 - Output Shaft

Figure 84. Install

F
1. Install the layshaft outer bearing cup into the rear
case.
G H 2. Assemble the transfer gear output shaft as
follows:
2.1. Install the outer bearing outer cup into the
case.
2.2. Apply oil onto the inner taper bearing.
J
2.3. Push the inner bearing onto the transfer
P gear/shaft.
E 2.4. Install a service spacer of the specified
Q dimension.
Dimension: 13.7 mm
2.5. Install the inner bearing outer cup into the
D case.
2.6. Put the transfer gear assembly in position
against the case from inside.
2.7. Use the service tool to hold the transfer gear
in position. Refer to Figure 85.
Special Tool: Transfer Gear Assembly Tool
(Qty.: 1)
Figure 85.

C
M
B S
K
N
A
L

K
A Plug
B Spring
C Spool
D Bolt 1 H Transfer gear
E Speed sensor S Transfer gear retaining tool
F Bolt 2 2.8. If the gear is not held in position
G Thick washer the bearings may get damaged during
H Yoke assembly.
J Oil seal
K Transfer gear shaft assembly 2.9. Apply oil onto the outer bearing.
L Inner taper roller bearing 2.10. Use the service tool to push the outer
M Inner bearing outer cup bearing into the rear case.
N Solid spacer
P Outer taper roller bearing Special Tool: Bearing Assembly Tool (Qty.:
Q Outer bearing outer cup 1)
2.11. Do not install the oil seal at this stage.

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06 - Semi-Automatic Gearbox
58 - Output Shaft

3. Measure the transfer gear output shaft assembly 3.7. Install a DTI (Dial Test Indicator) to measure
end float as follows: Refer to Figure 86. the end float of the output shaft.
Figure 86. 3.8. Set the torque wrench to the specified
torque value and measure the end float
while you rotate the output shaft.
3.9. Select the right size spacer based on the
example given in the table. Refer to Table
Z 38.
U
V 3.10. Note: If the measurement obtained is
outside the spacer kit range, then check
the assembly of the bearings.
W
X 3.11. Disassemble the service tools and install
the correct size spacer. Assemble the
T transfer gear output shaft.
3.12. Install the service tool sleeve over the
output shaft and secure with the service
tool 1.
Y 3.13. Tighten the service tool 1 to the correct
torque value.
Z
Torque: 50 N·m
V
3.14. Make sure that there is no end float and
the rolling torque is less than the specified
X value.
Torque: 1.5 N·m
3.15. If the rolling torque exceed the specified
value then check that the output shaft is
installed correctly.
3.16. If the rolling torque is too high, install the
next largest spacer.
3.17. If the rolling torque is too low, install the
next smallest spacer.
T Service tool sleeve
U Service tool 1 3.18. Use the service tool to hold the transfer
V Service tool 2 gear in position. Refer to Figure 85.
W Bolt 3
3.19. Remove the service tool 1 and the service
X Support bracket
tool sleeve.
Y DTI
Z Torque wrench 4. Transfer gear output shaft final assembly.
3.1. Install the service tool sleeve over the 4.1. Use special tool to install a new oil seal.
transfer output shaft and secure with the Make sure the seal is pushed square to the
service tool 1. housing.
3.2. Tighten the service tool 1 to the correct 4.2. Install the yoke, the thick washer and the
torque value. bolt 2.
Torque: 50 N·m 4.3. Hold the yoke with the tool.
3.3. Temporarily loosen the service tool sleeve. Special Tool: Drive Coupling Spanner (Qty.:
3.4. Install the support bracket to the gearbox 1)
case. 4.4. Tighten the bolt to the correct torque value.
3.5. Install the service tool 2 so that the fork end 4.5. The combined seal and bearing rolling
engages in the groove of the service tool 1. torque should not exceed the specified
3.6. Tighten the bolt 3 to secure the service tool value when fully torque tightened provided,
2 to the support bracket. the correct size spacer has been selected.
Torque: 2 N·m

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06 - Semi-Automatic Gearbox
58 - Output Shaft

5. If removed, install the speed sensor as follows: 6. Install the pressure maintenance valve as
follows:
5.1. Install the O-ring on the sensor. Make sure
that it is correctly installed. 6.1. Apply oil to the spool and install to the case.
5.2. Attach the sensor with the bolt 1. 6.2. Install the spring.
5.3. Tighten the bolt 1 to the correct torque 6.3. Use a new sealing washer and install the
value. plug.
6.4. Tighten the plug to the correct torque value.

Table 38. Spacer Selection Example

Service spacer 13.7
Subtract end float obtained at step 3.7 0.41
Total 13.29
Subtract bearing tolerance and pre-load 0.12
Result 13.17
Use next smallest spacer i.e. 13.15

After Installation
1. Instal the clutch shafts and the front case.

Table 39. Torque Values

Item Nm
A 56
D 28
F 300

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 27 - Driveline
06 - Semi-Automatic Gearbox
85 - Oil Feed Pipe

85 - Oil Feed Pipe

Remove and Install

(For: PS764, PS766)

Remove
1. Remove the adaptor bolts 1.
2. Remove all the sealing washers 1 (x4).
3. Remove the external oil feed pipe.
Figure 87.

C
B

B External oil feed pipe

C Adaptor bolts 1 (x2)
D Sealing washers 1 (x4)

Install
1. Install the external oil feed pipe with the adaptor
bolts 1 and the sealing washers 1.
2. Tighten the bolts 1 to the correct torque value.

Table 40. Torque Values

Item Description Nm
C Adaptor bolts 1 26.5

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06 - Semi-Automatic Gearbox
86 - Oil Transfer Pipe

86 - Oil Transfer Pipe

Remove and Install

The oil transfer pipe is located on the rear case, if

the pipe is damaged or the gearbox is contaminated
then the pipe must be removed for cleaning or
replacement.

Remove
1. Remove the adaptor bolts 2.
2. Remove all the sealing washers 2.
3. Remove the oil transfer pipe.
Figure 88.

S
T

U
U

S Adaptor bolts 2 (x2)

T Oil transfer pipe
U Sealing washers 2 (x4)

Install
1. Install the oil transfer pipe with the adaptor bolts
2 and sealing washers 2.
2. Tighten the bolts 2 to the correct torque value.

Table 41. Torque Values

Item Description Nm
S Adaptor bolts 2 26.5

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 27 - Driveline
06 - Semi-Automatic Gearbox
90 - Front Case

90 - Front Case Clean

Consumables
Clean ........................................................... 27-124
Description Part No. Size
Check (Condition) ........................................ 27-125
Cleaner/Degreaser 4104/1557 0.4 L
Remove and Install ..................................... 27-125 - General purpose
solvent based parts
cleaner

1. Carefully remove all traces of gasket or gasket

compound from the front and rear case mating
faces. When removing gasket compound use a
gasket removal product such as Loctite Chisel.
Take care not to damage the mating faces. Clean
the faces with a fine carborundum paper. Use
a solvent cleaner and a clean cloth to finally
remove all traces of oil or debris
2. Clean the inside of the cases using a suitable
degreasing agent.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner

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06 - Semi-Automatic Gearbox
90 - Front Case

Check (Condition) Remove and Install

Consumables
Description Part No. Size (For: PS764, PS766)
JCB Threadlocker 4101/0250 0.01 L
Special Tools
and Sealer (Medium 4101/0251 0.05 L
Strength) Description Part No. Qty.
Gearbox Assembly 892/01082 1
1. If the gearbox cases are to be renewed, be Cradle
sure to install blanking plugs and adaptors as
required. Inspect the original cases and identify Consumables
the blanking plug and adaptor positions. Transfer Description Part No. Size
the plugs and adaptors to the new cases. Apply JCB Multi-Gasket 4102/1212 0.05 L
JCB Threadlocker and Sealer to the threads JCB Threadlocker 4101/0250 0.01 L
before installation. and Sealer (Medium 4101/0251 0.05 L
Consumable: JCB Threadlocker and Sealer Strength)
(Medium Strength)
The Disassembly and Assembly procedures given
illustrate and describe the 6x4 gearbox. Procedures
for the 4x4 version of the gearbox are identical
in most respects. Where there are differences,
procedures are identified under the heading 4x4
Gearbox.

With the gearbox removed from the machine, place

suitable wooden blocks to securely support the
assembly. If the gearbox is installed with an integral
park brake the brake assembly must be removed
before you disassemble the gearbox. Refer to (PIL
27-06).

Gearboxes compatible with a lock-up torque

converter are installed with a control valve and
interconnecting pipe. These components must be
removed before dismantling the gearbox.

Disassemble
1. Remove the main hydraulic pump and driveshaft.
2. Remove the solenoid control valve. Refer to (PIL
27-06-15).
3. Use suitable lifting equipment to put the gearbox
in a work cradle. Refer to Figure 89.
Special Tool: Gearbox Assembly Cradle (Qty.: 1)
3.1. Clamp the gearbox at the three clamping
points on the rear case.

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06 - Semi-Automatic Gearbox
90 - Front Case

Figure 89. 7. Remove the 4WD (Four Wheel Drive) clutch

assembly. Refer to (PIL 27-06-07).
8. Separate the front and rear cases as follows:
8.1. Remove the bolts 2 that attach the cases.
Refer to Figure 91.
Figure 91.

F
A

A Clamping points (x3)

4. Do not attempt to disassemble the gearbox
further until it is safely positioned in a suitable
work cradle.
5. Remove the torque converter housing as follows:
Refer to Figure 90.
Figure 90.

C D G
B

F Front case
G Bolt 2
8.2. With suitable lifting equipment carefully lift
the front case.
8.3. Make sure you remove all the shaft bearing
outer cups.
8.4. The cups may be left on the bearings, or
inside the front case. Keep the cups with
their relative bearings.
8.5. Remove and discard the sealing O-rings
from the front case.
8.6. Remove the oil transfer pipes from the front
E case only when they are damaged or the oil
is contaminated. Refer to Figure 92.
B Bolt1
C Torque converter housing
D O-ring 1 (x5)
E O-ring 2 (x3): Only for lock-up torque converter
variants
5.1. Remove the bolts 1.
5.2. Lift off the housing.
5.3. Remove and retain the O-rings 1 (x5).
5.4. For lock-up torque converter variants:
Remove and retain the O-rings 2 (x3).
6. Remove the gearbox oil pump. Refer to (PIL
27-06-24).

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06 - Semi-Automatic Gearbox
90 - Front Case

Figure 92. 9.3. Forward/Input clutch shaft.

9.4. Layshaft clutch.
H 9.5. Main shaft clutch.
10. Remove the bearing outer cups from the rear
case and centre of the transfer gear. Refer to
Figure 94.
Figure 94.

R
Q S
T

H Transfer pipes (x3)

9. Carefully remove the clutch shaft assemblies in
the sequence given below: Refer to Figure 93.
Figure 93.

L M K Q Bearing cups
N R Rear case
S Transfer gear
P T Layshaft bearing cup
11. The layshaft bearing cup cannot be removed until
the transfer gear output shaft has been removed.
12. Keep the bearings cups together with their
relative bearings.

Install
1. Make sure that the sealing rings (x4) on the
clutch pack shafts are in good condition and
lubricated with oil.
2. Install the bearing outer cups at their correct
positions in the rear case and centre of the
J transfer gear.
J O-rings 3 3. Install the clutch shaft assemblies in the
K 6 Speed clutch (not installed on 4x4 gearbox) sequence given below: Refer to Figure 95.
L Reverse clutch unit
M Forward/Input clutch shaft
N Layshaft clutch
P Main shaft clutch
9.1. 6 Speed clutch (not installed on 4x4
gearbox).
9.2. Reverse clutch unit.

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06 - Semi-Automatic Gearbox
90 - Front Case

Figure 95. 5.1. Make sure that the O-rings are correctly
installed to the rear case. Refer to Figure
L M K 95.
N 5.2. Apply a thin bead of sealant to the rear case
mating face as shown in the figure. Refer to
P
Figure 97.
Consumable: JCB Multi-Gasket
Figure 97.

J O-rings 3 V
K 6 Speed clutch (not installed on 4x4 gearbox) V Sealant
L Reverse clutch unit
M Forward/Input clutch shaft 5.3. Make sure that the shaft bearing outer cups
N Layshaft clutch are correctly installed in the front case.
P Main shaft clutch 5.4. Carefully lower the front case over the
3.1. Main shaft clutch. clutch shafts until it mates with the rear
case. Do not use excessive force when you
3.2. Layshaft clutch. Take care not to damage install the case.
the rear bearing on the transfer gear teeth
when you install the layshaft clutch. 5.5. Install the bolts 2 that attach the cases
together. Refer to Figure 98.
3.3. Forward/Input clutch shaft.
Figure 98.
3.4. Reverse clutch unit.
3.5. 6 Speed clutch (not installed on 4x4 F
gearbox).
4. Before you install the rear case make sure that
the sealing rings (x4) on the clutch pack shafts
are in good condition and lubricated with oil.
Refer to Figure 96.
Figure 96.

U
G

F Front case
G Bolt 2
U Sealing rings (x4)
5.6. Tighten the bolts to the correct torque value.
5. Assemble the front and rear cases as follows:

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 27 - Driveline
06 - Semi-Automatic Gearbox
90 - Front Case

6. Measure the end float of the clutch shafts except 7.2. The end float of the shaft should be within
the input shaft as follows: Refer to Figure 99. the specified range.
6.1. For 4x4 gearbox: Remove the plug 1. Length/Dimension/Distance: 0.02 –0.16
mm
6.2. For 6x4 gearbox: Remove plug 1 and plug
2. 8. Provided components are assembled correctly
the end float will be within the limits given. Check
6.3. Install a bolt to the threaded hole in the end that the shafts can be rotated by hand (turn the
of the shaft. input shaft and output yoke). The shafts should
6.4. Pull the bolt to detect excessive end float. rotate smoothly. The end floats can be checked
Remove the bolt. to confirm correct assembly.
6.5. The end float of the shafts should be within 9. Install the 4WD clutch assembly.
the specified range.
10. Install the gearbox oil pump.
Length/Dimension/Distance: 0.02 –0.16
mm 11. Install the torque converter housing as follows:
6.6. Apply sealant to the plug 1 and plug 2 (for Refer to Figure 100.
6x4 gearbox only).
11.1. Make sure that the front case and torque
Consumable: JCB Threadlocker and Sealer converter housing mating faces are clean,
(Medium Strength) dry and not damaged.
6.7. Tighten the applicable plugs to the correct 11.2. Install the O-rings 1 (x5) to the front case.
torque value.
11.3. For gearboxes installed with lock up
Figure 99. torque converter: Install the O-rings 2 (x3)
to the front case.
L W X K
M N Figure 100.
E
P

D Y
D O-ring 1 (x5)
E O-ring 2 (x3): Only for Lock up torque converter
variants
W Loctite 509
K 6 Speed clutch (not installed on 4x4 gearbox)
L Reverse clutch unit 11.4. Apply a bead of Loctite 509 of the specified
M Forward/Input clutch shaft thickness to the front case.
N Layshaft clutch Dimension: 3 mm
P Main shaft clutch
W Plug 1 11.5. According to the gearbox configuration
X Plug 2 Install the 13 or 14 bolts 2. Refer to Figure
101. or Refer to Figure 102.
7. Measure the end float of the input shaft as
follows: Refer to Figure 99.
7.1. Pull the input shaft to detect excessive end
float.

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06 - Semi-Automatic Gearbox
90 - Front Case

Figure 101. 13 Bolts Configuration

C

B Bolt 1 (x13)
C Torque converter housing
Figure 102. 14 Bolts Configuration
C

B Bolt 1 (x14)
C Torque converter housing
11.6. Tighten the bolts to the correct torque
value.
12. Install the solenoid control valve.
13. Install the main hydraulic pump and driveshaft.

Table 42. Torque Values

Item Description Nm
B Bolt 1 56
G Bolt 2 56
W-X Plug 102

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 27 - Driveline
06 - Semi-Automatic Gearbox
91 - Rear Case

91 - Rear Case Clean

Clean ........................................................... 27-131 Refer to Front Case - Clean (PIL 27-06-90).
Check (Condition) ........................................ 27-132

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 27 - Driveline
06 - Semi-Automatic Gearbox
91 - Rear Case

Check (Condition)

Refer to Front Case - Check Condition (PIL

27-06-90).

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 27 - Driveline
06 - Semi-Automatic Gearbox
95 - Coupling Yoke 4WD

95 - Coupling Yoke 4WD Introduction

Introduction .................................................. 27-133 The drive yoke is an important component of a
Remove and Install ..................................... 27-134 driveshaft assembly. The drive yoke assembly allows
a driveshaft or PTO (Power Take-Off) to flex or slip
with their given application. The drive yoke is also
essential for allowing u-joints to rotate properly with
the driveshaft.

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06 - Semi-Automatic Gearbox
95 - Coupling Yoke 4WD

Remove and Install Figure 103.

Special Tools
Description Part No. Qty.
Drive Coupling 892/00812 1
Spanner

Remove
1. Bend back the stake nut locking ring.
2. Clean the area around the yoke. Do not allow
particles of grit to fall into the gearbox.
3. Use service tool 892/00812 to hold the yoke and
at the same time undo the nut. The nut is very
tight, the help of an assistant will be required.
Discard the nut.
Special Tool: Drive Coupling Spanner (Qty.: 1)
4. Remove the yoke and the washer.
5. If necessary remove the oil seal. Do not damage
the seal housing.

A Yoke
B Stake nut
C Oil seal
D Oil seal interface
E Washer
F Locking ring

Install
1. Make sure that the oil seal interface on the yoke
is clean and free from wear or damage.
2. If necessary install a new oil seal. Locate the seal
in the position shown, the seal does not locate to
the back of the housing.
3. Lubricate the lips of the oil seal.
4. Install the yoke.
5. Install the stepped washer the correct way
around with the plan face facing the stake nut as
shown.

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 27 - Driveline
06 - Semi-Automatic Gearbox
95 - Coupling Yoke 4WD

6. Install a NEW stake nut. Tighten to the correct

torque value.
7. Stake the nut to the shaft using a square ended
staking tool, as shown.

Table 43. Torque Values

Item Nm
B 400

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 27 - Driveline
14 - Torque Converter

14 - Torque Converter

Contents Page No.

27-14-00 General ......................................................................................................................... 27-137

27-14-06 Control Valve ................................................................................................................ 27-145

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 27 - Driveline
14 - Torque Converter
00 - General

00 - General Introduction
Introduction .................................................. 27-137 The torque converter is a type of fluid coupling that
Component Identification ............................. 27-138 is used to transfer rotating power from the engine to
Operation ..................................................... 27-138 a rotating driven load.
Check (Operation) ....................................... 27-139
The torque converter normally takes the place of
Remove and Install ..................................... 27-143 a mechanical clutch in a vehicle with an automatic
transmission, allowing the load to be separated from
the power source.

It is usually located between the engine flywheel and

the transmission.

The key characteristic of a torque converter is its

ability to multiply torque when there is a substantial
difference between input and output rotational
speed, thus providing the equivalent of a reduction
gear. Some torque converters are equipped with a
temporary locking mechanism which rigidly locks the
engine to the transmission when their speeds are
nearly equal, to avoid slippage and a resulting loss
of efficiency.

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14 - Torque Converter
00 - General

Component Identification Operation

Figure 104. The torque converter is similar to a fluid coupling,
which utilises the centrifugal force exerted in the
transmission oil to transmit power from the engine to
D the gearbox. It multiplies the torque from the engine
and functions as a combined clutch and infinitely
variable reduction gearbox.

The torque converter is enclosed in a casing and

consists of three basic parts, the impeller, reaction
member and turbine.
A
The impeller is driven by the engine.
B The reaction member does not rotate. Its hub
engages with a splined tube on the gearbox oil pump
and is held stationary.

The turbine is engaged with the splined end of the

G C gearbox input shaft.

The impeller driven by the engine, forms one set

of shaped blades, it can be likened to a centrifugal
pump imparting energy to the transmission oil. This
F E energy is transferred to another set of shaped
blades, which form the turbine. The turbine is
connected to the gearbox and converts the energy
back to a mechanical torque.
H
When the impeller is rotating faster than the turbine,
the fixed reaction member causes some of the
energy in the oil to be transferred back to the impeller.
This has the effect of multiplying the torque available.

When the impeller (input) is running much faster

than the turbine (output) there is a substantial
circulation of transmission oil around the blades. The
oil circulation is maximum when the turbine (output)
is stalled, and is almost zero when the impeller and
turbine speeds are equal i.e. the ratio is near 1:1.
If the turbine (output) is stalled whilst the impeller
(input) is revolving, all the power is dissipated as
A Impeller heat.
B Turbine
C Reaction member Because of the absence of a direct mechanical
D Drive plate (engine driven bevel gearbox) connection between the engine and the gearbox,
E Drive to gearbox input shaft the flexibility of the torque converter drive greatly
F Spline location for reaction member reduces wear on the transmission, absorbing shocks
G Direct drive from the engine to the gearbox oil and torsional vibration from the engine. The engine
pump cannot be stalled due to overload, as the fluid
H Direction of oil flow coupling slips.

For illustration refer to Component Identification (PIL

27-14-00).

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14 - Torque Converter
00 - General

Check (Operation)

(For: PS760, PS764, PS766) torque converter. This is the point at which, due to
torque applied by the engine the torque converter
CAUTION Do not stall the converter for longer stops transmitting drive to the gearbox.
than 10 seconds or the transmission fluid will
overheat. Make sure the transmission oil level The engine speed at which stalling occurs is
is correct before and after carrying out the test. compared to speeds recorded for a machine in
Make sure you check the oil level at normal normal condition.
operating temperature.
Notice: Before starting the stall test, make sure Stall tests can be used to diagnose faults with the
that the mainline and clutch pressures are correct. transmission.
If the pressures are not correct, the clutches
could slip, resulting in premature wear of the Technical Data Check List
transmission friction plates. Also make sure the
machine neutral circuit and steer circuit pressures Record the test results in a check list for easy fault
are correct. identification. This section includes a blank check list
to copy and use as required. Refer to Figure 105.

Stall Test The check list will help the engineer to identify the
cause of a gearbox fault, and if required, can be sent
The purpose of the stall test is to check the to the JCB Technical Service Team via e-mail.
performance of the transmission by stalling the

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 27 - Driveline
14 - Torque Converter
00 - General

Figure 105.

27 - 140 9823/1600-1 27 - 140

 27 - Driveline
14 - Torque Converter
00 - General

Procedure 4. When fully engaged, the park brake electrically

disconnects the transmission drive. This
The purpose of the stall test is to check the prevents the machine from being driven with
performance of the transmission by `stalling' the the park brake on. Therefore, so that we can
torque converter. This is the point at which, due to complete the test, move the park brake lever
torque applied by the engine, the torque converter fractionally forward until the warning light is just
stops transmitting drive to the gearbox. The engine extinguished.
speed at which `stalling' occurs is compared to
speeds recorded for a machine in normal condition. 5. Hold the lever in this position for the duration of
Abnormal stall speed results can be used to identify the test.
possible faults as follows: 6. Do not move the lever too far forward, otherwise
the park brake will not be fully operational.
1. Poor engine performance
7. Do not disconnect the switch at the park brake.
2. Faulty torque converter
8. Select the 1st speed forward drive and open
3. Faulty gearbox hydraulic clutches
throttle fully. Record the engine speed from the
4. Faulty torque converter relief valve tachometer.

5. Transmission hydraulic leaks 9. Repeat the test in reverse drive.

6. Faulty hydraulic system relief valves 10. Repeat the test with the machine in each
configuration as described in the stall data tables.
For normal stall speed values refer to driveline- semi- Refer to driveline- semi-automatic gearbox, refer
automatic gearbox, refer to (PIL 27-06). to (PIL 27-06).

Do not stall the converter for longer than 10 seconds 11. For the machines with powershift gearboxes,
or the transmission fluid will overheat. Make sure repeat the test in 2nd and 3rd gears in both
that the oil level is correct and at normal operating forward and reverse drive.
temperature.
12. All recorded readings should be as specified.
If the machine is installed with a variflow hydraulic Refer to driveline- semi-automatic gearbox, (PIL
pump, make sure that the hydraulic oil temperature 27-06).
is above 50 °C ( 121.9 °F). Also make sure that
the valve block LSRV (Load Sense Relief Valve) Interpreting the Test Results
pressure and the variflow pump Delta P pressure are
set correctly. If all the engine speeds are below the stated figures
either the engine is losing power and should be
Before completing the following test, remove the serviced/ overhauled or the torque converter reaction
transmission dipstick. If there is any sign of member clutch is slipping. To check the engine,
smoke emitting from the dipstick tube stop the select neutral, open throttle fully and operate a
test immediately and dismantle the transmission for hydraulic service to 'blow off' the main relief valve.
servicing. Engine speed should fall to slightly below the
maximum governed speed. Refer to (PIL 15-00). If
1. Check all engine fluid levels. Run the engine at engine speed is correct the torque converter reaction
maximum speed and check the no load speed. member clutch is slipping.
Refer to Engine, General, General, Technical
Data, (PIL 15-00-00). If all the engine speeds are higher than the stated
figures in all gears the torque converter safety relief
2. Make sure that the engine and transmission are valve may be faulty. Alternatively there may be
at normal working temperature (the transmission internal oil leakage.
oil must be above the specified temperature).
Run engine at maximum speed and check the If the engine speeds are higher than the stated
engine speed is correct (High Idle/ maximum figures in some gears, check the transmission for
governed speed). Refer to engine- general, refer clutch slippage or internal leakage.
to (PIL 15-00).
The example given below shows how the results can
Temperature: 50 °C ( 121.9 °F)
be used to isolate a suspect clutch.
3. Apply the park brake and foot brake firmly.
If necessary, set the machine against a fixed
obstruction.

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 27 - Driveline
14 - Torque Converter
00 - General

Table 44.
Stall Test Results- 4 Speed Powershift
Gear Clutches engaged
Forward RPM (Revolutions Reverse RPM
Per Minute)
1st T, Z 1990 W, Z 1980
2nd U, Z 2060 V, Z 1975
3rd T, Y 1985 W, Y 1990

In the example shown, the engine speed is

abnormally high when 2nd gear forward drive is
selected, indicating a slipping clutch, possibly U or
Z. We can now use the results to determine which
clutch is at fault.

As per the details from the table, 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 the clutch U is slipping.

Clutches may slip for several reasons. Hydraulic

leakage is possible and this can be confirmed by
carrying out a pressure test. Refer to driveline- semi-
automatic gearbox, refer to (PIL 27-06).

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14 - Torque Converter
00 - General

Remove and Install 3.3. Make a note that it is important to protect

the converter drive tube against damage or
contamination at all times.
(For: PS760, PS764, PS766) 4. Install the drive plate retaining bolt 1 (x4).
Special Tools
Description Part No. Qty. 5. Tighten the drive plate retaining bolt to the correct
torque value.
Torque Converter 892/01110 1
Alignment Tool 6. Remove the alignment tool.
7. Install the remaining bolt 1 (x2).
Remove
8. Keep the torque converter and drive plate
1. Due to the configuration of the engine and
assembly on the flywheel.
transmission mounting system, we recommend
to remove the engine and the transmission as a 9. Install the bolt 1 (x3) on the drive plate and the
full assembly. flywheel.
2. The torque converter is part of the gearbox 10. Check the converter run-out as shown.
assembly. Remove the gearbox with torque
converter. 11. Make sure that the converter run-out is within the
specified limits.
Install Dimension: 0.38 mm
1. Make sure that the flywheel face, drive plate and 12. If the run-out exceeds the specified limit, do the
hardware are clean and free from burrs or other following.
surface imperfections.
12.1. Remove the converter.
2. Keep the drive plate on the torque converter.
12.2. Check the spigot for burrs.
3. Place the specified torque converter alignment 12.3. Remove the drive plate.
tool over the torque converter spigot.
12.4. Rotate the specified drive plate to the
Special Tool: Torque Converter Alignment Tool
specified angle on the torque converter.
(Qty.: 1)
Angle: 180 °
3.1. Make a note that the alignment tool is used
one way around for the 12” and the other 12.5. Do the steps 3 to 12 again.
way round for W300 torque converters.
Figure 107.
3.2. Make sure that the tool locates in two of the G
torque converter bolt holes as shown. Refer
to Figure 106.
E
Figure 106.
A

D
B F

A Drive plate
E Bolt 1
F DTI (Dial Test Indicator)
G Bolt 2
13. Remove the torque converter and drive plate
assembly from the flywheel.
B Drive plate retaining bolts 14. Install the torque converter with its drive plate
C Alignment tool assembly onto the transmission input shaft.
D Torque converter assembly

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 27 - Driveline
14 - Torque Converter
00 - General

15. Make sure that the converter pump drive shaft

engages with the recesses in the pump.
16. Take care not to damage the oil seal.
17. Rotate the engine flywheel so that one bolt hole
is in a six O' clock position.
18. Rotate the torque converter and drive plate
assembly so that one bolt hole is in a six O' clock
position.
19. Install the transmission/torque converter
assembly to the engine.
19.1. It is very important to install the torque
converter at the gearbox and engine
flywheel correctly.
19.2. Failure to locate the converter correctly will
result in damage to the gearbox oil pump
on engine start up.
20. Remove the access plate from the bottom of the
engine flywheel case.
21. Install the flanged bolt 2 in the six 'O' clock
position through the access hole.
22. Tighten the flanged bolt 2 by hand.
23. Rotate the flywheel until the next bolt 2 hole is
accessible.
24. Install and hand tighten the next bolt 2.
25. Do the steps 21 to 24 for all the bolts 2.
26. Tighten the bolt 2 to the specified torque value.
27. Install the access plate.

Table 45. Torque Values

Item Nm
B 84
G 44

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 27 - Driveline
14 - Torque Converter
06 - Control Valve

06 - Control Valve Figure 108.

E
Remove and Install
C
(For: PS760, PS764, PS766)
Gearboxes compatible with a lock-up torque
converter are installed with a control valve and an
interconnecting pipe. Before you disassemble the C
gearbox the pipe and valve must be removed.
D
Remove
1. Remove the pipe nuts and lift off the pipe.
2. Remove the capscrews and remove the solenoid
control valve.
D D
3. Make sure to remove the O-rings (x3) from the
C A
bottom of the valve.
B

A Nuts
B Pipe
C Control valve
D Capscrews (x3)
E O-rings (x3)

Install
1. Make sure that the valve sealing interface is not
damaged.
2. Install new O-rings to the valve.
3. Carefully put the valve in position against the
gearbox.
3.1. Make sure that the O-rings are not loose in
their seat.
4. Attach the valve with the capscrews.
5. Tighten the capscrews to the correct torque
value.

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 27 - Driveline
14 - Torque Converter
06 - Control Valve

6. Install the pipe and tighten the nuts to the correct

torque value.

Table 46. Torque Values

Item Nm
A 56
D 9

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 27 - Driveline
47 - Propshaft

47 - Propshaft

Contents Page No.

27-47-00 General ......................................................................................................................... 27-149

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Notes:

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 27 - Driveline
47 - Propshaft
00 - General

00 - General Introduction
Introduction .................................................. 27-149 The propeller shaft or propshaft is usually the shaft
Check (Condition) ........................................ 27-150 that connects the gearbox to the differential or
Lubricate ...................................................... 27-150 drivehead.
Remove and Install ..................................... 27-151
The propshaft is a mechanical component for
transmitting torque and rotation, usually used to
connect components of a drivetrain that cannot be
connected directly because of distance or the need
to allow for relative movement between them.

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 27 - Driveline
47 - Propshaft
00 - General

Check (Condition) Lubricate

1. Make the machine safe. Refer to (PIL 01-03). 1. Make the machine safe. Refer to (PIL 01-03).
2. Check the propshaft tube for damage or cracks. 2. Make sure you have the correct grease.
3. Check the centre bearing (if installed) for Refer to: PIL 75-00-00.
security, cracks or damage.
3. Use a grease gun to lubricate the universal joint
4. Check the universal joints for security, cracks grease points until fresh grease appears past the
or damage. Make sure that there is no play in seals of all four bearings in each joint.
the joint and that grease points are present (if 3.1. If grease does not appear, push the
installed). propshaft away from the bearing that
5. Check the sliding joints for security, cracks or grease does not appear from and grease
damage. Make sure that there is no play in again.
the joint and that grease points are present (if 3.2. If grease still does not appear, remove and
installed). examine the bearing. Renew if necessary.
6. Check any sensor or sensor ring for security, Refer to: PIL 27-47-00.
cracks or damage (if installed).
4. Remove any excess grease.
7. Make sure the correct fasteners are installed and
tightened to the correct torque.
8. Renew any defective component as needed.

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 27 - Driveline
47 - Propshaft
00 - General

Remove and Install Install

Consumables 1. The installation procedure is the opposite of the
Description Part No. Size removal procedure. Additionally do the following
JCB Threadlocker 4101/0250 0.01 L steps.
and Sealer (Medium 4101/0251 0.05 L 2. Lubricate the sliding joints with specified grease
Strength) and then align the shafts against identification
Special MPL-EP 4003/1501 0.4 kg marks previously made or, in the case of a
Grease 4003/1506 12.5 kg shaft being renewed, use the manufacturer's
4003/1510 50 kg alignment markings.
Consumable: Special MPL-EP Grease
Before you remove the propshaft, always mark on
both companion flanges and also mark the sliding 3. The retaining straps stretch with use, therefore
joints to help correct alignment when you install. these straps must always be replaced with new
ones.
Remove 4. For Synchro shuttle machines, apply JCB
1. Make the machine safe. Refer to (PIL 01-03). Threadlocker and Sealer to threads of all flange
bolts.
2. Put chocks against the all four wheels. Consumable: JCB Threadlocker and Sealer
(Medium Strength)
3. Remove the strap bolts and straps.
5. The propshaft must have both ends exactly on
4. Remove the flange bolts and remove the
the same plane. The yokes must not be at right
propshaft from the machine.
angles or at an intermediate angle.
Figure 109.
Figure 110.

C Y
B

X Correct installation - yokes correctly aligned on

the same plane
Y Incorrect installation - yokes at right angles to
each other
A Bolts Z Incorrect installation - yokes at intermediate
B Strap angles to each other
C Flange bolts
6. Tighten the bolts to the correct torque value.

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 27 - Driveline
47 - Propshaft
00 - General

Table 47. Torque Values

Item Nm
A 75–85
C 118

27 - 152 9823/1600-1 27 - 152

 33 - Electrical System
Contents Page No.

Acronyms Glossary .................................................................................................................................... 33-2

33-00 Electrical System

33-00-00 General ............................................................................................................................. 33-3
33-00-50 Schematic Circuit ............................................................................................................. 33-4
33-09 Power Distribution
33-09-00 General ............................................................................................................................. 33-7
33-09-06 Relay ................................................................................................................................ 33-9
33-12 Harness
33-12-30 Gearbox .......................................................................................................................... 33-13
33-57 Electronic Diagnostic
33-57-00 General ........................................................................................................................... 33-15
33-57-03 Servicemaster ................................................................................................................ 33-17
33-57-90 Fault Codes .................................................................................................................... 33-19
33-84 Sensor
33-84-09 Speed Sensor ................................................................................................................ 33-21

9823/1600-1
2018-05-22
Acronyms Glossary

2WD Two Wheel Drive

4WD Four Wheel Drive
CAN Controller Area Network
DLA Data Link Adaptor
ECU Electronic Control Unit

9823/1600-1
2018-05-22
 33 - Electrical System
00 - Electrical System

00 - Electrical System

Contents Page No.

33-00-00 General ............................................................................................................................. 33-3

33-00-50 Schematic Circuit ............................................................................................................. 33-4

33 - 1 9823/1600-1 33 - 1
Notes:

33 - 2 9823/1600-1 33 - 2
 33 - Electrical System
00 - Electrical System
00 - General

00 - General

Fault-Finding

(For: PS760, PS764, PS766)

33 - 3 9823/1600-1 33 - 3
 33 - Electrical System
00 - Electrical System
50 - Schematic Circuit

50 - Schematic Circuit

33 - 4 9823/1600-1 33 - 4
 33 - Electrical System
09 - Power Distribution

09 - Power Distribution

Contents Page No.

33-09-00 General ............................................................................................................................. 33-7

33-09-06 Relay ................................................................................................................................ 33-9

33 - 5 9823/1600-1 33 - 5
Notes:

33 - 6 9823/1600-1 33 - 6
 33 - Electrical System
09 - Power Distribution
00 - General

00 - General Introduction
Introduction ...................................................... 33-7 The electrical circuits are protected by fuses. If a
Health and Safety ........................................... 33-8 fuse blows, find out why and rectify the fault before
installing a new one.

A full up to date list of fuses and relays and their

locations can be found in the relevant operator
manual, maintenance section.

33 - 7 9823/1600-1 33 - 7
 33 - Electrical System
09 - Power Distribution
00 - General

Health and Safety

Notice: Always replace fuses with ones of correct
ampere rating to avoid electrical system damage.
Notice: When installing auxiliary electrical
components always ensure that the additional
load rating is suitable for that particular circuit. It
is unacceptable to simply increase the fuse rating
as this can cause overloading and consequential
failure of wiring, along with failure of integral
circuit components, which the fuse is protecting.

33 - 8 9823/1600-1 33 - 8
 33 - Electrical System
09 - Power Distribution
06 - Relay

06 - Relay Operation
Operation ......................................................... 33-9 Relays are used in electrical circuits for a variety
Operation (Electrical) ..................................... 33-10 of reasons. However, the more usual application
is to protect components like switches etc. from
being overloaded. A relatively small current (from
the switch) energises the relay coil, this coil causes
internal contacts to open (or close) and therefore
controls a larger current in another circuit.

Although relays look similar, internally they can be

different, for example, they can be single contact or
double contact; normally closed or normally open.
Make sure you install the correct type of relay,
otherwise the machine electrical circuits will not
function properly.

Relays are normally not supplied with the gearbox.

It is the responsibility of the O.E.M. to provide relays
for the protection of components.

33 - 9 9823/1600-1 33 - 9
 33 - Electrical System
09 - Power Distribution
06 - Relay

Operation (Electrical)

(For: PS764, PS766)

Listed below are the gearbox components requiring
relay protection:

• Neutral Start
• Ignition
• Transmission Dump
• Forward Drive
• Buzzer (if installed)
• Park Brake
• Reverse Drive
• 2 Wheel Drive (if 4WD transmission)
• Drive (Layshaft / Main shaft)

Note: The above list does not include any relays

that may be required for machine electrics such as
indicators, lights etc.

33 - 10 9823/1600-1 33 - 10
 33 - Electrical System
12 - Harness

12 - Harness

Contents Page No.

33-12-30 Gearbox .......................................................................................................................... 33-13

33 - 11 9823/1600-1 33 - 11
Notes:

33 - 12 9823/1600-1 33 - 12
 33 - Electrical System
12 - Harness
30 - Gearbox

30 - Gearbox

33 - 13 9823/1600-1 33 - 13
 33 - Electrical System
57 - Electronic Diagnostic

57 - Electronic Diagnostic

Contents Page No.

33-57-00 General ........................................................................................................................... 33-15

33-57-03 Servicemaster ................................................................................................................ 33-17
33-57-90 Fault Codes .................................................................................................................... 33-19

33 - 14 9823/1600-1 33 - 14
 33 - Electrical System
57 - Electronic Diagnostic
00 - General

00 - General Introduction
Introduction .................................................... 33-15 JCB machines use the latest developments in
Health and Safety .......................................... 33-16 electronic management of machine systems. This
means that machine systems such as service
hydraulics, engine, transmission and steering are
controlled using ECU (Electronic Control Unit)'s.
The ECU's process inputs from electrical sensors
and then send signals to electrical actuators on the
applicable devices. The ECU's are also connected
to the machine CAN (Controller Area Network) bus
electronic communication system.

Fault Finding
Faults with ECU controlled systems can be difficult
or impossible to trace using traditional methods. In
addition to the primary function of machine control
the ECU's are also able to detect possible faults
with sensors and actuators. The faults are logged
using a code system. Use Servicemaster to see and
understand these codes. In addition Servicemaster
has direct links to relevant on screen help information
about relevant devices. This information is designed
to help you identify, test, and if applicable, remove
and replace devices.

Poor Maintenance
System faults that are present, or have happened in
the past can be seen. This is not only useful when
fault finding but can also identify poor standards of
maintenance - for example a log showing a history
of water in fuel detected. Use Servicemaster to see
and understand these logs.

Machine Set-up Data

Machine parameters such as tyre sizes, gear shift
points and engine injector calibration codes are all
stored and used by the relevant control ECU's.
During the life of the machine it will be necessary
to change some of these parameters. Without the
correct data the machine will not operate correctly.

Re-Programming ECU's
The ECU's use pre-loaded data to compute
responses to inputs from sensors. If an ECU is
replaced the correct data files must be programmed
(`flashed') into the ECU memory. New data files may
also be issued by JCB Service to improve machine
operation. This will also require the ECU to be re-
programmed.

Summary
With the latest Servicemaster software loaded on
your laptop and you can:

33 - 15 9823/1600-1 33 - 15
 33 - Electrical System
57 - Electronic Diagnostic
00 - General

• Fault find. Health and Safety

• Check maintenance standards, to see if the
machine has been abused. WARNING Make sure you read and follow any
• View and change machine set-up data. on screen instructions. Failure to follow the
• Flash ECU's with the correct data files instructions could result in death or injury.

33 - 16 9823/1600-1 33 - 16
 33 - Electrical System
57 - Electronic Diagnostic
03 - Servicemaster

03 - Servicemaster Disconnect and Connect

Introduction ............................................... 33-
Operation .................................................. 33-
(For: PS760, PS764, PS766)
Disconnect and Connect ............................... 33-17 Special Tools
Description Part No. Qty.
Machine Cable 718/20237 1
Data Link Adaptor 892/01174 1
(DLA) Kit

To use Servicemaster, connect your laptop computer

to the machine CAN (Controller Area Network) bus.
Connection is made using the DLA (Data Link
Adaptor) and the applicable cables.

Figure 111.

A B

A USB PC Cable - 718/20235

B Serial PC Cable - 718/20236
C USB DLA - 728/26500
D Machine Cable - 718/20237
E Kit - 892/01174 (contains items A, B, C and D)

33 - 17 9823/1600-1 33 - 17
 33 - Electrical System
57 - Electronic Diagnostic
03 - Servicemaster

Note: Connect the USB cable directly to the laptop

computer. Do not connect the cable via a USB hub.

Note: Older DLA and laptop computers may not be

compatible with USB ports. Use the serial PC cable
to connect the DLA to the laptop serial port.

1. Make sure the machine ignition system is OFF.

2. To use the Servicemaster diagnostic tool,
connect the laptop computer to the machine.
Special Tool: Data Link Adaptor (DLA) Kit (Qty.:
1)
Special Tool: Machine Cable (Qty.: 1)
3. Connect the USB PC Cable to the DLA and a free
port on the laptop computer.
4. Connect the Machine Cable to the DLA. The
Machine Cable has a 15-way D-type connector
on one end and a 9-way CAN connector on the
other. Plug the 15-way connector into the DLA
and tighten the thumb screws.
Figure 112.

C
D
A USB PC Cable
B Serial PC cable
C Centre pin location tab
D Locking ring
5. Connect the 9-way CAN connector into the
machines Diagnostics Connector as follows:
5.1. Position the CAN connector to align the
centre pin location tab with the diagnostics
connector.
5.2. Couple the connectors. Turn the locking
ring clockwise to secure the connectors.

33 - 18 9823/1600-1 33 - 18
 33 - Electrical System
57 - Electronic Diagnostic
90 - Fault Codes

90 - Fault Codes

33 - 19 9823/1600-1 33 - 19
 33 - Electrical System
84 - Sensor

84 - Sensor

Contents Page No.

33-84-09 Speed Sensor ................................................................................................................ 33-21

33 - 20 9823/1600-1 33 - 20
 33 - Electrical System
84 - Sensor
09 - Speed Sensor

09 - Speed Sensor Introduction

Introduction .................................................... 33-21
Remove and Install .................................. 33-
(For: PS764, PS766)
The layshaft clutch, 2WD (Two Wheel Drive) / 4WD
(Four Wheel Drive) clutch, reverse clutch, mainshaft
clutch and forward / input clutch are all part of the
mainshaft assembly.

Refer to the mainshaft remove and install procedure.

Refer to (PIL 27-06-54).

33 - 21 9823/1600-1 33 - 21
Notes:

33 - 22 9823/1600-1 33 - 22
 72 - Fasteners and Fixings
Contents Page No.

72-00 Fasteners and Fixings

72-00-00 General ............................................................................................................................. 72-3
72-03 Screws
72-03-00 General ............................................................................................................................. 72-7
72-06 Bolts
72-06-00 General ........................................................................................................................... 72-11

9823/1600-1
2017-09-22
Notes:

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 72 - Fasteners and Fixings
00 - Fasteners and Fixings

00 - Fasteners and Fixings

Contents Page No.

72-00-00 General ............................................................................................................................. 72-3

72 - 1 9823/1600-1 72 - 1
Notes:

72 - 2 9823/1600-1 72 - 2
 72 - Fasteners and Fixings
00 - Fasteners and Fixings
00 - General

00 - General Fastener Type Colour Part Number

Suffix
Zinc Nickel - Black, chalky N (e.g.
Introduction black texture 1315/3712N)
Zinc flake - Black, slight B (e.g.
JCB Fasteners (Before September 2017) black gloss 1315/3712B)

Some external fasteners on JCB machines are Torque and Angle Tightening
manufactured using an improved type of corrosion
resistant finish. This type of finish is called Dacromet Insufficient pre-load of a bolted joint can cause
and replaces the original Zinc and Yellow Plating major problems, such as cylinder head warp, leaking
used on earlier machines. The two types of fasteners gasket joints etc. There are several methods of
can be readily identified by colour and part number achieving an accurate pre-load of a bolted joint, the
suffix. Refer to Table 1. Fastener Types. two main methods used on the JCB engine are:
Table 48. • Torque Control Tightening - Using a torque
Fastener Type Colour Part Number meter to control the torque is the most
Suffix popular means of controlling pre-load, and
in the majority of instances this method is
Zinc and Yellow Golden Finish Z (e.g. adequate. It should be noted that with this
1315/3712Z) process, the majority of the torque is used
Dacromet Mottled Silver D (e.g. to overcome friction, therefore slight variations
Finish 1315/3712D) in the frictional conditions can lead to large
changes in the bolt pre-load.
Note: As the Dacromet fasteners have a lower torque • Angle Control Tightening - Where a more
setting than the Zinc and Yellow fasteners, the torque precise pre-load is required, the torque and
figures used must be relevant to the type of fastener. angle tightening method is used. The bolt
is tightened to a predetermined torque (this
A Dacromet bolt should not be used in conjunction may be done in stages), and then as a
with a Zinc or Yellow plated nut, as this could final sequence, the bolt is tightened to a
change the torque characteristics of the torque predetermined angle - this method of tightening
setting further. For the same reason, a Dacromet nut the bolts results in a smaller variation in the
should not be used with a Zinc or Yellow plated bolt. final pre-load. It is critical that the predetermined
tightening angle is accurately achieved, failure
All bolts used on JCB machines are high tensile and to tighten accurately to the specified angle could
must not be replaced by bolts of a lesser tensile result in the bolt pre-load being incorrect - this
specification. will lead to eventual failures. It is good practice
to replace all bolts that have been tightened
Dacromet bolts, due to their high corrosion using the torque + angle procedure.
resistance are used in areas where rust could
occur. Dacromet bolts are only used for external
Tightening Method
applications. They are not used in applications
such as gearbox or engine joint seams or internal The following example explains the recommended
applications. torque and angle procedure. A torque angle gauge
should be used for accuracy, but as a visual check,
JCB Fasteners (After September 2017) the bolts can be match marked as described below.

1. Tighten the bolt to the specified torque (specified

Table 49. torque values will be detailed in the relevant PIL
Fastener Type Colour Part Number sections).
Suffix
2. Mark a line across the centre of the bolt, and a
Zinc flake-silver White alu- D (e.g. second line on the part to be clamped - the two
minium (sil- 1315/3712D) lines should be aligned. Refer to Figure 113.
ver-grey), Dull
Zinc and heavy Silver (Bright iri- V (e.g.
trivalent passi- descent) 1315/3712V)
vated with seal
Zinc Nickel - sil- Dark, dull silver Not assigned
ver/grey grey

72 - 3 9823/1600-1 72 - 3
 72 - Fasteners and Fixings
00 - Fasteners and Fixings
00 - General

Figure 113.

0°

3. Mark a third line at the specified torque angle - in

this instance the additional torque angle is 90°.
This line must be marked the specified angle in
a clockwise direction (to further tighten the bolt).
Refer to Figure 114.
Figure 114.

+90°

4. In some instances, angle torque tightening can

be specified in two stages, for instance in this
example, the first angle quoted is 90° and then a
second angle of 180°. The additional 180° angle
is from the LAST tightened position. Refer to
Figure 115.
Figure 115.

+180°

+90°

5. Tighten the bolt so that the line on the bolt

aligns with the angle(s) marked on the item to
be clamped - remember, to ensure complete
accuracy an angle gauge should be used.

72 - 4 9823/1600-1 72 - 4
 72 - Fasteners and Fixings
03 - Screws

03 - Screws

Contents Page No.

72-03-00 General ............................................................................................................................. 72-7

72 - 5 9823/1600-1 72 - 5
Notes:

72 - 6 9823/1600-1 72 - 6
 72 - Fasteners and Fixings
03 - Screws
00 - General

00 - General Introduction
Introduction ...................................................... 72-7 Use the torque setting tables (Technical Data) only
Technical Data ................................................. 72-8 where no torque setting is specified in the text. Note:
Dacromet fasteners are lubricated as part of the
plating process, do not lubricate. Torque settings are
given for the following conditions:

Table 50. Up to September 2017

Type Condition 1 Condition 2
no coating Unlubricated fas- Zinc flake silver
teners (Dacromet) fas-
teners.
2 (obso- Zinc fasteners Lubricated zinc
lete from and yellow plated
September fasteners.
2017).
3, 4 (obso- Yellow plated fas- Where there is
lete from teners a natural lubri-
September cation. For ex-
2017). ample, cast iron
components.

Table 51. From September 2017

Type Condition 1 Condition 2
no coating Unlubricated fas- Dacromet) fas-
teners teners.
1 Zinc flake - silver Zinc flake silver
(Dacromet) fas-
teners.
5 Zinc and heavy
trivalent with seal
7 Zinc nickel - silver
8 Zinc nickel - black
9 Zinc flake - black

72 - 7 9823/1600-1 72 - 7
 72 - Fasteners and Fixings
03 - Screws
00 - General

Technical Data

Table 52. Torque Settings - Internal

Hexagon Headed Capscrews (Zinc)
Bolt Size
mm N·m
3 2
4 6
5 11
6 19
8 46
10 91
12 159
16 395
18 550
20 770
24 1,332

72 - 8 9823/1600-1 72 - 8
 72 - Fasteners and Fixings
06 - Bolts

06 - Bolts

Contents Page No.

72-06-00 General ........................................................................................................................... 72-11

72 - 9 9823/1600-1 72 - 9
Notes:

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 72 - Fasteners and Fixings
06 - Bolts
00 - General

00 - General Introduction
Introduction .................................................... 72-11 Use the torque setting tables (Technical Data) only
Technical Data ............................................... 72-12 where no torque setting is specified in the text. Note:
Dacromet fasteners are lubricated as part of the
plating process, do not lubricate. Torque settings are
given for the following conditions:

Table 53. Up to September 2017

Type Condition 1 Condition 2
no coating Unlubricated fas- Zinc flake silver
teners (Dacromet) fas-
teners.
2 (obso- Zinc fasteners Lubricated zinc
lete from and yellow plated
September fasteners.
2017).
3, 4 (obso- Yellow plated fas- Where there is
lete from teners a natural lubri-
September cation. For ex-
2017). ample, cast iron
components.

Table 54. From September 2017

Type Condition 1 Condition 2
no coating Unlubricated fas- Dacromet) fas-
teners teners.
1 Zinc flake - silver Zinc flake silver
(Dacromet) fas-
teners.
5 Zinc and heavy
trivalent with seal
7 Zinc nickel - silver
8 Zinc nickel - black
9 Zinc flake - black

Verbus-Ripp Bolts
Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.

Figure 116.

72 - 11 9823/1600-1 72 - 11
 72 - Fasteners and Fixings
06 - Bolts
00 - General

Technical Data Table 57. Torque Settings - Coarse

Metric Grade 8.8 Fasteners
Bolt Tread Hexa- Condi- Condi-
From JCB standard STD00019 issue 15.
Size Pitch gon (A/ tion 1 tion 2
1. This information does not apply to:- F)
mm mm mm N·m N·m
1.1. Hydraulic fittings (i.e. BSP, SAE O-ring 4 0.7 7 2.9 2.6
boss, UNF, four bolt split flange and JIC).
5 0.8 8 5.8 5.2
1.2. Locking type fasteners (those with a nylon 6 1 10 9.9 9
insert, or with distorted thread nuts such as
8 1.25 13 24 22
Cleveloc).
10 1.5 17 47 43
2. For information on fastener conditions, refer to 12 1.75 19 83 74
fasteners and fixings, bolts, general, introduction. 14 2 22 132 119
16 2 24 205 184
Table 55. Torque Settings - UNF S Fasteners 20 2.5 30 400 360
Bolt Treads Hexa- Condi- Condi- 24 3 36 690 621
Size per Inch gon (A/ tion 1 tion 2 30 3.5 46 1,372 1,235
F) 36 4 55 2,399 2,159
in in in N·m N·m
(1/4 in) 28 7/16 11.2 10 Table 58. Torque Settings - Coarse
(5/16 in) 24 1/2 22.3 20 Metric Grade 10.9 Fasteners
(3/8 in) 24 9/16 40 36 Bolt Thread Hexa- Condi- Condi-
(7/16 in) 20 5/8 64 57 Size Pitch gon (A/ tion 1 tion 2
F)
(1/2 in) 20 3/4 98 88
mm mm mm N·m N·m
(9/16 in) 18 13/16 140 126
4 0.7 7 4 3.6
(5/8 in) 18 15/16 196 177
5 0.8 8 8.1 7.3
(3/4 in) 16 1 1/8 343 309
6 1 10 13.9 12.5
(7/8 in) 14 1 15/16 547 492
8 1.25 13 34 30
(1 in) 12 1 1/2 814 732
10 1.5 17 67 60
(1 1/8 in) 12 1 7/8 1,181 1,063
12 1.75 19 116 104
(1 1/4 in) 12 2 1/4 1,646 1,481
14 2 22 185 167
16 2 24 288 259
Table 56. Torque Settings - UNF X Fasteners 20 2.5 30 562 506
Bolt Treads Hexa- Condi- Condi- 24 3 36 971 874
Size per Inch gon (A/ tion 1 tion 2 30 3.5 46 1,930 1,737
F)
36 4 55 3,374 3,036
in in in N·m N·m
(1/4 in) 28 7/16 17.6 15.9 Table 59. Torque Settings - Coarse
(5/16 in) 24 1/2 35.2 31.6 Metric Grade 12.9 Fasteners
(3/8 in) 24 9/16 64 57 Bolt Thread Hexa- Condi- Condi-
(7/16 in) 20 5/8 101 91 Size Pitch gon (A/ tion 1 tion 2
(1/2 in) 20 3/4 155 139 F)
(9/16 in) 18 13/16 221 199 mm mm mm N·m N·m
(5/8 in) 18 15/16 310 279 4 0.7 7 4.8 4.4
(3/4 in) 16 1 1/8 542 488 5 0.8 8 9.8 8.8
(7/8 in) 14 1 15/16 864 777 6 1 10 16.6 15
(1 in) 12 1 1/2 1,285 1,156 8 1.25 13 40 36
(1 1/8 in) 12 1 7/8 1,865 1,679 10 1.5 17 80 72
(1 1/4 in) 12 2 1/4 2,598 2,339 12 1.75 19 139 125
14 2 22 223 200
16 2 24 345 311

72 - 12 9823/1600-1 72 - 12
 72 - Fasteners and Fixings
06 - Bolts
00 - General

Bolt Thread Hexa- Condi- Condi-

Size Pitch gon (A/ tion 1 tion 2
F)
mm mm mm N·m N·m
20 2.5 30 674 607
24 3 36 1,165 1,048
30 3.5 46 2,316 2,084
36 4 55 4,049 3,644

Table 60. Torque Settings - Rivet Nuts / Bolts

Bolt Size
mm N·m
3 1.2
4 3
5 6
6 10
8 24
10 48
12 82

72 - 13 9823/1600-1 72 - 13
Notes:

72 - 14 9823/1600-1 72 - 14
 75 - Consumable Products
Contents Page No.

Acronyms Glossary .................................................................................................................................... 75-2

75-00 Consumable Products

75-00-00 General ............................................................................................................................. 75-3
75-09 Fluids
75-09-00 General ............................................................................................................................. 75-7
75-10 Locking Fluids
75-10-00 General ............................................................................................................................. 75-9
75-14 Solvents and Primers
75-14-00 General ........................................................................................................................... 75-13
75-15 Adhesive
75-15-00 General ........................................................................................................................... 75-17
75-16 Sealant
75-16-00 General ........................................................................................................................... 75-23

9823/1600-1
2018-05-28
Acronyms Glossary

PTFE Polytetrafluoroethylene
SAE Society of Automotive Engineers

9823/1600-1
2018-05-28
 75 - Consumable Products
00 - Consumable Products

00 - Consumable Products

Contents Page No.

75-00-00 General ............................................................................................................................. 75-3

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Notes:

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 75 - Consumable Products
00 - Consumable Products
00 - General

00 - General Health and Safety

Health and Safety ........................................... 75-3 Oil
Technical Data ................................................. 75-5 Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves
to prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear personal protective equipment.
Hold a piece of cardboard close to suspected
leaks and then examine the cardboard for signs of
fluid. If fluid penetrates your skin, get medical help
immediately.

Hygiene
JCB lubricants are not a health risk when used
correctly for their intended purposes.

However, excessive or prolonged skin contact can

remove the natural fats from your skin, causing
dryness and irritation.

Low viscosity oils are more likely to do this, so take

special care when handling used oils, which might be
diluted with fuel contamination.

Whenever you are handling oil products you must

maintain good standards of care and personal and
plant hygiene. For details of these precautions we
advise you to read the relevant publications issued
by your local health authority, plus the following.

Storage
Always keep lubricants out of the reach of children.

Never store lubricants in open or unlabelled

containers.

Waste Disposal
CAUTION It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants.
Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
accordance with local regulations. Use authorised
waste disposal sites.

All waste products must be disposed of in

accordance with all the relevant regulations.

75 - 3 9823/1600-1 75 - 3
 75 - Consumable Products
00 - Consumable Products
00 - General

The collection and disposal of used oil must be in Fires

accordance with any local regulations. Never pour
used oil into sewers, drains or on the ground. WARNING Do not use water to put out an oil fire.
This will only spread it because oil floats on water.
Handling Extinguish oil and lubricant fires with carbon
dioxide, dry chemical or foam.
New Oil
First Aid - Electrolyte
There are no special precautions needed for the
handling or use of new oil, beside the normal care
and hygiene practices. Eyes
In the case of eye contact, flush with water for 15
Used Oil min. always get medical attention.
Used oil can contain harmful contaminants.
Swallowing
Here are precautions to protect your health when
handling used oil: Do not induce vomiting. Drink large quantities of
water or milk. Then drink milk of magnesia, beaten
• Avoid prolonged, excessive or repeated skin egg or vegetable oil. Get medical help.
contact with used oil
• Apply a barrier cream to the skin before Skin
handling used oil. Note the following when
removing oil from skin: Flush with water, remove affected clothing. Cover
burns with a sterile dressing then get medical help.
• Wash your skin thoroughly with soap and
water
• Using a nail brush will help
• Use special hand cleansers to help clean
dirty hands
• Never use petrol, diesel fuel, or paraffin for
washing
• Avoid skin contact with oil soaked clothing
• Don't keep oily rags in pockets
• Wash dirty clothing before re-use
• Throw away oil-soaked shoes

First Aid - Oil

Eyes
In the case of eye contact, flush with water for 15
min. If irritation persists, get medical attention.

Swallowing
If oil is swallowed do not induce vomiting. Get
medical advice.

Skin
In the case of excessive skin contact, wash with soap
and water.

Spillage
Absorb with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a
chemical disposal area.

75 - 4 9823/1600-1 75 - 4
 75 - Consumable Products
00 - Consumable Products
00 - General

Technical Data

Table 61.
Item Capacity
(2)
Fluid/Lubricant Specification
Powershift 6 Speed
(1)
16 L (Dry) T04, Q8 EL4117 SAE (Society of Automo-
tive Engineers) 10W
11.5 L (Wet) Q8 EL4118 SAE 30
Powershift 4 Speed
(1)
15.5 L (Dry) T04, Q8 EL4117 SAE 10W
11 L (Wet) Q8 EL4118 SAE 30
(1) The values mentioned here is total system capacity. Use the MIN and MAX mark on dipstick when filling
the system.
(2) The capacity values are for reference only. Use the MIN and MAX mark on dipstick when filling the system.

EL4117 (SAE 10W) - This product is for use in

Transmissions where the ambient temperature range
is -32 –40 °C ( -25.6 –103.9 °F).

EL4118 (SAE 30) - This product is for use in

Transmissions where the ambient temperature range
is -5 –46 °C ( 23.0 –114.7 °F).

For further information refer to JCB Drivetrain Bulletin

GX061.

75 - 5 9823/1600-1 75 - 5
 75 - Consumable Products
09 - Fluids

09 - Fluids

Contents Page No.

75-09-00 General ............................................................................................................................. 75-7

75 - 6 9823/1600-1 75 - 6
 75 - Consumable Products
09 - Fluids
00 - General

00 - General

Introduction

It is most important that you read and understand this

information and the publications referred to. Make
sure all your colleagues who are concerned with
lubricants read it too.

Hygiene
JCB lubricants are not a health risk when used
properly for their intended purposes.

However, excessive or prolonged skin contact can

remove the natural fats from your skin, causing
dryness and irritation.

Low viscosity oils are more likely to do this, so take

special care when handling used oils, which might be
diluted with fuel contamination.

Whenever you are handling oil products you should

maintain good standards of care and personal and
plant hygiene. For details of these precautions we
advise you to read the relevant publications issued
by your local health authority, plus the following.

Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled
containers.

Waste Disposal
All waste products should be disposed of in
accordance with all the relevant regulations.

The collection and disposal of used oil should be in

accordance with any local regulations. Never pour
used engine oil into sewers, drains or on the ground.

75 - 7 9823/1600-1 75 - 7
 75 - Consumable Products
10 - Locking Fluids

10 - Locking Fluids

Contents Page No.

75-10-00 General ............................................................................................................................. 75-9

75 - 8 9823/1600-1 75 - 8
 75 - Consumable Products
10 - Locking Fluids
00 - General

00 - General Introduction
Introduction ...................................................... 75-9 All locking fluids should be used at all times in line
Technical Data ............................................... 75-10 with the manufacturer’s recommendations.

Locking fluids are used for the locking of threaded

fasteners and for the retention of ball & roller
bearings and similar cylindrical items on to shafts and
into housings. These fluids consist of an anaerobic
resin in a liquid form which hardens when confined
between closely fitting metal to metal and many
metal to non-metal surfaces.

The fluids available possess a wide span of

break-loose strengths, viscosities and gap filling
properties and are marketed for a variety of locking
and retaining purposes requiring different strength
grades. Some of the sealants in use in JCB are
also of anaerobic resin type and only differ from
the locking fluids in respect of viscosity and other
technical details.

Strength grades
Various strength grades of fluid are available,
the highest strength type for permanent locking
where disassembly is unlikely, medium strength
for permanent locking but allowing disassembly
with ordinary tools and low strength for locking
of components where frequent adjustment or easy
dismantling is required.

It is recommended that trials be carried out before

scheduling locking fluids for any new type of
application that has not been already proved as
satisfactory in production or when use at elevated
temperatures is intended.

Additional technical information is normally available

from the product manufacturers.

Approved locking fluids

The table shown in Technical Data shows the
approved locking fluids available to use on JCB
machines. The table also provides basic details to
help with selection of locking fluids. More up to
date information can be found on the manufacturer’s
website.

75 - 9 9823/1600-1 75 - 9
 75 - Consumable Products
10 - Locking Fluids
00 - General

Technical Data

Table 62. Locking Fluids Approved Product Information

Subsec- Commer- Product Colour Shelf Strength Comments
tion cial name Number life
High Loctite 4101/0100 Green 365 80 –120 bar For the retention of threads up to M20 di-
strength 270
(1)
fluores- d ( 1,159.4 – ameter where disassembly is unlikely and
cent 1,739.1 psi) for locking bearings etc. onto shafts and in-
R.A.S. Red breakaway to housing. Has a maximum gap fill of 0.05
threadlock strength mm.
for studs
(1)

High Loctite 4101/1400 Green, 365 More than Maximum gap fill of 0.25 mm. Maximum
strength 638 UV fluo- d 250 bar strength at room temperature.
rescent ( 3,623.2
psi) com-
pressive
shear
strength
High Per- 4101/0500 Red, flu- 365 100 – Fast curing ( 10 –15 min) thread locking up
strength mabond ores- d 150 bar to M20, especially for use on oily surfaces,
A115
(1)
cent ( 1,449.3 – plated and clean parts.
Loctite 2,173.9 psi)
262 prevailing
strength
High Loctite 4101/0600 Green, 365 More than Designed for holding gears and sprockets
strength 648(1) fluores- d 250 bar onto gearbox shafts and rotors on electric
Per- cent ( 3,623.2 motor shafts.
mabond psi) com-
A118 pressive
shear
strength
High Loctite 4101/1700 Green 365 260 – Designed for permanent locking and seal-
strength 2701 d 500 bar ing of threaded fasteners. Particularly suit-
( 3,768.1 – ed for use on inactive substrates and/or
7,246.3 psi) where maximum resistance to hot oil is re-
breakaway quired.
torque
Medium Loctite 4101/1100 Blue 365 140 – Suitable for all nuts, bolts, screws up to
to high 243 d 340 bar M36.
( 2,029.0 –
4,927.5 psi)
breakaway
torque
Medium Per- 4101/0900 Blue 365 80 –120 bar Maximum gap fill of 0.25 mm. Handling
strength mabond d ( 1,159.4 – strength in 10 –15 min.
A119
(1)
1,739.1 psi)
static shear
strength
Medium Loctite 4101/1200 Green, 365 150 – Product has a slow cure rate, used on parts
strength 640 fluores- d 330 bar unlikely to be disassembled.
cent ( 2,173.9 –
4,782.6 psi)
static shear
strength

75 - 10 9823/1600-1 75 - 10
 75 - Consumable Products
10 - Locking Fluids
00 - General

Subsec- Commer- Product Colour Shelf Strength Comments

tion cial name Number life
Medium Loctite 4101/0200 Blue, 365 80 –120 bar Suitable for all nuts, bolts and screws up to
strength 242
(1)
fluores- d ( 1,159.4 – M36 and hydraulic fittings up to 25mm in di-
Per- cent 1,739.1 psi) ameter. Permabond A113 and A1042 are
mabond static shear the preferred choices. The difference be-
A1042 strength tween A113 and A1042 is timing for han-
dling and working strength. A113 handling
Per- time 10 –25 min, working strength 1 h.
mabond A1042 handling time 5 –10 min, working
A113 strength 30 min.
Low Loctite 4101/0300 Purple, 365 15 –40 bar For screwed fasteners up to M20 that re-
strength 222 fluores- d ( 217.4 – quire easy disassembly or frequent ad-
cent 579.7 psi) justment. Maximum gap fill of 0.05 mm.
Achieves handling strength in 10 –30 min.
Low Per- 4101/1500 Blue 365 120 bar Allows dismantling of parts for mainte-
strength mabond d ( 1,739.1 nance. Suitable for sealing small hydraulic
A1098 psi) shear and pneumatic fittings. Handling strength in
strength 5 –10 min.
Low Loctite 4101/1600 Off- 365 17 bar For the locking and sealing of metal ta-
strength 567 white d ( 246.4 psi) pered threads and fittings. High lubricat-
breakaway ing properties prevent galling on stainless
torque steel, aluminium and all other metal pipe
threads and fittings.
Very low Loctite 4101/0400 Brown/ 365 7 –18 bar Can be disassembled with hand tools. 10
strength 932(1) red d ( 101.4 –30 min cure time for handling strength.
Per- –260.9 Used on large diameter screw threads big-
mabond psi) aver- ger than 50mm.
A011 age shear
strength
(1) This is a non preferred product.

75 - 11 9823/1600-1 75 - 11
 75 - Consumable Products
14 - Solvents and Primers

14 - Solvents and Primers

Contents Page No.

75-14-00 General ........................................................................................................................... 75-13

75 - 12 9823/1600-1 75 - 12
 75 - Consumable Products
14 - Solvents and Primers
00 - General

00 - General Introduction
Introduction .................................................... 75-13 This section contains information on primers,
Technical Data ............................................... 75-14 solvents, cleaning solutions etc. that are in use at
JCB.

All primers and solvents should be used at all times

in line with the manufacturer’s recommendations.

Approved primers and solvents

The table shown in Technical Data shows the
approved primers and solvents available to use on
JCB machines. The table also provides basic details
to help with the selection of primers and solvents.
More up to date information can be found on the
manufacturer’s website.

75 - 13 9823/1600-1 75 - 13
 75 - Consumable Products
14 - Solvents and Primers
00 - General

Technical Data

Table 63. Primers and Solvents Approved Product Information

Subsec- Commer- Product Colour Shelf Drying Comments
tion cial name Number life Time
Activa- Loctite 332/U7901 Colour- 365 Less than 5 Used to make low energy surfaces suit-
tor/Primer 770 less d s able for bonding with cyanocrylate adhe-
sives. It is recommended for polyethylene,
polypropylene, PTFE and thermoplastic
rubber materials. Can be used with Loctite
406 (332/U7899).
Activator Loctite 4104/1700 Clear 730 Apply and HIGHLY FLAMMABLE. Organic accelera-
7455 amber d leave to dry tor, non CFC solvent based surface activa-
for 30 s be- tor. Designed to promote the speed of cure
fore apply- of cyanoacrylic adhesives.
ing adhe-
sive
Activator Loctite 4104/0200 Colour- 365 1 –3 min Used with anaerobic products it increases
7471 less d cure speed. Recommended for inert sur-
Per- faces and large bond gaps.
mabond
A905
Water Loctite 4104/0500 - - - A water proofing solution for protecting
proofing water joints made using cyanoacrylate adhesive.
proofing Apply to Loctite 495 (4103/0900).
Solvent Loctite 4104/1500 Colour- 365 1 min at 20 HIGHLY FLAMMABLE, cleaner and de-
7063 less d °C ( 68.0 greaser. Removes grease, oil and dirt from
°F) electrical parts, tools and precision equip-
ment.
Cleaning Loctite 4101/2200 Colour- 365 No wipe Cleaning treatment to remove most greas-
fluid 7070 less d 5 –10 min, es, oils, lubrication fluids and metal cuttings
post wipe 1
–2 min
Cleaning Simple 332/E9240 Colour- 365 - An all purpose cleaner and degreaser used
fluid green ex- less d diluted in water for direct, spray and dip
treme tank procedures.
Applica- A4GBCJCB4104/3300 Blue 730 - Vinyl labels application fluid for use with the
tion fluid d insignia/livery labels.
Gasket Loctite 4104/3200 Colour- 730 Allow 10 – This is a product to aid the removal of
cleaner 7200 less d 15 min for cured chemical gaskets. Apply for time
gasket, 30 specified and remove gasket with soft
min for sil- scraper.
icone gas-
ket.
Hand Loctite 4104/3100 Light 540 - Is a heavy duty hand cleaner, specially for-
cleaner 7855 grey d mulated for the most difficult to remove
soils like polyurethane, paints, primers, ad-
hesives etc. The product is free from sil-
icone and harsh solvents. Can be used
without water.
Hand Sika hand 4104/1300 Off - - A non-abrasive hand cleaner for use when
cleaner cleaner white using direct glazing materials.

75 - 14 9823/1600-1 75 - 14
 75 - Consumable Products
14 - Solvents and Primers
00 - General

Subsec- Commer- Product Colour Shelf Drying Comments

tion cial name Number life Time
Direct Sika acti- 4104/2100 Clear 365 10 min mini- HIGHLY FLAMMABLE. A cleaning and acti-
glazing vator d mum drying vating agent specifically formulated for the
time treatment of bonded faces in direct glaz-
ing applications prior to applying the direct
glazing adhesive.
Direct Sika re- 4104/1900 Trans- - - A cleaning agent for removing contami-
glazing mover parent nates on painted surfaces and glass.
208 (use
4104/3600)
Direct Sika 4104/1200 Clear - - A cleaning agent for removing contami-
glazing cleaner nates on painted surfaces and glass.
205 (use
4104/3600)
Direct Sika 4104/2300 Black 270Application Used to prime painted surfaces and plas-
glazing primer d temperature tic substrates prior to bonding with Sikaflex
209 (use 10 –35 °C products.
4104/3500) ( 50.0 –95.0
°F)
Direct Sika akti- 4104/2400 Clear 365 10 min at Used to clean and give improved adhe-
glazing vator d more than sion on glass, ceramic-coated glass, the cut
15 °C ( 59.0 face of old polyurethane adhesive beads,
°F) or 30 polyurethane coated windows glass and
min at less paints.
than 15 °C
( 59.0 °F)
Active Tero- 4104/3400 Colour- 270 Minimum Applied with a clean cloth to the surface,
wipe for stat 8560 less d 30 s and the adhesive may then be applied after the
surface AC-25 maximum 1 drying time. Applied to glass or ceramic
h coating but only in the bonding area.
Direct Terostat 4102/3500 Black 0.1 L Approx. 2 Used to promote adhesion in direct glazing
glazing 8519 P bot- min to glass and glass ceramics.
tle =
365
d.
0.01
L
and
0.035
L
bot-
tle =
540
d
Cleaner Teroson 4104/3600 Clear 730 Depend- Used for degreasing and cleaning of sub-
FL clean- d ing on con- strates prior to application of adhesives and
er ditions be- sealants.
tween 2 –
10 min.

75 - 15 9823/1600-1 75 - 15
 75 - Consumable Products
15 - Adhesive

15 - Adhesive

Contents Page No.

75-15-00 General ........................................................................................................................... 75-17

75 - 16 9823/1600-1 75 - 16
 75 - Consumable Products
15 - Adhesive
00 - General

00 - General Introduction
Introduction .................................................... 75-17 All adhesives should be used at all times in line with
Technical Data ............................................... 75-18 the manufacturer’s recommendations.

Adhesives are used for the bonding of a number

of engineering materials used in production at JCB.
Many types are available on the market but in the
interests of variety reduction and economy only a
limited selection is purchased for regular use.

Types of adhesive
Various types of adhesive are covered by JCB
Standards:

1. General purpose adhesives for bonding

laminated plastics, wood, rubber etc. to
themselves and to each other.
2. The more expensive cyanoacrylate adhesives
for use where high strength, resistance to many
chemicals and fast cure times are required.
3. Adhesives specially developed for bonding of
foam rubber to painted metal surfaces.

Additional health and safety for

cyanoacrylates
These adhesives require very careful handling on
account of their exceptional properties. They bond
together strongly and rapidly to most surfaces
including body tissue, the curing process being
initiated by surface moisture. For further information
on cyanoacrylates refer to the Manufacturer’s
recommendations.

Approved adhesives
The tables shown in Technical Data are the approved
adhesives available to use on JCB machines. The
tables also provide basic details to help with the
selection of adhesives. More up to date information
can be found on the manufacturer’s website.

75 - 17 9823/1600-1 75 - 17
 75 - Consumable Products
15 - Adhesive
00 - General

Technical Data

Table 64. Adhesives Approved Product Information

Subsec- Commer- Product Colour Shelf Technical Comments
tion cial name Number life data
High Per- 4103/3100 Mixed 730 d 3 –5 min Two part adhesive mixed in equal parts. A
strength mabond grey for han- toughened adhesive system which bonds
5002 dling metals, plastics, wood, glass, ceramics and
strength composites; even plated or coated surfaces
can be securely fastened.
High Loctite 4103/1000 Green 365 d 16 –30 bar This product is a single component anaero-
strength 601 fluores- ( 231.9 – bic adhesive. Used to bond cylindrical fitting
cent 434.8 psi) parts, particularly where low viscosity is re-
static shear quired. Maximum gap fill is 0.15 mm.
strength
Cyano- Loctite 4103/3500 Colour- - 18 –26 bar Suitable for most materials including plastic
acrylate 424 less to ( 260.9 and rubber. Takes 30 s to cure to working
straw –376.8 strength.
psi) shear
strength
Cyano- Loctite 4103/2300 Colour- 180 d 18 –26 bar Designed for general purpose use. For use
acrylate 401 less ( 260.9 – on acidic and porous surfaces, reaching
376.8 psi) handling strength in seconds. Materials in-
tensile clude plated metals, composite materials,
strength wood, cork, foam, leather and paper.
Cyano- Loctite 332/U7899 Colour- 180 d 18 –26 bar Designed for bonding of plastics and elas-
acrylate 406 less ( 260.9 – tomeric materials where very fast fixturing
376.8 psi) is required. Can be used with Loctite 770
lap shear as a primer (332/U7901)
strength
Cyano- Loctite 4103/2400 Black 120 d 22 bar 0.2 mm, gap fill. A rubber toughened ethyl
acrylate 410 ( 318.8 psi) cyanoacrylate adhesive with enhanced re-
lap shear sistance to peel and shock. Bonds rubber,
strength metals and plastics for use in difficult condi-
tions.
Cyano- Loctite 4103/3800 Black - 22 –30 bar A rubber toughened adhesive with in-
acrylate 480 ( 318.8 – creased flexibility and peel strength along
434.8 psi) with enhanced resistance to shock.
lap shear
strength
Cyano- Loctite 4103/0900 Colour- 270 d 12 h maxi- High speed bonding, suitable for rubber to
acrylate 495 less mum cure itself and other materials reaching handling
Per- time strength in a matter of seconds. Joint must
mabond be waterproofed with Loctite water proofing
C2 (4104/0500).
Low Dunlop 4103/1100 Clear 90 d - Sprayable adhesive, non-structural appli-
strength 1727 to light cations. For the bonding of flexible foam
British vita straw to themselves, wood, painted metal, chip-
company board, fibreglass, hessian, felt etc.
VB 165
Acrylic 3M 4941P 4103/3900 Dark 730 d Peel adhe- High bond acrylic double sided foam tape.
foam grey sion 350 Its allows more complete bond contact area
strip ad- N/ 100 mm when bonding rigid or irregular materials
hesive due to its conformability. Its core adhesive
composition makes the product well suited
to many paints and primers.

75 - 18 9823/1600-1 75 - 18
 75 - Consumable Products
15 - Adhesive
00 - General

Subsec- Commer- Product Colour Shelf Technical Comments

tion cial name Number life data
General Araldite 4103/1400 Clear / 730 d 560 bar Two part, equal parts by weight. Wear pad
purpose XD 580 cream ( 8,115.9 fixing to castings and telescopic compo-
gap fill- psi) flexural nents, alignments of fixings pads without
ing ma- strength expensive machining. This product is a
terial general purpose gap-filling material. Cure
time 2 h at 25 °C ( 77.0 °F).
Methacry- Loctite 4103/3600 Cream - - This is a sag resistant, two component,
late Speed- to light equal parts, methacrylate adhesive system
bonder yellow formulated to bond automotive grade cold
H3151 rolled steel without the use of an external
primer. Suitable for bonding a wide variety
of plastic and metal substrates. Provides
a long open time ( 40 –60 min) for correct
aligning of parts.
Methacry- Plexus 4103/3700 Off- 365 d 186 – Two part methacrylate adhesive for struc-
late MA420 white or 206 bar tural bonding of thermoplastic, metal and
blue ( 2,695.6 composite assemblies. Combined at 10:1
–2,985.5 ratio. It has a working time of 4 –6 min.
psi)
Structur- Scotch- 332/S7420 Black 180 d - Two part acrylic based adhesive (10:1 ra-
al plastic weld tio by vol.) that can bond many low surface
structural energy plastics, including many grades of
plastic ad- polypropylene, polyethylene and TPO’s
hesive without special surface preparation.
Non-pre- Evo-Stick 4103/0800 None- 365 d HIGHLY A thin even film of adhesive should be ap-
ferred 528 pre- FLAMMA- plied to both surfaces being bonded and al-
adhesive ferred BLE lowed to become touch dry. This is a con-
tact adhesive and coated surfaces can-
not therefore be slid into position since the
bond forms on contact. It is often conve-
nient to align the parts along an edge and
then bring the two areas into contact.
Direct Sika 4103/2100 Black - - A one component polyurethane pre-poly-
glazing 250PC mer based adhesive. A mastic adhesive
Sikat- which reacts with atmospheric moisture to
ack Ultra- form a rubber like solid.
fast (use
4103/4000
or
4102/4900)
Direct Sika 4103/2200 Black - - For bonding glass to cab frames. A mas-
glazing 255FC tic adhesive which reacts with atmospheric
(use moisture to form a rubber like solid. When
4102/5000) using this product ensure both surfaces
are clean and dry. Use Sika cleaner 205
(4104/1200).
Direct Sikaflex 4103/3200 Black - - A high performance, elastic, gap, filling one
glazing 552 (use part structural adhesive cures on exposure
4102/5000) to atmospheric moisture to form a durable
elastomer. Contains no isocyanate.

75 - 19 9823/1600-1 75 - 19
 75 - Consumable Products
15 - Adhesive
00 - General

Subsec- Commer- Product Colour Shelf Technical Comments

tion cial name Number life data
Industri- Loctite 333/Y7062 Light - 307 bar Single component, heat activated formu-
al grade Hysol Grey ( 4,449.3 lation develops tough, strong, structur-
epoxy E-214 HP Paste psi) tensile al bonds which provide excellent peel re-
adhesive strength sistance and impact strength. When fully
cured, the product offers superior thermal
shock resistance, excellent mechanical and
electrical resistance properties and with-
stands exposure to a wide variety of sol-
vents and chemicals. Bonds to a wide vari-
ety of materials, including metals, glass, ce-
ramics and plastics. Cure at 120 °C ( 247.8
°F) or above until completely firm. Heat up
to 150 °C ( 301.8 °F) for 2 h, to maximize
properties.
Anaero- Scotch- 333/L9575 Green 365 d - Single component anaerobic adhesives de-
bic ad- weld signed to secure cylindrical metal assem-
hesive RT-20 blies such as bearings on shafts, bush-
(Dimethacry- ings, sleeves, housings, and keyways. Help
late) prevent loosening, corrosion and leakage
caused by shock and vibration. Full cure
time 24 h. Temperature range = - 54 °C
( 129.1 °F) to 450 °C ( 841.4 °F). Not rec-
ommended for use on most plastics due to
potential cracking of plastic parts.
Direct Terostat 4102/4900 Black 540 - Cure rate: approx. 3 –4 mm/ 24 h. Glazing
glazing 8597 CT d in time: maximum 20 min (period of time be-
orig- tween beginning of material application until
inal inserting of the pane).
pack-
aging
Direct Teroson 4102/5000 Black, 365 - Skin formation time: approx. 10 min. Cure
glazing 939CT / off- d in rate: approx. 3 mm/ 24 h.
Terostat white, orig-
MS939 grey, inal
black pack-
aging
Direct Terostat 4103/4000 Black 180 d 80 bar One component, pumpable adhe-
glazing 8900 HV ( 1,159.4 sive/sealant based on polyurethane, which
psi) tensile cures by reaction with moisture to an elas-
strength tic rubber. The skin formation and curing
time are dependent on humidity, tempera-
ture and depth of joint. High temperature
and high moisture reduces curing time.
Sag resistant, temperature range of - 40 °C
( 103.9 °F) to 90 °C ( 193.9 °F).
Direct Tero- 4103/4100 Black 270 d 85 bar Single component, moisture curing, ad-
glazing stat 8594 ( 1,231.9 hesive/sealant for repair. Product with
HMLC psi) tensile high shear modulus and low conductivity.
strength Suitable for all applications that require very
high electrical insulation of the adhesive
used for the bonding of windows. Sag resis-
tant.

75 - 20 9823/1600-1 75 - 20
 75 - Consumable Products
15 - Adhesive
00 - General

Subsec- Commer- Product Colour Shelf Technical Comments

tion cial name Number life data
Direct Terostat 4103/4200 Black 365 80 bar One component, pumpable adhe-
glazing 8900 LV d in ( 1,159.4 sive/sealant based on polyurethane, which
car- psi) tensile cures by reaction with moisture to an elas-
tridges.strength tic rubber. The skin formation and curing
180 time are dependent on humidity, tempera-
d in ture and depth of joint. High temperature
sausage and high moisture reduces curing time.
pack. Sag resistant, temperature range of - 40 °C
180 ( 103.9 °F) to 90 °C ( 193.9 °F) short expo-
d in sure (up to 1 h) of 130 °C ( 265.8 °F).
hob-
bocks
and
drums
Direct Sika 295 4103/4300 Black, 365 d - Direct glazing adhesive for plastic glazing
glazing UV white panels. One component polyurethane ad-
hesive of paste like consistency. 60 min
tack free time, 1 d cure time ( 4 mm at 23
°C ( 73.4 °F)). Good UV, fresh water and
seawater resistance. Do not apply below
temperatures of 10 °C ( 50.0 °F) or above
35 °C ( 95.0 °F).

75 - 21 9823/1600-1 75 - 21
 75 - Consumable Products
16 - Sealant

16 - Sealant

Contents Page No.

75-16-00 General ........................................................................................................................... 75-23

75 - 22 9823/1600-1 75 - 22
 75 - Consumable Products
16 - Sealant
00 - General

00 - General Introduction
Introduction .................................................... 75-23 All sealants should be used at all times in line
Technical Data ............................................... 75-24 with the manufacturer’s recommendations. Sealants
are used mainly for the sealing of screwed joints,
sealing flanges and flat surfaces and where gap
filling properties are required.

Types of Sealant
Various types of sealant are specified in JCB
Standards:

1. Those for the sealing of screwed joints.

2. Sealants for joining flanges and flat surfaces.
(Flange size and likelihood of dismantling
require consideration when selecting this type of
sealant).
3. Sealants for use where gap filling properties are
required. (The gap dimensions, joint movement
if any, type of materials being joined and
aesthetic appearance require consideration
when selecting this type of sealant).

Approved Sealants
The table shown in Technical Data are the approved
sealants available to use on JCB machines. The
table also provides basic details to help with selection
of sealants. More up to date information can be found
on the manufacturer’s website.

75 - 23 9823/1600-1 75 - 23
 75 - Consumable Products
16 - Sealant
00 - General

Technical Data

Table 65. Sealants Approved Product Information

Subsec- Com- Product Colour Shelf Technical Comments
tion mercial Number life data
name
High Loctite 4102/0500 Green 730 d 250 bar Non drip formulation, used on larger fittings,
strength 275(1) ( 3,623.2 coarse threads.
Per- psi) torque
mabond strength
A140 (on M8)
High Forge- 4102/3100 Yellow 270 d 25 bar Can be painted over with some 2 pack
strength way ( 362.3 psi) paint. Maximum width of joint = 35 mm,
240FC
(1)
breaking minimum width = 2 mm, minimum depth =
strength 2 mm. Recommended depth of joint = width
of joint.
Medium Loctite 4102/3500 Green - More than Used for locating pins in radiator assem-
to high 620 241 bar blies, sleeves into pump housings and
strength ( 3,492.7 bearings in auto transmissions. Not suitable
psi) shear for plastics. Diametrical clearance: up to
strength 0.2 mm
Medium Loc- 4102/2000 Red, flu- 365 d 90 bar Typically used as form-in-place gasket on
strength tite 518 ores- ( 1,304.3 rigid flanged connections.
Gasket cent psi) tensile
Elimina- strength
tor
Medium Loctite 4102/4100 Red gel, - 80 bar It is manufactured to minimise air bubbles
strength 5182 fluores- ( 1,159.4 in the package. Used to seal gaskets, hous-
cent psi) shear ings, cases and covers. It can also be used
strength to repair and replace cut gaskets (up to
0.08 mm in thickness).
Medium Loctite 4102/2500 Clear 365 d 6 mm gap Formulated to withstand weathering and
strength 595 filling extreme temperature cycling. Used for pot-
ting, coating and sealing. Can be applied
horizontal, vertical and overhead.
Medium Loctite 4102/1900 Yellow 365 d 170 bar A fast curing thread sealant used on coarse
strength 577(1) ( 2,463.8 threads and pipe fittings up to 75 mm
Per- psi) break- thread size. Clearance for gap filling 0.8
mabond away mm.
A1044 torque
Medium Loctite 4102/2700 Blue 365 d 140 – Taper thread sealant, non-fluorescing to
strength 2431 340 bar see oil leaks. Suitable for all taper fittings
( 2,029.0 up to M36.
–4,927.5
psi) break-
away
torque
Low Clayton 4102/2200 White 12 h Maximum Seals pipes and plugs against leakage of
strength Dewan- opaque full seal pres- air, fuels, lubricants and coolants. Hardens
dre air cure sure 29 to a tough seal resistant to shock and vibra-
brake bar ( 420.3 tion. Easily dismantled.
sealant psi)
SC1252
Low Red 4102/0800 - - Resistant Non-hardening paste jointing for joints reg-
strength Her- to oil ularly opened for servicing.
metite

75 - 24 9823/1600-1 75 - 24
 75 - Consumable Products
16 - Sealant
00 - General

Subsec- Com- Product Colour Shelf Technical Comments

tion mercial Number life data
name
Low Loctite 4102/1100 White 730 d 40 –100 Used where slow cure is required to permit
strength 572 opaque bar ( 579.7 component alignment. PTFE (Polytetrafluo-
–1,449.3 roethylene) filler.
psi) break-
away
torque
Gas- Loc- 4102/3200 Blue to 0.2 72 h full Easy disassembly, used as form-in-place
keting tite 509 green mm strength on gasket.
medium Gasket gap steel
strength Elimi- filling
nator
Flange
Sealant
Gas- Loctite 4102/1200 Red 730 d 2 h working Does not creep or relax after curing, no bolt
keting 574
(1)
strength re-tightening is required. Oil resistant. Ideal
medium Per- for formed in-situ gaskets.
strength mabond
A136
Sealant Loctite 4102/2600 Black 365 d Resists Used to dress new or worn gaskets. Dries
for gas- FAG 2 / pressures slowly, sets to pliable film for easy disman-
kets Loctite up to tling.
5922 345 bar
( 5,000.0
psi)
Rubber Dow 4102/0900 Clear or 270 d 16.7 bar A synthetic rubber joint sealant suitable for
jointing corning translu- ( 242.0 joints between non-porous surfaces such
com- 781 cent psi) tensile as glass and metal, metal and metal where
pound Loc- strength relatively large gap filling properties are re-
tite su- quired. Suitable for vertical and overhead
perflex applications under normal atmospheric con-
clear ditions. Joint movement approx.+/-12.5%.
RTV3 Cure time to 6 mm depth in 24 h.
EVO-
stick
stan-
dard in-
dustri-
al clear
silicone
sealant
Dun-
lop high
modulus
silicone
sealant
DP2205
Epoxy Loc- 4102/2400 Slightly - - 0.05 L container requires special bi-mixer
resin tite fast coloured / (gun) so it is mixed as dispensed, 0.024 L
epoxy trans- is mixed by hand.
sealant parent

75 - 25 9823/1600-1 75 - 25
 75 - Consumable Products
16 - Sealant
00 - General

Subsec- Com- Product Colour Shelf Technical Comments

tion mercial Number life data
name
Room Loctite 4102/3400 Metal- - Dry to Designed for flange sealing, good resis-
tempera- 5910, lic black touch in 40 tance to oils and allows high joint move-
ture vul- Flange paste min ment.
canising sealant,
RTV Sil-
icon
Room Loctite 4102/4200 Black 730 d 18 bar Used for gaskets. Excellent resistance to
tempera- 5970 ( 260.9 engine oils. Typical applications include
ture vul- psi) tensile stamped sheet metal covers (timing covers
canising strength and oil sumps) where good oil resistance
and the ability to withstand high joint-move-
ment are required.
Room Loc- 4102/2900 Black 270 d 16 bar Thixotropic allowing easy application, hori-
tempera- tite su- ( 231.9 zontal, vertical and overhead. Seals against
ture vul- perflex psi) tensile water and many solvents.
canising black strength
silicone
Room Loctite 4102/3700 Grey 730 d 14 bar Designed specifically for on line, low pres-
tempera- 5901 ( 202.9 sure tests carried out before product be-
ture vul- psi) shear gins to cure. Product exhibits excellent re-
canising strength sistance to automotive engine oils. Primari-
ly for flange sealing, it withstands high joint-
movement requirements.
Room Loctite 4102/3900 Black 730 d 20 bar Generally used for sealing applications, but
tempera- 5368 paste ( 289.9 also for bonding and for high temperature
ture vul- psi) tensile protection.
canising strength
Room Loctite 4102/4000 Clear 730 d 20 bar Designed specifically for use as a bond-
tempera- 5366 paste ( 289.9 ing agent to ensure perfect sealing, as
ture vul- psi) shear well as bonding and protection. Examples
canising strength are sealing side windows in trains, seal-
ing heat sources (heat exchangers and wa-
ter heaters) and for protection/insulation of
electrical boxes.
Room Hylomar 332/D5695 Black 540 d 40 bar A special purpose adhesive and sealant
tempera- 607 paste ( 579.7 that can be used for a variety of applica-
ture vul- psi) tensile tions. It has good resistance to oils and
canising strength aqueous anti-freeze agents, and is particu-
larly suitable for high strength applications
in odour sensitive environments.
Joining Loctite 4102/3800 Black 730 d 14 bar JCB Service ONLY. Introduced for joining
oil pan to 5900 paste ( 202.9 the oil pan to the bedplate face during ser-
bedplate psi) shear vice. High resistance to engine oils. The
strength joint should be clamped to spread the ad-
hesive and allowed to cure for 7 d before
heavy service duty.
Anti-cor- To mil- 4102/4300 Yellow - Type 1 Used to coat surfaces of dissimilar metals
rosive itary Class C prior to assembly to prevent corrosion. Zinc
spec chromate containing substance ideal for ap-
TT- plication to joints between aluminium and
P-1757B steel to prevent corrosion and seizure. FOR
1CY USE ON MILITARY VEHICLES ONLY.

75 - 26 9823/1600-1 75 - 26
 75 - Consumable Products
16 - Sealant
00 - General

Subsec- Com- Product Colour Shelf Technical Comments

tion mercial Number life data
name
Gas- Bondloc 4102/4500 Clear/ - Full cure B555 is an anaerobic gasket sealant. It
keting B555 Opaque time 24 seals close fitting joints between rigid metal
medium h. 50 bar faces and flanges. Tensile strength to ISO
strength ( 724.6 6922.
psi) tensile
strength
Seam Terolan 4102/4600 Light 90 d - Serves as a seam sealant between sheet
sealant 3412 grey metal butt and overlap joints (interior
AA-25 seems) on vehicle bodies. Can be cured at
temperatures of minimum 140 °C ( 283.8
°F) (effective metal temperature) for 15
min. The material is applied to electro-dip
coated steel sheets.
Direct Sikaflex 4102/2800 Yellow - - Direct glazing one component polyurethane
glazing 221 based adhesive and sealant compound.
(use Tack free time of 50 min.
4102/4800)
Direct Sikaflex 4102/2300 Black - - A one component polyurethane pre-poly-
glazing 252 mer based sealant. For sealing glass to
(use frames. A mastic sealant which reacts with
4102/4700)
(1)
atmospheric moisture to form a rubber like
solid.
Direct Teroson 4102/4700 - 365 - The substrates must be clean, dry, oil and
glazing PU92 d in grease free. Skin formation time: approx.
CT orig- 20 min Cure rate: approx. 4 mm/ 24 h
inal
pack-
aging
Direct 930 4102/4800 Yellow 365 - The substrates must be clean, dry, oil and
glazing JCB d in grease free. It can be necessary to rough-
Branded orig- en the surface or to use a primer/adhe-
yellow inal sion promoter to provide optimum adhe-
CT pack- sion. When manufacturing of plastics, ex-
aging ternal release agents are often used; these
agents must be absolutely removed prior.
Skin formation time : approx. 20 min Cure
rate : approx. 4 mm/ 24 h
Direct Terostat 4102/4900 Black - - Isocyanate free solution. Designed for use
glazing 8597 without primer or activator. When you use
CT this sealant on operator station, it should be
used with Teroson PU 8519P black primer
(and Teroson 450 clear adhesion promoter
when specified specially). Cross compatible
with all OEM / OES / AAM DGX sealants,
including MS and PU chemistry (any re-
maining bead must be fully cured before
application).

75 - 27 9823/1600-1 75 - 27
 75 - Consumable Products
16 - Sealant
00 - General

Subsec- Com- Product Colour Shelf Technical Comments

tion mercial Number life data
name
Silicone Si- 4102/5100 Black - - High modulus permanently flexible 100 %
sealant - ka/Ever- silicone. Temperature resistant up to 300
Heat re- build °C ( 571.6 °F). Ideal for sealing industrial
sistant Heat and high performance gaskets, oven doors
Mate etc.
Gas- Loctite 4102/6100 Opaque - - Introduced for Heavy products India (swing
ket and 510 pink motor/ gearbox face).
sealing
(1) This is a non preferred product.

75 - 28 9823/1600-1 75 - 28
 78 - After Sales
Contents Page No.

Acronyms Glossary .................................................................................................................................... 78-2

78-24 Maintenance Schedules

78-24-00 General ............................................................................................................................. 78-3
78-24-03 Maintenance Intervals ...................................................................................................... 78-5
78-24-06 Pre-start Cold Checks, Service Points and Fluid Levels .................................................. 78-6
78-24-09 Functional Tests and Final Inspection .............................................................................. 78-7
78-81 Clothing and Personal Protective Equipment (PPE)
78-81-00 General ............................................................................................................................. 78-9
78-93 Special Tools
78-93-00 General ........................................................................................................................... 78-11
78-93-03 Parts List ........................................................................................................................ 78-12
78-96 Units of Measurement
78-96-00 General ........................................................................................................................... 78-19

9823/1600-1
2017-06-09
Acronyms Glossary

2WD Two Wheel Drive

4WD Four Wheel Drive

9823/1600-1
2017-06-09
 78 - After Sales
24 - Maintenance Schedules

24 - Maintenance Schedules

Contents Page No.

78-24-00 General ............................................................................................................................. 78-3

78-24-03 Maintenance Intervals ...................................................................................................... 78-5
78-24-06 Pre-start Cold Checks, Service Points and Fluid Levels .................................................. 78-6
78-24-09 Functional Tests and Final Inspection .............................................................................. 78-7

78 - 1 9823/1600-1 78 - 1
Notes:

78 - 2 9823/1600-1 78 - 2
 78 - After Sales
24 - Maintenance Schedules
00 - General

00 - General Introduction
WARNING Maintenance must be done only by
Introduction ...................................................... 78-3 suitably qualified and competent persons.
Operation ......................................................... 78-4
Before doing any maintenance make sure the
machine is safe, it must be correctly parked on
solid, level ground.
To prevent anyone starting the engine, remove
the ignition key. Disconnect the battery (by means
of the battery isolator if installed) when you are
not using electrical power. If you do not take these
precautions you could be killed or injured.

A badly maintained machine is a danger to

the operator and the people working around the
operator. Make sure that the regular maintenance
and lubrication tasks listed in the service schedules
are done to keep the machine in a safe and efficient
working condition.

To ensure the correct functioning of the engine

and emissions control system all operation and
maintenance must be conducted in accordance
with the instructions in this manual. Incorrect
operation, maintenance or repair of the engine
and emissions control system may lead to reduced
product life, loss of performance or malfunctions.
It is the machine owner's responsibility to ensure
maintenance is conducted properly in accordance
with the requirements in this manual.

Apart from the daily tasks, the schedules are based

on the machine running hours. Keep a regular
check on the hourmeter readings to correctly gauge
the service intervals. When there is no hourmeter
installed, use the calendar equivalents to determine
the service intervals.

Do not use a machine which is due for a service.

Make sure any defects found during the regular
maintenance checks are corrected immediately.

More frequent checks of engine components than

the engine manufacturer recommends do not
invalidate emissions warranty.

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 78 - After Sales
24 - Maintenance Schedules
00 - General

Operation

The schedules show the service tasks which must be

done and their intervals.

The services must be done at either the hourly

interval or the calendar equivalent, whichever occurs
first.

The intervals given in the schedules must not

be exceeded. If the machine is operated under
severe conditions (high temperature, dust, water,
etc.) shorten the intervals.

Table 66.
Service task can be completed by a
competent operator. Details of how to
complete the service task are given in
the Operator's Manual.
We recommend that a Service Engi-
neer completes the service task. De-
tails of how to complete the service
task are given in the Service Manual.

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 78 - After Sales
24 - Maintenance Schedules
03 - Maintenance Intervals

03 - Maintenance Intervals

Introduction

Table 67.
Interval (h) Calendar Equivalent
10 Daily
50 Weekly
500 Six months
1000 Yearly
2000 Two years

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 78 - After Sales
24 - Maintenance Schedules
06 - Pre-start Cold Checks, Service Points and Fluid Levels

06 - Pre-start Cold Checks, Service

Points and Fluid Levels

Introduction

(For: PS760, PS764, PS766)

Table 68. Pre-start Cold Checks Service Points and Fluid Levels
Component Operation 10 50 100 500 1,000 2,000
(1)

Transmission
Transmission oil level Check
Transmission oil Change
Transmission filter Change
Transmission strainer Clean
Drive shafts Security/ Grease
(1) First 100 hours Service only, to be completed by your Distributor.

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 78 - After Sales
24 - Maintenance Schedules
09 - Functional Tests and Final Inspection

09 - Functional Tests and Final

Inspection

Introduction

(For: PS760, PS764, PS766)

Table 69. Functional Test and Final Inspection
Component Operation 10 50 100 500 1,000 2,000
(1)

Transmission
2WD (Two Wheel Drive)/ 4WD Check
(Four Wheel Drive) Selection
Forward/ Reverse and Gear Check
change - Operation
Transmission main line pres- Check
sure
(2)

Clutch disconnect Check

Neutral start operation Check
Clutch pack pressures
(2)
Check
BRAKES (Clydesdale and
Hayes types)
Park brake operation Check
(1) First 100 Hours service only, to be completed by your Distributor.
(2) Jobs should be done only by a Specialist person.

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 78 - After Sales
81 - Clothing and Personal Protective Equipment (PPE)

81 - Clothing and Personal Protective Equipment (PPE)

Contents Page No.

78-81-00 General ............................................................................................................................. 78-9

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 78 - After Sales
81 - Clothing and Personal Protective Equipment (PPE)
00 - General

00 - General

Introduction

Do not wear loose clothing or jewellery that can get

caught on controls or moving parts. Wear protective
clothing and personal safety equipment issued or
called for by the job conditions, local regulations or
as specified by your employer.

78 - 9 9823/1600-1 78 - 9
 78 - After Sales
93 - Special Tools

93 - Special Tools

Contents Page No.

78-93-00 General ........................................................................................................................... 78-11

78-93-03 Parts List ........................................................................................................................ 78-12

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 78 - After Sales
93 - Special Tools
00 - General

00 - General

Introduction

The tools shown are the special tools required for

completing the procedures described in this manual.
These tools are available from JCB Service or in
some instances can be manufactured locally.

The tools are divided into three categories:

• Special Tool = Only available from JCB.

• Recommended Tool = Available from JCB but
other tool manufacturers/suppliers may offer a
tool with the same characteristics.
• General Tool = A tool which is widely available.

Tools other than those listed will be required. It is

expected that such general tools will be available in
any well equipped workshop or be available locally
from any good tool supplier.

Before you start work, make sure that all safety

precautions are observed in accordance with the
information contained within the relevant support
documentation.

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 78 - After Sales
93 - Special Tools
03 - Parts List

03 - Parts List Introduction

Introduction .................................................... 78-12
Component Identification ............................... 78-13

27 - Driveline

Tool Category Part No. Description Qty. Comments

Special Tool 823/10420 Thrust Washer Kit 1
Special Tool 892/00223 Hand Pump Pressure 1
Test
Special Tool 892/00229 Flowmeter 1
Special Tool 892/00278 Pressure Gauge (0-40 1
Bar)
Special Tool 892/00292 Oil Filter Removal Tool 1
Special Tool 892/00812 Drive Coupling Spanner 1
Special Tool 892/01082 Gearbox Assembly 1
Cradle
Special Tool 892/01083 Transfer Gear 1
Assembly Tool
Special Tool 892/01084 Bearing Assembly Tool 1
Special Tool 892/01110 Torque Converter 1
Alignment Tool
Special Tool 993/59300 Pressure Test Adaptor 1
Special Tool 998/10738 Adaptor Spanner 1

33 - Electrical System

Tool Category Part No. Description Qty. Comments

Special Tool 718/20237 Machine Cable 1
Special Tool 892/01174 Data Link Adaptor 1
(DLA) Kit

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 78 - After Sales
93 - Special Tools
03 - Parts List

Component Identification

Special Tool - 718/20237 - Machine Cable

Special Tool - 823/10420 - Thrust Washer Kit

After using a spacer, obtain a replacement to keep the
set complete.

Item Part No. Description Qty.

1 823/10421 Shim 4.3mm thick 1
2 823/10422 Shim 4.4mm thick 1
3 823/10423 Shim 4.5mm thick 1
4 823/10424 Shim 4.6mm thick 1
5 823/10425 Shim 4.7mm thick 1
5 823/10426 Shim 4.8mm thick 1

Special Tool - 892/00223 - Hand Pump Pressure Test

Special Tool - 892/00229 - Flowmeter

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 78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool - 892/00278 - Pressure Gauge (0-40 Bar)

Special Tool - 892/00292 - Oil Filter Removal Tool

Use to install or remove spin-on filter canister.

Special Tool - 892/00812 - Drive Coupling Spanner

PTO coupling spanner for yoke type couplings.

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 78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool - 892/01082 - Gearbox Assembly Cradle

620.0
325.0 171.6
151.9 103.4 20.0
111.6
R 5.0
TYP
168.0

10.0

160.0
49
51.8 73.2 REF
107.3

0
1.
2
2

R1

48
R1 2 5
. 0
600.0

140.1
6 0 .7
9
216.6

1 5 3 .2

263.6
325.6 REF

R1 3 7 .0

9
TYP 9 PLACES
0
09.
R1

R6
2
20.0

.0

25.0
== 2.9 30
TYP 9 PLACES 53.2
95.0
142.3 118.7

Support legs will also be required. These must be

locally manufactured so that the gearbox can be
supported as shown at A.

Special Tool - 892/01083 - Transfer Gear Assembly Tool

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 78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool - 892/01084 - Bearing Assembly Tool

Special Tool - 892/01110 - Torque Converter Alignment Tool

Special Tool - 892/01174 - Data Link Adaptor (DLA) Kit

Item Part No. Description Qty.
1 1 Interconnecting 1
cable, DLA to
machine ECU
diagnostics socket.
2 2 Interconnecting 1
cable, DLA to
machine ECU
C D
B E
A
J F
H G

diagnostics socket.
3 3 Kit carrying case. 1
4 Interconnecting 1
cable, DLA to laptop
PC.
5 Data Link Adaptor 1
(DLA), enables data
5 exchange between
the machine ECU
(Electronic Control
4 Unit) and a laptop
PC loaded with
the applicable
diagnostics
software.
6 Interconnecting 1
6 cable, DLA to laptop
PC.

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 78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool - 993/59300 - Pressure Test Adaptor

Special Tool - 998/10738 - Adaptor Spanner

78 - 17 9823/1600-1 78 - 17
 78 - After Sales
96 - Units of Measurement

96 - Units of Measurement

Contents Page No.

78-96-00 General ........................................................................................................................... 78-19

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 78 - After Sales
96 - Units of Measurement
00 - General

00 - General Table 75. Flow

Measurement Convert to Multiply by
Technical Data (unit)
Litre/Minute (L/ UK Gal- 0.220
m) lon/Minute
The standard units of measurement used by JCB are US Gal- 0.264
listed below together with the formula for conversion lon/Minute
for countries using non metric standards.
Table 76. Area
Standard Units Measurement Convert to Multiply by
(unit)
Table 70. Force Square Millime- Square Inch 0.0015
Measurement Convert to Multiply by tre (mm²) (in²)
(unit) Square Metre Square Foot 10.764
Newton (N) Kilogram force 0.102 (m²) (ft²)
(kgf) Square Yard 1.196
Pound force 0.225 (yd²)
(lbf)
Table 77. Torque
Table 71. Length Measurement Convert to Multiply by
(unit)
Measurement Convert to Multiply by
(unit) Newton metre Pound force 0.7376
(Nm) foot (lb f ft)
Millimetre (mm) Inch (in) 0.0394
Metre (m) Feet (ft) 3.281 Table 78. Pressure
Yard (yd) 1.094 Measurement Convert to Multiply by
Kilometre (km) Mile (mile) 0.621 (unit)
Bar Pound force/ 14.5
Table 72. Mass inch² (psi)
Measurement Convert to Multiply by Table 79. Fuel Consumption
(unit)
Measurement Convert to Multiply by
Gram (g) Ounce (oz) 0.035
(unit)
Kilogram (kg) Pound (lb) 2.205
Kilometre/Litre Miles/Gallon 2.825
Tonne Ton 0.984 (km/l) (mpg)
Miles/ US Gal- 2.352
Table 73. Speed lon
Measurement Convert to Multiply by Table 80. Temperature
(unit)
Kilometre/Hour mile/hour (mph) 0.621 Measurement Convert to Formula
(km/h) (unit)
Metre/Second feet/second (ft/ 3.281 Degrees Cel- Degrees Multiply by 9,
(m/s) s) sius (°C) Fahrenheit (°F) Divide by 5,
Add 32
Table 74. Volume Table 81. Power
Measurement Convert to Multiply by Measurement Convert to Multiply by
(unit) (unit)
Cubic Centime- Cubic Inch (in³) 0.061 KiloWatt (kW) Horsepower 1.341
tre (cm³) (hp)
Cubic Metre Cubic Foot (ft³) 35.315
(m³) Table 82. Time
Cubic Yard (yd³) 1.308
Millilitre (ml) Fluid ounce (fl 0.035 Measurement (unit)
oz) Second (s)
Litre (l) UK Gallon 0.220 Minute (min)
US Gallon 0.264 Hour (h)

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 78 - After Sales
96 - Units of Measurement
00 - General

Table 83. Current

Measurement (unit)
Ampere (A)

Table 84. Voltage

Measurement (unit)
Volt (V)

Table 85. Noise Levels

Measurement (unit)
Sound pressure level (LpA)
Sound power level (LwA)

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