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.

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

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

This manual contains original instructions, verified by

the manufacturer (or their authorized representative).

Copyright 2017 © 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:

9823/0100-1
 Spine Cards

SERVICE MANUAL SERVICE MANUAL

Volume 1 Volume 2

SD55 Axle SD55 Axle

EN 9823/0100 EN 9823/0100

SERVICE MANUAL SERVICE MANUAL

Volume 3 Volume 4

SD55 Axle SD55 Axle

EN 9823/0100 EN 9823/0100

9823/0100-1
Notes:

9823/0100-1
 01 - Machine
Contents Page No.

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

9823/0100-1
2018-05-25
Notes:

9823/0100-1
2018-05-25
 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 9823/0100-1 01 - 1
Notes:

01 - 2 9823/0100-1 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 9823/0100-1 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 9823/0100-1 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 9823/0100-1 01 - 5

12 - Maintenance Safety
Health and Safety
Raised Machine
Never position yourself or any part of your body
under a raised machine which is not correctly
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be
killed.
Air Conditioning Maintenance
The air conditioning system is a closed loop system
and contains pressurised refrigerant. No part of the
system should be disconnected until the system
has been discharged by a refrigeration engineer
or a suitably trained person. You can be severely
frostbitten or injured by escaping refrigerant.
Compressed Air
Compressed air is dangerous. Wear personal
protective equipment. Never point a compressed air
jet at yourself or others.
Springs
Always wear personal protective equipment when
dismantling assemblies containing components
under pressure from springs. This will protect against
eye injury from components accidentally flying out.
Metal Splinters
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper drift to remove and install metal pins.
Always wear personal protective equipment.
Communications
Bad communications can cause accidents. If two
or more people are working on the machine, make
sure each is aware of what the others are doing.
Before starting the engine make sure the others are
clear of the danger areas. Examples of danger areas
are: the rotating blades and belt on the engine, the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured
if these precautions are not taken.
Repairs
If your machine does not function correctly in
any way, get it repaired straight away. Neglect of
necessary repairs could result in an accident or affect
your health. Do not try to do repairs or any other
type of maintenance work you do not understand. To
avoid injury and/or damage get the work done by a
specialist engineer.
01 - 6 9823/0100-1
01 - Machine
03 - Safety
12 - Maintenance Safety
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose
service line has been vented before connecting or
removing hoses. Make sure the engine cannot be
started while the hoses are open.
'O' rings, Seals and Gaskets
Badly installed, damaged or rotted 'O' rings, seals
and gaskets can cause leakages and possible
accidents. Renew whenever disturbed unless
otherwise instructed. Do not use Triochloroethane or
paint thinners near 'O' rings and seals.
Arc Welding
To prevent the possibility of damage to electronic
components, disconnect the battery and the
alternator before arc-welding on the machine or
attached implements.
If the machine is equipped with sensitive electrical
equipment, i.e. amplifier drivers, electronic control
units (ECUs), monitor displays, etc., then disconnect
them before welding. Failure to disconnect the
sensitive electrical equipment could result in
irreparable damage to these components.
Parts of the machine are made from cast iron, welds
on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable
or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to
the same component that is being welded to avoid
damage to pivot pins, bearings and bushes. Attach
the welder earth (ground) cable a distance from the
part being welded no more than 0.6 m.
Counterweights
Your machine may be installed with counterweights.
They are extremely heavy. Do not attempt to remove
them.
Accumulators
The accumulators contain hydraulic fluid and gas at
high pressure. Prior to any work being carried out
on systems incorporating accumulators, the system
pressure must be discharged by a JCB dealer, as
the sudden release of the hydraulic fluid or gas may
cause serious injury or death.
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
cool before servicing the unit.
Soft Ground
A machine can sink into soft ground. Never work
under a machine on soft ground.
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 9823/0100-1 01 - 7

18 - Operating Safety
Health and Safety
Training
Make sure that you have had adequate training and
that you are confident in your ability to operate the
machine safely before you use it. Practice using the
machine and its attachments until you are completely
familiar with the controls and what they do. With
a careful, well trained and experienced operator,
your machine is a safe and efficient machine. With
an inexperienced or careless operator, it can be
dangerous. Do not put your life, or the lives of others,
at risk by using the machine irresponsibly. Before you
start to work, tell your colleagues what you will be
doing and where you will be working. On a busy site,
use a signalman. Before doing any job not covered
in this manual, find out the correct procedure. Your
local JCB distributor will be glad to advise you.
Fuel
Fuel is flammable, keep naked flames away from the
fuel system. Stop the engine immediately if a fuel
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel
which could cause a fire. There could be a fire and
injury if you do not follow these precautions.
Machine Condition
A defective machine can injure you or others. Do not
operate a machine which is defective or has missing
parts. Make sure the maintenance procedures in this
manual are completed before using the machine.
Machine Limits
Operating the machine beyond its design limits can
damage the machine, it can also be dangerous.
Do not operate the machine outside its limits. Do
not try to upgrade the machine performance with
unapproved modifications or additional equipment.
Engine/Steering Failure
If the engine or steering fails, stop the machine as
quickly as possible. Do not operate the machine until
the fault has been corrected.
Exhaust Gases
Machine exhaust gases can harm and possibly kill
you or bystanders if they are inhaled. Do not operate
the machine in closed spaces without making sure
there is good ventilation. If possible, install an
01 - 8 9823/0100-1
01 - Machine
03 - Safety
18 - Operating Safety
exhaust extractor. If you begin to feel drowsy, stop
the machine at once and get into fresh air.
Worksites
Worksites can be hazardous. Examine the site
before working on it. You could be killed or injured
if the ground gives way under your machine or if
piled material collapses onto it. Check for potholes
and hidden debris, logs, ironwork etc. Any of these
could cause you to lose control of your machine.
Check for utilities such as electric cables (overhead
and underground), gas and water pipes etc. Mark
the positions of the underground cables and pipes.
Make sure that you have enough clearance beneath
overhead cables and structures.
Communications
Bad communications can cause accidents. Keep
people around you informed of what you will be
doing. If you will be working with other people,
make sure any hand signals that may be used are
understood by everybody. Worksites can be noisy, do
not rely on spoken commands.
Parking
An incorrectly parked machine can move without an
operator. Follow the instructions in the Operator's
Manual to park the machine correctly.
Banks and Trenches
Banked material and trenches can collapse. Do not
work or drive too close to banks and trenches where
there is danger of collapse.
Safety Barriers
Unguarded machines in public places can be
dangerous. In public places, or where your visibility
is reduced, place barriers around the work area to
keep people away.
Sparks
Explosions and fire can be caused by sparks from
the exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
material, vapour or dust.
Hazardous Atmospheres
This machine is designed for use in normal out
door atmospheric conditions. It must not be used
in an enclosed area without adequate ventilation.
Do not use the machine in a potentially explosive
atmosphere, i.e. combustible vapours, gas or dust,
without first consulting your JCB dealer.
01 - 8

Regulations
Obey all laws, worksite and local regulations which
affect you and your machine.
Electrical Power Cables
You could be electrocuted or badly burned if you get
the machine or its attachments too close to electrical
power cables. You are strongly advised to make
sure that the safety arrangements on site comply
with the local laws and regulations concerning work
near electric power lines. Before you start using the
machine, check with your electricity supplier if there
are any buried power cables on the site. There is
a minimum clearance required for working beneath
overhead power cables. You must obtain details from
your local electricity supplier.
Working Platform
Using the machine as a working platform is
hazardous. You can fall off and be killed or injured.
Never use the machine as a working platform
unless with approved man-basket or man-crate (if
applicable).
Machine Safety
Stop work at once if a fault develops. Abnormal
sounds and smells can be signs of trouble. Examine
and repair before resuming work.
Hot Components
Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
cool before servicing the unit.
Travelling at High Speeds
Travelling at high speeds can cause accidents.
Always travel at a safe speed to suit working
conditions.
Hillsides
Operating the machine on hillsides can be
dangerous if the correct precautions are not taken.
Ground conditions can be changed by rain, snow, ice
etc. Check the site carefully. When applicable, keep
all attachments low to the ground.
Visibility
Accidents can be caused by working in poor visibility.
Use your lights to improve visibility. Keep the road
lights, windows, mirrors and cameras clean (when
fitted). Do not operate the machine if you cannot see
01 - 9 9823/0100-1
01 - Machine
03 - Safety
18 - Operating Safety
clearly. Modification of the machine's configuration
by the user (e.g. the fitting of large and non-
approved attachments) may result in a restriction of
the machine visibility.
Hands and Feet
Keep your hands and feet inside the machine. When
using the machine, keep your hands and feet clear
of moving parts. Keep your hands and feet within the
operator compartment while the vehicle is in motion.
Controls
You or others can be killed or seriously injured
if you operate the control levers from outside the
machine. Operate the control levers only when you
are correctly seated.
Passengers
Passengers in or on the machine can cause
accidents. Do not carry passengers.
Fires
If your machine is equipped with a fire extinguisher,
make sure it is checked regularly. Keep it in the
correct machine location until you need to use it. Do
not use water to put out a machine fire, you could
spread an oil fire or get a shock from an electrical
fire. Use carbon dioxide, dry chemical or foam
extinguishers. Contact your nearest fire department
as quickly as possible.
Roll Over Protection
If the machine starts to roll over, you can be crushed
if you try to leave the cab. If the machine starts to roll
over, do not try and jump from the cab. Stay in the
cab, with your seat belt fastened.
Confined Areas
Pay extra attention to proximity hazards when
operating in confined areas. Proximity hazards
include buildings, traffic and bystanders.
Safe Working Loads
Overloading the machine can damage it and make it
unstable. Study the specifications in the Operator's
Manual before using the machine.
Lightning
If you are inside the machine during a lightning storm
stay in the machine until the storm has passed. If
you are outside of the machine during a lightning
storm stay away from the machine until the storm
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 9823/0100-1 01 - 10
 01 - Machine
06 - About this Manual

06 - About this Manual

Contents Page No.

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

01 - 11 9823/0100-1 01 - 11
Notes:

01 - 12 9823/0100-1 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 9823/0100-1 01 - 13
Notes:

01 - 14 9823/0100-1 01 - 14
 27 - Driveline
Contents Page No.

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

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

9823/0100-1
2018-05-30
Acronyms Glossary

DTI Dial Test Indicator

LSD Limited Slip Differential

9823/0100-1
2018-05-30
 27 - Driveline
20 - Axle(s)

20 - Axle(s)

Contents Page No.

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

27 - 1 9823/0100-1 27 - 1
Notes:

27 - 2 9823/0100-1 27 - 2
 27 - Driveline
20 - Axle(s)
00 - General

00 - General Introduction
Introduction ...................................................... 27-3 Axles are an integral component of a wheeled
Technical Data ................................................. 27-4 vehicle. The axle transmits a driving torque to the
Component Identification ................................. 27-5 wheel, as well as maintaining the position of the
Drain and Fill ................................................... 27-7 wheels relative to each other and to the vehicle body.
Check (Level) ................................................ 27-10
Lubricate ........................................................ 27-11
Remove and Install ....................................... 27-12
Disassemble and Assemble .......................... 27-17

27 - 3 9823/0100-1 27 - 3
 27 - Driveline
20 - Axle(s)
00 - General

Technical Data

Table 1. SD 55/NT Axle

Type JCB Drivetrain spiral bevel input with epicyclic hub reduction.
Designation SD 55/NT
Types of Oil immersed multi-plate disc located in hubs.
Brakes
Installation Centre pivot or rigid pad mount
Number of 1
steer cylin-
ders
Weight Pin: 367 kg approx. Pad: 365 kg approx.
(dry, with
no steer
cylinders
and without
wheels)
Ratios Option1 Option2 Option3 Option4 Option5 Option6 Option7
Overall 10.46:1 12.24:1 16.2:1 18.6:1 19.2:1 20.93:1 23.625:1
Crownwheel 1.94:1 2.26:1 3.0:1 3.44:1 3.55:1 3.875:1 4.375
and Pinion
Number of
Teeth
Crownwheel 31 34 33 31 32 31 35
Pinion 16 15 11 9 9 8 8
Hub Reduc- 5.4:1
tion 6.0:1 (SD40 and SD70 hubs only)
Input type 1480 half yoke
Toe-in 0°
Caster an- 0°
gle
Camber an- 1°
gle
Kingpin in- 0°
clination

Table 2. Service Brake - 2 Plate, Positive Retraction (Power Braked Machines)

Type Oil-immersed multi-plate disc
Actuation Hydraulic
Location Outboard - Axle hub
Friction plates 2 per brake (i.e. 4 per axle)
Outside diameter 220 mm
Inside diameter 180 mm
Nominal facing area/ plate 12616 mm²

27 - 4 9823/0100-1 27 - 4
 27 - Driveline
20 - Axle(s)
00 - General

Component Identification

Unit Identification Figure 2.

The axle serial number is stamped on the unit

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

A Identification plate

27 - 5 9823/0100-1 27 - 5
 27 - Driveline
20 - Axle(s)
00 - General

Main Component Identification

Figure 3.

6 7 8 10

1
2

5 11

Item Description
Table 3. 5 Stub axle arm
Item Description 6 Brake piston
1 Counter plates 7 Reaction pin
2 Friction plates 8 Brake piston housing
3 Brake carrier 10 Drive head housing
4 Driveshaft 11 Differential unit

27 - 6 9823/0100-1 27 - 6

Drain and Fill
Notice: The oil level must be checked with the
machine level, otherwise a false indication of the
amount of oil will be given.
Notice: It is not recommended that the machine
be driven with the axle partially filled with oil.
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Get access to the axle drain plug.
3. Clean the area around the drain plug.
4. Drain the oil.
4.1. Place a container of suitable size beneath
drain plug to catch the oil.
4.2. Remove the hexagonal drain plug and its
washer (if installed) or the tapered plug.
Allow oil to drain out. Wipe it clean (metallic
particles should be carefully removed).
Install
1. Install the drain plug (and sealing washer- if
installed), tighten to the correct torque.
1.1. To Make sure you use the correct torque
tightening information, identify the correct
Figure 4. JCB Axle (Inboard Brakes)
C
A
B
A Axle fill/level plug
C Hub drain plug
27 - 7 9823/0100-1
27 - Driveline
20 - Axle(s)
00 - General
axle for your machine. Refer to Figure 4.
and Refer to Figure 5.
1.2. Then make sure you identify the correct
plug for your machine.
1.3. Then use the related torque information for
the drain plug. Refer to Table 4. and Refer
to Table 5.
2. Remove the hexagonal fill/level plug with its
sealing washer (if installed) or the tapered plug.
3. Fill with the specified oil until oil is level with the
bottom of the hole. Refer to (PIL 75-00).
4. Clean the fill/level plug.
5. Install the fill/level plug with its sealing washer (if
installed) or the tapered plug.
6. Tighten the fill/level plug to the correct torque
value.
6.1. To Make sure you use the correct torque
tightening information, identify the correct
axle for your machine. Refer to Figure 4.
and Refer to Figure 5.
6.2. Then make sure you identify the correct
plug for your machine.
6.3. Then use the related torque information for
the fill/level plug. Refer to Table 4. and Refer
to Table 5.
C
B Axle drain plug
27 - 7
 27 - Driveline
20 - Axle(s)
00 - General

Figure 5. JCB Axle (Braked Hubs)

F

D
E

D Axle fill/level plug E Axle drain plug

F Hub drain plug

Figure 6. Hexagonal Plug and Seal- Figure 7. Taper Plug (January 2011 Onwards)
ing Washer (Prior to January 2011)

Table 4. JCB Axles With Inboard Brakes

Function of Plug Installed Description Torque (Nm)
Axle drain plug with hexagonal Hex head plug and washer (3/4 in 90
head and bonded washer BSP)
Axle drain plug with tapered plug Taper plug (3/4 in BSP) 80
Axle fill plug with hexagonal head Hex head plug and washer (3/4 in 90
and bonded washer BSP)
Axle fill plug with tapered plug Taper plug (3/4 in BSP) 80

Table 5. Axles With Braked Hubs

Function of Plug Installed Description Torque (Nm)
Axle drain plug with hexagonal Hex head plug and washer (3/4 in 90
head and bonded washer BSP)
Axle drain plug with tapered plug Taper plug (3/4 in BSP) 80

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00 - General

Function of Plug Installed Description Torque (Nm)

Axle fill plug with hexagonal head Hex head plug and washer (3/4 in 90
and bonded washer BSP)
Axle fill plug with tapered plug Taper plug (3/4 in BSP) 80

Also refer to hub, general, drain and refill, (PIL

27-00).

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Check (Level)

(For: 55 Series (1 Piece Axle))

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

1. Make the machine safe.

2. Clean the area around the fill/level plug.
3. Remove the plug and the sealing washer.
4. Oil should be level with the bottom of the hole.
5. Add the recommended oil if necessary.
6. Clean and install the plug and the washer.
Figure 8.
A

B
A Fill/level plug
B Drain plug

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Lubricate

When greasing, raise the wheels and swing them

from lock to lock. This will ensure the full penetration.

Figure 9.

3 1 5

4 6

10
7 9

1 Grease point 2 Grease point

3 Grease point 4 Grease point
5 Grease point 6 Grease point
7 Grease point 8 Grease point
9 Grease point 10 Grease point

27 - 11 9823/0100-1 27 - 11

Remove and Install
Special Tools
Description Part No. Qty.
Splined Bolt Socket 892/00822 1 5. Loosen the road wheel retaining nuts.
WARNING A raised and badly supported
machine can fall on you. Position the machine
on a firm, level surface before raising one end.
Ensure the other end is securely chocked. Do
not rely solely on the machine hydraulics or jacks
to support the machine when working under it.
Disconnect the battery, to prevent the machine
being started while you are beneath it.
WARNING If, for whatever reason, a wheel stud
is renewed, all the studs for that wheel must be
changed as a set, since the remaining studs may
have been damaged.
Remove and Install (PIN Mounted)
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Use the special tool to remove the bolt to
disconnect the propshaft from the axle.
Special Tool: Splined Bolt Socket (Qty.: 1)
3. Disconnect the brake pipes from the axle swivel
hubs, blank off the exposed connections.
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00 - General
4. Disconnect the hydraulic pipes from the steer
cylinder, blank off all exposed connections.
6. Prop the machine on each side.
7. Remove the road wheels.
8. Position a jack underneath the balance point.
8.1. Important: The drive head assembly is
offset, so the balance point of the axle is not
at the centre of the axle. Attach a ‘cradle’ to
the jack that will partially support the axle.
9. Remove the nut and pivot pin retaining bolt.
10. Use a suitable puller to remove the pivot pin.
11. Lower the jack so that the axle is clear of the
mounting yoke and remove the axle.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Apply Loctite 242 to the threads of bolts.
3. Whenever a wheel has been removed, check the
wheel nut torques every two hours until they stay
correct.
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00 - General

Figure 10.

E
D

C B

A Bolt B Nut
C Tripod jack D Nut
E Bolt F Pivot pin

Remove and Install (PAD Mounted)
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Use the special tool to remove the bolt to
disconnect the propshaft from the axle.
Special Tool: Splined Bolt Socket (Qty.: 1)
3. Disconnect the brake pipes from the axle swivel
hubs, blank off the exposed connections.

27 - 13 9823/0100-1 27 - 13

4. Disconnect the hydraulic pipes from the steer
cylinder, blank off all exposed connections.
5. Loosen the road wheel retaining nuts.
6. Prop the machine on each side.
7. Remove the road wheels.
8. Position a jack underneath the balance point.
8.1. Important: The drive head assembly is
offset, so the balance point of the axle is not
at the centre of the axle. Attach a ‘cradle’ to
the jack that will partially support the axle.
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00 - General
9. Remove the nut, bolts and washers.
10. Lower the jack so that the axle is clear of the
mounting yoke and remove the axle.
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Apply Loctite 242 to the threads of bolts.
3. Whenever a wheel has been removed, check the
wheel nut torques every two hours until they stay
correct.
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00 - General

Figure 11.

B E

A Bolt B Nut
C Tripod jack D Nut

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E Bolt F Washer

Table 6. Torque Values

Item Nm
A 44
B 680
D 476

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Disassemble and Assemble

Consumables 6. Remove the brake pack.

Description Part No. Size
7. Remove the circlip.
JCB Gear Oil HP 4000/0505 20 L
4000/0503 200 L 8. The wear limit of friction plates is to the depth of
JCB Multi-Gasket 4102/1212 0.05 L the cross hatching.
JCB Threadlocker 4101/0250 0.01 L 9. Check all plates for flatness and damage.
and Sealer (Medium 4101/0251 0.05 L
Strength) 10. Scoring of the counter plates to a certain limit is
permissible.
Disassembly 11. Install a new brake pack, if it is damaged.
Note: Make sure that only one side at a time is 12. Make sure that you do not install new plates
disassembled to prevent damage to the bearings and individually.
preserve the crown wheel and the backlash settings.
13. Remove all the three reaction pins and check
The axle must be removed from the machine when them for damage.
you disassemble the rear axle brakes.
14. Before you remove the brake housing and the
Before you disassemble the rear axle brakes, it is piston assembly make sure that you support
mandatory to mark the components for alignment the differential with the driveshaft or any other
and to identify the right hand and left hand side, to suitable support.
make suer that it is correctly assembled at the time
of assembly. 15. Mark the brake piston housing and the
drivehead.
1. Use a heavy duty (6 point) socket to remove the
bolt. 16. Remove the capscrews.

2. Carefully remove the stub axle arm from the 17. Remove the brake housing and the piston
drivehead. assembly.

3. If necessary, tap the case with a soft faced 18. Remove the brake piston from the brake housing.
hammer and remove all traces of the old sealant 19. Remove and discard the seal 1 and seal 2.
from the mating faces.
20. Check the housing bore for damage and scoring.
4. The brake pack consist of three friction plates
and four counter plates. There are two counter 21. Nicks or cuts in the seals may be the reason for
plates, one at each end of the brake pack, which loss of brake fluid.
are not attached to the plate carrier.
5. If it is necessary to install the plates again then
make a note of their position and correct the
orientation.

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Figure 12.

K J
L

N
P

M Q

G F B E C D

A Bolt B Counter plate

C Plate carrier D Circlip
E Reaction pin F Cross hatching
G Oil flow holes H Suitable support for differential
J Brake piston housing K Drivehead housing
L Capscrew M Nut
N Seal 1 P Brake piston
Q Seal 2

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Assembly Consumable: JCB Threadlocker and Sealer

(Medium Strength)
1. Remove all traces of the old sealant from the
mating faces of the drive head and the brake 21. Put the stub axle on to the drivehead. Make sure
piston housing. that they are aligned correctly.

2. Install a new seal 1 and seal 2. Make sure they 22. Install the bolt and tighten the bolt to the correct
seat squarely in their grooves. torque value.

3. Carefully push the brake piston into the brake Table 7. Torque Values
piston housing. Item Description Nm
4. Apply JCB Multigasket to the drivehead mating A Bolt 98
face and then install the brake piston housing L Capscrew 46
assembly.
Consumable: JCB Multi-Gasket
5. Make sure that the brake piston housing is
aligned correctly.
6. Install the capscrews, tighten the screws to the
correct torque value.
7. Remove the differential support.
8. Soak the new friction plates in JCB Special Gear
Oil before assembly.
Consumable: JCB Gear Oil HP
9. Assemble the three friction plates and four
counter plates onto the brake carrier.
10. If the original brake pack is reused then place the
plates to their original position.
11. Install the circlip.
12. Make sure that brake pack oil flow holes must be
aligned with each other when being installed to
the brake pack carrier.
13. Put the three reaction pins into their grooves and
lubricate them.
14. Push the pins fully into their location holes in the
housing.
15. Install the three reaction pins into their grooves
and secure them. Press the pins fully into location
holes in the housing.
16. Install one counter plate into the housing,
lubricate it and then the other counter plate.
17. If the old counter plates are re installed then put
them into their original position.
18. Fully press the brake pack in the housing.
19. Apply JCB multigasket to the mating surface of
the drivehead.
Consumable: JCB Multi-Gasket
20. Apply sealant to the bolt thread.

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22 - Drivehead

Contents Page No.

27-22-00 General ........................................................................................................................... 27-21

27-22-06 Crownwheel .................................................................................................................... 27-41
27-22-09 Pinion Gear .................................................................................................................... 27-43

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00 - General Introduction
Introduction .................................................... 27-21 The axle drivehead transmits drive from the input
Component Identification ............................... 27-22 coupling yoke to the driveshafts through the
Disassemble and Assemble .......................... 27-28 differential unit.

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Component Identification

For: 55 Series (3 Piece Axle) ..... Page 27-22 Figure 13.

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

(For: 55 Series (3 Piece Axle))

Unit Identification
The axle serial number is stamped on the unit
identification plate. When ordering replacement A
parts, always quote the details on the unit
identification plate. In the case of gear replacements,
always check the part number stamped on the gear,
and the number of teeth.
A Identification plate

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Location Drawing (448/00063)

Figure 14.

1 15 11 10 16

14
13

12

2
3
5 4
6

7
8

Item Description
Table 8. 10 Bolt Verbus-ripp
Item Description 11 Crownwheel and pinion
assembly
1 Drive case
12 Bearing (taper roller)
2 Bearing (taper roller)
13 Side nut
3 Shim
14 Brake piston
4 Spacer
15 Differential assembly
5 Bearing (taper roller)
16 Brake piston housing
6 Pinion seal
7 Coupling yoke
8 Stake nut

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(For: 55 Series (1 Piece Axle)) Figure 16.

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

Figure 15.

A Identification plate

A Identification plate

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00 - General

Main Component Identification

Figure 17.

4 5

2 3 6 7 8

Item Description
5 Bevel gears
Table 9.
6 Side nut locking pin
Item Description
7 Differential housing
1 Coupling yoke
8 Crownwheel
2 Driveshaft
3 Side nut
4 Pinion

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Location Drawing (448/00040)

Figure 18.

15 10

14

12

13

1
2
11
3
4
5

Item Description
Table 10. 4 Spacer
Item Description 5 Bearing (taper roller)
1 Drivehead carrier 6 Pinion seal
2 Bearing (taper roller) 7 Coupling yoke
3 Shim 8 Stake nut

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Item Description
10 Bolt-Verbus Ripp
11 Crown wheel and pinion
assembly
12 Bearing (taper roller)
13 Side nut
14 Side nut locking pin
15 Differential assembly

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Disassemble and Assemble

For: 55 Series (3 Piece Axle) ..... Page 27-28 2. Mark the brake piston housing and the drivehead
For: 55 Series (1 Piece Axle) ..... Page 27-35 for their correct assembly with respect to each
other. Refer to Figure 19.
(For: 55 Series (3 Piece Axle)) 3. Remove the brake piston housing. Refer to
Special Tools Figure 19.
Description Part No. Qty. 4. Remove the differential side nut locking pin to
Drive Coupling 892/00812 1 allow for readjustment on assembly. Refer to
Spanner Figure 20.
Setting Tool Kit 892/00918 1
Figure 20.
Spacer Kit 921/53300 1
Torque Wrench 993/70111 1 C
(10-100Nm)
Support Bracket 997/11000 1

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

The crownwheel and pinion are matched and should

be replaced as a pair, if either of them are damaged
or excessively worn.

The two differential case halves are also matched as
are the differential side gears and planet gears, do
not use unmatched halves or gears.
1. Place the drivehead with the crownwheel at the
top and then remove the capscrews. Refer to
Figure 19.
Figure 19.
C Side nut locking pin
5. Remove the other brake piston housing if it is
damaged, but its locking pin must be removed
to allow the side load adjustment on assembly.
Refer to Figure 20.
6. Lift off the crownwheel/ differential assembly.
Refer to Figure 21.

B A

A Capscrew
B Brake piston housing

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Figure 21. Figure 22.

H
D
J

G
F

E Pinion
F Pinion seal
D Crownwheel/ differential assembly G Outer bearing cone
H Inner bearing cup
7. If it is necessary to remove the brake piston J Shim
housings then mark the crownwheel end of the
drivehead case to make sure that they are 11. If necessary, drive out the pinion inner bearing
correctly assembled at the time of assembly. cup and shims. Refer to Figure 22.
Refer to Figure 21.
12. Discard the shims. Refer to Figure 22.
8. Use the spanner to lock the drive yoke and then
remove the stake nut and the yoke. Refer to 13. Do the step 11 to remove the outer bearing cup.
Figure 22. Refer to Figure 22.
Special Tool: Drive Coupling Spanner (Qty.: 1) 14. There are no shims for the outer bearing cup.
Refer to Figure 22.
9. Use a soft faced hammer to hit the pinion end
shaft until the pinion is free from its front bearing 15. Remove the pinion spacer. Refer to Figure 23.
and then remove the pinion. Refer to Figure 22.
Figure 23.
10. Remove the pinion seal and the outer bearing
cone. Refer to Figure 22.
K L

K Inner bearing cone

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

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17. Disassembly of the differential unit. Refer to 6. Put the top half of the differential housing on
Figure 24. to the differential and make sure that you have
aligned it correctly. Refer to Figure 25.
17.1. Remove the bolts.
Figure 25.
17.2. Lift off the top half housing.
Figure 24.
M

R
N
R
N S

S P
Q
P
Q

M Bolt
N Top half housing
M Bolt P Spherical washer 1
N Top half housing Q Spherical washer 2
P Spherical washer 1 R Differential bearing cone
Q Spherical washer 2 S Differential gear
R Differential bearing cone
7. Apply Loctite 242 to the threads of the bolts and
S Differential gear
then install them. Refer to Figure 25.
17.3. Remove the differential gears, the
8. Tighten the bolt to the correct torque value. Refer
spherical washer 1 and spherical washer
to Figure 25.
2.
17.4. Remove the differential bearing cones. 9. Check the gears for free rotation. Refer to Figure
25.
Assembly 10. Install the new inner bearing cone on to the
pinion. Refer to Figure 26.
1. If necessary, install a new crownwheel to the
differential case half.
2. Install the crownwheel retaining bolt.
3. Tighten the bolt to the specified torque value.
Torque: 94 N·m
4. Assemble the differential gear and the spherical
washer 1 and spherical washer 2 into the bottom
half of the differential housing. Refer to Figure 25.
5. Install the differential bearing cones. Refer to
Figure 25.

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Figure 26. Figure 27.

H
K L
J

G
F
K Inner bearing cone
L Pinion spacer
11. Install the largest available solid spacer
E Pinion
(14.20mm) from the solid spacer setting kit. Refer
F Pinion seal
to Figure 26.
G Outer bearing cone
Special Tool: Spacer Kit (Qty.: 1) H Inner bearing cup
J Shim
12. Find the correct thickness for the shims. Refer to
Front Drivehead, Pinion Gear- Calibrate. Refer to 17. Before you put the pinion into the bore, make
Figure 26. sure that it is matched with the crownwheel.
Refer to: PIL 27-22-09. Refer to Figure 27.

13. Install the shims behind the pinion inner bearing
cup. Refer to Figure 27.
14. Use a puller tool to make sure that the inner
bearing cup is installed in square. Do not use a
hammer. Refer to Figure 27.
18. The code numbers etched on the pinion end
face and the crownwheel perimeter should be the
same. Refer to Figure 27.
19. Install the pinion outer bearing cone. Refer to
Figure 27.

15. Install the outer bearing cup. Refer to Figure 27.
16. Put the pinion into its bore. Refer to Figure 27.
20. Do not install the oil seal at this stage. Refer to
Figure 27.
21. Install the special tool sleeve and the special
pinion shaft adapter. Refer to Figure 28.
Special Tool: Setting Tool Kit (Qty.: 1)
22. Tighten the adaptor to the correct torque value.
Refer to Figure 28.
23. Make sure that the pinion is free to rotate and
there is end float. Refer to Figure 28.
24. End float will prevent the bearing from damage.
Refer to Figure 28.

27 - 31 9823/0100-1 27 - 31

Figure 28.
T Z
U
1
T Pinion shaft adaptor
U Special tool sleeve
V Special bracket
W Bolt (M10x30)
25. If the pinion is not free to rotate or there is no end
float at this stage check the bearing is installed
correctly. Refer to Figure 28.
26. Make sure that the correct size spacer is
installed. Refer to Figure 28.
27. Use two bolts (M10x30) to install the special
bracket to the drivehead housing. Refer to Figure
28.
Special Tool: Support Bracket (Qty.: 1)
28. Install the special tool support pillar to the bracket
so that the fork end engages in adaptor. Refer to
Figure 28.
29. Make sure that the fork is centrally located on the
adaptor. Refer to Figure 28.
30. If necessary, align the bracket again. Refer to
Figure 28.
31. Install a DTI (Dial Test Indicator). Refer to Figure
29.
32. Make sure that the DTI is installed on the
drivehead not on the bracket. Refer to Figure 29.
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Figure 29.
Y
X Support pillar
Y DTI
Z Torque wrench
33. Set the torque wrench to the specified value and
measure the end float while you rotate the shaft.
Refer to Figure 29.
Torque: 35 N·m
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
34. Correct size solid spacer selection. Refer to
Figure 29. Refer to Table 11.
34.1. To select the correct size spacer, subtract
the end float obtained at step 33 from the
solid spacer size (14.20 mm).
34.2. Also subtract 0.04 mm to allow for
theoretical bearing tolerance and pre load.
34.3. The result is the size of spacer to be
installed from the solid spacer kit.
34.4. If there is no spacer of this size, fit the next
nearest size spacer from the spacer kit.
Special Tool: Spacer Kit (Qty.: 1)
35. Remove the sleeve and the temporary spacer.
Refer to Figure 28.
36. When you remove the temporary spacer make
sure that the outer bearing is not damaged. Refer
to Figure 28.
37. Install the correct size spacer from the spacer kit.
Refer to Figure 28.
27 - 32

38. Install the sleeve. Refer to Figure 28.
39. Tighten the adaptor to the specified value, to
protect against bearing damage while spacer
selection is verified and make sure that the pinion
is free to rotate. Refer to Figure 28.
Torque: 50 N·m
40. Check there is no end float and pinion is free to
turn smoothly by hand. Refer to Figure 28.
41. Remove the adaptor and install the stake nut.
Refer to Figure 28.
42. Check that rolling torque is less than 2.0 Nm. If
the rolling torque exceeds 2.0 Nm, check that the
shaft is assembled correctly. Refer to Figure 28.
43. If the pinion is not free to rotate then check the
correct size spacer is installed or not. Refer to
Figure 28.
44. If rolling torque measured at step 42 is too high
then install the next larger size spacer. If the
rolling torque is too low then install the next
smallest size spacer. Refer to Figure 28.
45. If a correct spacer is not available from the range,
check that drivehead is assembled correctly.
Refer to Figure 28.
46. Remove the stake nut and the sleeve. Refer to
Figure 28.
47. Lubricate the seal lips and then install the new oil
seal. Refer to Figure 30.
Figure 30.
AA
AB
AC
AA Oil seal
AB Coupling yoke
AC Stake nut
48. Install the coupling yoke and the new stake nut.
Refer to Figure 30.
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49. Gradually tighten the stake nut to the minimum
specified torque value, occasionally rotate the
coupling yoke. Refer to Figure 30.
Torque: 250 N·m
50. If the correct size spacer is selected, the rolling
torque should be within the specified torque
value including the seal drag. Refer to Figure 30.
Torque: 2.3 –3.4 N·m
51. When the torque value is correct, use a square-
ended staking tool to stake the nut to the pinion
shaft. Refer to Figure 30.
52. The stake nut tightening torque value can be
increased to a maximum of 300 Nm if the pinion
rolling torque does not exceed the maximum of
3.4 Nm. Refer to Figure 30.
Figure 31.
53. If the brake piston housing is removed then install
one at the opposite end to the crownwheel. Refer
to Figure 33.
54. Apply Loctite 574 to the drivehead mating face,
then install the brake piston housing. Refer to
Figure 33.
55. Make sure that the mark made between the
drivehead and the brake piston housing at the
time of disassembly is aligned. Refer to Figure
33.
56. Install the crownwheel/ differential assembly into
the drivehead. Refer to Figure 32.
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Figure 32. 60. Adjust the differential side nuts to give a bearing
pre-load of the specified value.
Torque: 1.13 –2.26 N·m
D
61. Measure the pre-load by taking another rolling
torque reading and subtracting the torque figure
measured at step 50. The difference is the
bearing pre-load.
62. Measure the crownwheel backlash, it should be
within the specified limit.
Dimension: 0.17 –0.28 mm
63. Adjust the differential side nuts by equal amounts
when you change the backlash.
64. When the backlash and pre-load are both
correct, install the side nut locking pins. Refer to
Figure 33.
65. Check the tooth marks to make sure that
the crownwheel and pinion are set correctly.
D Crownwheel/ differential assembly Refer to Front Drivehead, Crownwheel- Check
(Operation).
57. Install the other side brake piston housing onto Refer to: PIL 27-22-06.
the drivehead. Refer to Figure 33.
Figure 34.
Figure 33.

AD

B A

Table 11. Spacer Selection Example

Value
(1)

Temporary spacer size 14.20

A Capscrew Subtract end float 0.25
B Brake piston housing Total 13.95
C Side nut locking pin
AD Differential side nut Subtract tolerance and 0.04
pre-load
58. Install the capscrews. Refer to Figure 33. Result 13.91
Use next smallest spac- 13.90
59. Tighten the capscrews to the correct torque
er
value. Refer to Figure 33.
(1) All the values are in millimetre (mm).

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Table 12. Torque Values 7. Remove the bearing outer race 1 and bearing
outer race 2 from the drivehead carrier bores.
Item Description Nm
M Bolt 46 8. Drive off the taper roller bearing cone 1 from the
T Pinion shaft adaptor 50 crownwheel differential case half.
AC Stake nut 250 9. Remove the differential assembly from the
A Capscrew 56 carrier.

(For: 55 Series (1 Piece Axle)) 10. Mark the position of the drive yoke on the splined
shaft.
Special Tools
Description Part No. Qty. 11. Use the special tool to prevent the drive yoke
from rotating and remove the pinion nut.
Drive Coupling 892/00812 1
Spanner Special Tool: Drive Coupling Spanner (Qty.: 1)
Setting Tool Kit 892/00918 1 12. Remove the drive yoke.
Spacer Kit 921/52600 1
Spacer Kit 921/53300 1 13. Remove the pinion shaft from the drivehead
carrier.
Torque Wrench 993/70111 1
(10-100Nm) 14. Prise the pinion oil seal out of the bore.
Support Bracket 997/11000 1
15. Remove the pinion tail bearing.
Consumables
16. If necessary, remove the bearing outer race 3.
Description Part No. Size
JCB Multi-Gasket 4102/1212 0.05 L 17. If necessary, remove the bearing cup from
JCB Threadlocker 4101/0250 0.01 L the opposite side of the drivehead carrier and
and Sealer (Medium 4101/0251 0.05 L remove the pinion shims.
Strength)
18. Remove the spacer and the taper roller bearing
cone 3 from the pinion.
Disassembly
Disassemble the differential unit (If
The drivehead consists of the drivehead carrier necessary)
and pinion assembly, and the differential unit. A
separate disassembly procedure is given for each 1. For LSD (Limited Slip Differential) Refer to Front
sub assembly. Differential, Disassemble and Assemble.

Disassemble the Drivehead Carrier
1. Drain the oil from the axle centre case.
2. Completely remove both hub assemblies with the
driveshafts.
3. Mark the installation position of the drivehead
carrier with respect to the axle case.
4. Remove the drivehead carrier retaining bolt and
then remove the drivehead carrier from the axle
case.
2. Remove the differential assembly retaining bolt
and separate the case half 1 and case half 2.
3. Remove the side gears and the thrust washer 1
(2 off each).
4. Remove the bevel gears and thrust washer 2 (4
off each) from the trunnion pins.
5. Remove the taper roller bearing cone 2 from the
differential case half.
6. Remove the Verbus-ripp bolts.

5. Clean the drivehead carrier and axle case mating 7. Remove the crownwheel from the differential
faces. case half.

6. Pull out the tension pin 1 and tension pin 2, and

remove the castellated nut 1 and castellated nut
2.

27 - 35 9823/0100-1 27 - 35
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00 - General

Figure 35.

D K L

T
M
Q
G E C
P
R W N
S
F
H J

V
A
B

AG
U
AD
AE
Z

AF
AC

AB
AA

X Y

27 - 36 9823/0100-1 27 - 36

Table 13.
Item Description
A Drivehead carrier retain-
ing bolt
B Drivehead carrier
C Tension pin 1
D Tension pin 2
E Castellated nut 1
F Castellated nut 2
G Bearing outer race 1
H Bearing outer race 2
J Taper roller bearing
cone 1
K Differential assembly
L Differential assembly re-
taining bolt
M Case half 1
N Case half 2
P Side gear
Q Thrust washer 1
R Bevel gear
S Thrust washer 2
T Taper roller bearing
cone 2
U Verbus-ripp bolt
V Crownwheel
W Trunnion pin
X Pinion nut
Y Drive yoke
Z Pinion shaft
AA Pinion oil seal
AB Pinion tail bearing
AC Bearing outer race 3
AD Bearing cup
AE Drive pinion shim
AF Spacer
AG Taper roller bearing
cone 3
Assembly
The procedure below refers to the following aspects
of the drivehead assembly, which are covered
separately in detail.
• Pinion depth setting
• Crownwheel and pinion meshing
Both the crownwheel and pinion and the bevel gear
1 and bevel gear 2 are matched and should be
replaced as a set, if any of their components are
damaged or excessively worn. The two differential
27 - 37 9823/0100-1
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22 - Drivehead
00 - General
housing halves are also matched. Do not use
unmatched halves.
Assemble the differential unit (if necessary)
1. For LSD Refer to Front Differential, Disassemble
and Assemble.
2. Assemble the trunnion pin, bevel gear 1 and the
bevel gear 2 then the thrust washer 1 and thrust
washer 2 into differential half case 2.
3. Put the differential half case 1 onto the half case
2. Make sure you align them properly.
4. Apply sealant to the differential assembly
retaining bolt and then install it.
Consumable: JCB Threadlocker and Sealer
(Medium Strength)
5. Tighten the bolt to the correct torque value.
6. Check the gears for free rotation.
7. Use new Verbus-ripp bolts to install the
crownwheel.
8. Tighten the bolt to the correct torque value. Refer
to table1.
Assemble the drivehead carrier
1. Measure the correct thickness for the seam.
Refer to Front Drivehead, Pinion Gear- Calibrate.
Refer to: PIL 27-22-09.
2. Install the shim behind the new bearing cup.
3. Install the new pinion head bearing cone onto the
pinion.
4. Install the pinion and bearings into the drivehead
case.
5. Install the largest available solid spacer (14.20
mm).
Special Tool: Spacer Kit (Qty.: 1)
6. Apply a coat of oil and then install the pinion tail
bearing.
7. Do not install the oil seal at this stage.
8. Install the special tool sleeve and the special
pinion shaft adaptor from the setting kit.
Special Tool: Setting Tool Kit (Qty.: 1)
9. Tighten the adaptor to the correct torque value.
10. Make sure that the pinion is free to rotate and
there is end float, this will prevent any damage
to the bearing. If the pinion is not free to rotate
or there is no end float at this stage check the
27 - 37
 27 - Driveline
22 - Drivehead
00 - General

bearing is installed properly. Also check that the Figure 37.

correct size spacer is installed.
11. Use two (M10x30) nuts and bolts to install the
special bracket on the drivehead housing.
Special Tool: Support Bracket (Qty.: 1) AN

Figure 36.
AM

AL
AJ

AK
AH

AM DTI
AN Torque wrench
16. Set the torque wrench to the specified value and
measure the end float while you rotate the shaft.
Torque: 35 N·m
Special Tool: Torque Wrench (10-100Nm) (Qty.:
1)
AH Special tool sleeve
AJ Adaptor 17. To select the right size spacer do the following
AK Special bracket steps. Refer to Table 16.
AL Support pillar 17.1. Subtract the end float obtained in step
12. Install the special support pillar on the bracket so 16 from the solid spacer thickness value
that the fork end engages with the adaptor. (14.20 mm).
17.2. Subtract 0.04mm to allow for theoretical
13. Make sure that the fork is centrally located on the bearing tolerance and pre-load.
adaptor.
17.3. The result is the size of spacer to be
14. If necessary, align the bracket again. installed from the solid spacer setting kit.
15. Install a DTI. Make sure that the DTI is mounted Special Tool: Spacer Kit (Qty.: 1)
on the drivehead and not on the bracket. 17.4. If there is no spacer of this size, then install
the next nearest size spacer.
18. Remove the sleeve and the temporary spacer.
19. Install the correct size spacer from the solid
spacer setting kit.
20. Make sure that you do not damage the outer
bearing.
21. Again install the sleeve and then install the
adaptor.

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22. Tighten the adaptor to the correct torque value,
to protect against bearing damage while spacer
selection is verified making sure the pinion is free
to rotate.
23. Check there is no end float and the pinion is free
to turn smoothly by hand.
24. Remove the adaptor and then install the nut.
25. Make sure that the rolling torque is less than 2.0
Nm, if the rolling torque exceeds 2.0 Nm, then
check that the shaft is assembled correctly or not.
26. If the pinion is not free to rotate, check the correct
size spacer has been installed.
27. If the rolling torque measured at step 25 is
too high, install the next larger size spacer. If
the rolling torque is too low, install the next
smallest size spacer. If a correct spacer is not
available from the range, check that drivehead is
assembled correctly.
41. Measure the backlash between the crownwheel
and the pinion and it should be within the
specified limit.
Length/Dimension/Distance: 0.17 –0.28 mm
42. When altering the backlash adjust both the
castellated nut in equal amounts.
43. When the backlash and pre-load are both
correct, install the tension pin 1 and tension pin 2.
44. Check the tooth marks to verify that the
crownwheel and the pinion are set correctly.
45. Apply JCB Multigasket to the mating faces of the
drivehead carrier and the axle case.
Consumable: JCB Multi-Gasket
46. Install the drivehead carrier to the axle case with
the crownwheel towards the short driveshaft.
47. Install the drivehead carrier retaining bolts.

28. Remove the adaptor and the sleeve. 48. Tighten the bolt to the correct torque value.

29. Lubricate the seal lips and then install the new 49. Reassemble both driveshafts and hub
oil seals. assemblies.

30. Install the coupling yoke and the new stake nut.
Table 14. Torque Settings (55 Series)
31. Gradually tighten the stake nut up to the specified Item Description Nm
torque value, while occasionally rotating the
coupling yoke. A Drivehead carri- 98
er retaining bolt
Torque: 250 N·m U Verbus-ripp bolt 94
32. If the correct size spacer is selected then the
pinion rolling torque should with in the specified
limit. Table 15. Torque Settings (70 and 80 Series)

Torque: 2.3 –3.4 N·m Item Description Nm

A Drive head car- 166
33. The nut tightening torque value can be increased rier retaining
to a maximum of 300 Nm but the pinion rolling bolt
torque does not exceed the maximum of 3.4 Nm. U 'Verbus Ripp' 200
bolt
34. Finally stake the nut into the slot.
35. Install the differential assembly onto the
drivehead carrier. Table 16. Spacer Selection Example
Value
(1)

36. Push the taper roller bearing onto the spigot of

the differential half case2. Temporary spacer size 14.20
Subtract end float 0.25
37. Install the bearing outer race 1 and bearing outer Total 13.95
race 2.
Subtract tolerance and 0.04
38. Install the castellated nut 1 and castellated nut 2 preload
to the drivehead carrier. Result 13.91
39. Do not install the tension pin 1 and tension pin 2 Use next smallest spac- 13.90
at this stage. er
(1) All the values are in millimetre (mm).
40. Adjust the castellated nut to give an increase in
input pinion rolling torque of between 1.36 and
2.5 Nm more than that specified in Step25.

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Table 17. Torque Values

Item Description Nm
L Differential assembly 46
retaining bolt
AJ Adaptor 50

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06 - Crownwheel

06 - Crownwheel
Introduction .................................................... 27-41
Check (Operation) ......................................... 27-42
Introduction
A crown wheel is a rotating gear wheel with teeth set
at right angles to its plane, it is usually matched with a
pinion gear that meshes with the crown wheel. They
are mainly used in vehicles to maintain a forward
movement.

27 - 41 9823/0100-1 27 - 41
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22 - Drivehead
06 - Crownwheel

Check (Operation) Figure 40.

Crownwheel and Pinion Meshing

Meshing of the gears should be checked by marking
three of the pinion teeth with engineers marking
compound and rotating the pinion. The marking will
then be transferred to the crown wheel teeth.

1. Correct tooth marking.

Figure 38.

2. Pinion too deeply in mesh. Move the crown wheel

towards the pinion to correct the backlash.
Figure 39.

3. Pinion too far out of mesh. Move the crown wheel

away from the pinion to correct the backlash.

27 - 42 9823/0100-1 27 - 42
 27 - Driveline
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09 - Pinion Gear

09 - Pinion Gear Introduction

Introduction .................................................... 27-43 A pinion gear is a small gear that meshes with a
Calibrate ........................................................ 27-44 larger crownwheel. They are mainly used in vehicles
to maintain a forward movement.

27 - 43 9823/0100-1 27 - 43
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22 - Drivehead
09 - Pinion Gear

Calibrate and record the height. The bearing cups and

rollers are matched sets. Always keep the
Special Tools bearing assemblies together. Make sure that you
Description Part No. Qty. measure only the inner bearing.
Shim Kit 921/M0229 1 Figure 43.

Pinion Depth Setting

E
Determine the pinion depth setting shim size as
follows:
E Inner bearing height
1. Note the deviation figure etched on the pinion
and the deviation figure on the drivehead Shim Size Calculation Example
housing. Both figures are in units of 0.01 mm.
Note: The pinion depth may be etched on the Table 18. Calculation 1.
gear face or on the rear of a gear tooth. Actual Drivehead Case Size
Special Tool: Shim Kit (Qty.: 1) Item Typical Fig- Description
ures
Figure 41.
A 187.6 mm Nominal drive-
D head case size,
fixed at the fac-
tory
B -0.14 mm Drivehead
case deviation,
marked on the
case
Sum of A and B 187.46 mm Actual drive-
head case size

Table 19. Calculation 2. -

Actual Pinion and Bearing Size
Item Typical Fig- Description
ures
D Pinion depth C 150.0 mm Nominal pinion
length, fixed at
Figure 42. the factory
D 0.10 mm Pinion devia-
tion, marked on
the pinion
E 36.6 mm Bearing size, in-
ner pinion bear-
ing
Sum of C, D 186.70 mm Actual pinion
and E and bearing
size

Table 20. Calculation 3. Shim Size

= Calculation 1 - Calculation 2
Typical Figures Description
187.46 - 186.70 = Select the nearest shim
0.76mm size from the shim kit.
B Deviation figure
2. Assemble the pinion inner bearing and its
cup on a flat surface. Lightly oil and rotate
the bearing before measurement. Make sure
that the bearing cup is square and measure

27 - 44 9823/0100-1 27 - 44
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24 - Differential

24 - Differential

Contents Page No.

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

27 - 45 9823/0100-1 27 - 45
Notes:

27 - 46 9823/0100-1 27 - 46

00 - General
Introduction ....................................................
Component Identification ...............................
Check (Condition) ..........................................
Disassemble and Assemble ..........................
27 - 47
27 - Driveline
24 - Differential
00 - General
Introduction
27-47 A differential is a particular type of simple planetary
27-49 gear train.
27-53
27-54 The differential couples the drive shaft to half-shafts
that connect to the rear driving wheels. The purpose
of the differential is to allow a speed differential
between the inner and outer wheel while being driven
by the input shaft. In its most common form, the
differential consists of a pinion and ring and planetary
bevel gears to connect the output shafts.
The axle can have the following type of differentials.
1. Open Differential.
2. LSD (Limited Slip Differential).
Open Differential
A standard differential, or what is referred to as an
open carrier. A conventional open differential always
supplies close to equal (because of limited internal
friction) torque to each side. The differential gearing
allows the outer drive wheel to rotate faster than the
inner drive wheel during a turn. This is necessary
when the vehicle turns, making the wheel that is
travelling around the outside of the turning curve roll
farther and faster than the other.
In a standard [open type] differential, the rotational
velocity of the input shaft is the average of the
rotational velocity of the output shafts under normal
traction conditions. Therefore, increasing the speed
of one output shaft will decrease the speed of the
other output shaft.
The problem is an open differential always tries to
balance the torque. It means that if the spider gears
are pushing on both drive gears and one of them
offers lots of resistance and the other side offers no
resistance then it will try to find a balance where both
sides are receiving almost no torque at all. All the
rotational energy is guided to the side with the least
resistance. In the end, that side spins very fast and
the pressure on each drive gear is the same. Almost
no torque is needed to spin one wheel, and since
the open differential always sends the same amount
of torque to both output shafts, almost no torque is
going to the other side as well.
Limited Slip Differential (LSD)
In the most basic sense, a LSD equalizes the
difference in either speed between output shafts or
applied torque between output shafts to maintain
traction in adverse or performance conditions. The
benefits of installing an LSD are:
1. Enhanced traction in snow, gravel, and sand.
9823/0100-1 27 - 47
 27 - Driveline
24 - Differential
00 - General

2. More predictable handling at the limits of grip.

This type behaves as an open differential unless one

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

An LSD can use clutches when engaged, or may

also be a solid mechanical connection like a locker
or spool. It is called limited slip because it does just
that; it limits the amount that one wheel can slip.

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00 - General

Component Identification

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

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

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

Figure 44. Limited Slip Differential (LSD)

E
F
H
J
K
N P
A M

G K
C J
H
G

A Verbus-ripp bolts B Crownwheel

C Bolts D Differential assembly case
E Differential assembly case F Shims
G Shims H Counter plates
J Friction plates K Pressure plates
L Side gears M Trunnion pins
N Bevel gears P Thrust washers

27 - 49 9823/0100-1 27 - 49
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24 - Differential
00 - General

(For: Limited Slip Differential (LSD))

Figure 45.

AA
R M
N
L
H
T
G1 Q S
S Q
T

K
G2
J X

AE

AB
C
AD

AC
D1
F C
E
Y
Z
W

F
U
AA A B D2

A Bolt 1 B Drivehead carrier

C Roll pin D1 Castellated nut 1
D2 Castellated nut 2 E Bearing cup
F Bearing cone G1 Differential case half
G2 Differential case half H Verbus-ripp bolt
J Crownwheel K Bolt 2

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00 - General

L Trunnion pin M Planet gear

N Thrust washer P Side gear
Q Shim 1 R Counter plate
S Friction plate T Pressure plate
U Stake nut V Washer
W Drive flange X Pinion
Y Collapsible spacer Z Oil seal
AA Pinion tail bearing AB Pinion head bearing cone
AC Pinion head bearing cap AD Shim 2
AE Bush

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

Figure 46.

E
F
H
J
K
N P
A M

G K
C J
H
G

A Verbus-ripp bolts B Crownwheel

C Bolts D Differential assembly case
E Differential assembly case F Shims
G Shims H Counter plates
J Friction plates K Pressure plates
L Side gears M Trunnion pins
N Bevel gears P Thrust washers

27 - 51 9823/0100-1 27 - 51
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00 - General

(For: Limited Slip Differential (LSD))

Figure 47.

E
F
H
J
K
N P
A M

G K
C J
H
G

A Verbus-ripp bolts B Crownwheel

C Bolts D Differential assembly case
E Differential assembly case F Shims
G Shims H Counter plates
J Friction plates K Pressure plates
L Side gears M Trunnion pins
N Bevel gears P Thrust washers

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24 - Differential
00 - General

Check (Condition)
1. For JCB axles only: measure and note the
thickness of the friction plates, the result must not
be less than the specified dimension.
Dimension: 1.25 mm
2. Check the condition of the friction material, which
should be even over both surfaces. If in doubt,
discard the set (friction and counter plates).

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00 - General

Disassemble and Assemble

For: Limited Slip Differential (LSD) 2. Remove the crownwheel.

................................................... Page 27-54
For: 55 Series (1 Piece Axle), 55 Series (3
Piece Axle), Limited Slip Differential (LSD)
................................................... Page 27-57
For: Limited Slip Differential (LSD)
................................................... Page 27-60
(For: Limited Slip Differential (LSD))
3. Put marks on the two halves of the differential
housing before disassembly to make sure of
correct assembly.
4. Remove the capscrews.
5. Disengage the two halves of the differential and
remove the following components:

The numerical sequence shown on the illustration is 5.1. Trunnion pins.

intended as a guide for disassembly. 5.2. Side gears.
The number of friction and counter plates shown in 5.3. Bevel gears.
the illustration is typical only. The actual number of 5.4. Spherical washers.
plates is determined by the axle variant.
5.5. Pressure plates.
Important: The crownwheel and pinion are matched
5.6. Counter plates.
and should be replaced as a pair if either one is
damaged or excessively worn. The two halves of 5.7. Friction plates.
the differential housing are also matched as are the
5.8. Shims.
differential side gears and bevel gears, do not use
unmatched halves or gears. 6. Make a note of the relative positions of the
friction plates, counter plates and spacers before
Disassemble disassembly, they must be installed in the same
positions.
1. Use a heavy duty socket to remove the verbus-
ripp bolts. Discard the bolts.

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00 - General

Figure 48. Limited Slip Differential (LSD)

E
F
H
J
K
N P
A M

G K
C J
H
G

A Verbus-ripp bolts B Crownwheel

C Bolts D Differential assembly case
E Differential assembly case F Shims
G Shims H Counter plates
J Friction plates K Pressure plates
L Side gears M Trunnion pins
N Bevel gears P Thrust washers

Assemble 1.6. Thrust washers.

1. Install the following components into the 2. Do not install the shims at this stage.
crownwheel half of the differential assembly:
3. Align the two halves of the differential assembly
1.1. Trunnion pins. with the bolts. Make sure that the marks made
during disassembly are aligned.
1.2. Side gears with pressure plates.
4. Use a DTI (Dial Test Indicator) (or feeler gauges),
1.3. Counter plates.
with two screwdrivers or suitable levers, gently
1.4. Friction plates. apply pressure to prise the side gear away from
the trunnion pins.
1.5. Bevel gears.

27 - 55 9823/0100-1 27 - 55
 27 - Driveline
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00 - General

Figure 49.

5. Measure and record the end float of the side
gear.
6. Turn the differential assembly over and repeat
steps 4 and 5 for the second side gear.
7. Disassemble the differential assembly.
8. Add shims to give an end float between the
specified range.
Length/Dimension/Distance: 0.1 –0.2 mm
8.1. Shimming must be carried out whenever
the differential is dismantled, however, the
end float 0.1 and 0.2 mm (0.004 and
0.008 in) can be exceeded on previously
assembled differential as this is only an
initial setting figure which allows for bedding
in.
8.2. Select the minimum number of shims to
give the correct thickness.
9. Do the steps 4 to 6 again.
10. If the end float is correct, tighten the bolts to the
correct torque value.
11. Install the crownwheel with new verbus-ripp
bolts.
12. Tighten the verbus-ripp bolts to the correct torque
value.

Table 21. Torque Values

Item Nm
A
(1)
94
A
(2)
200
C 56
(1) The torque value is applicable for the 40 Series drivehead.
(2) The torque value is applicable for the 85 Series drivehead.

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00 - General

(For: 55 Series (1 Piece Axle), 55 Series (3 3. Put marks on the two halves of the differential
Piece Axle), Limited Slip Differential (LSD)) housing before disassembly to make sure of
correct assembly.
The numerical sequence shown on the illustration is
4. Remove the capscrews.
intended as a guide for disassembly.
5. Disengage the two halves of the differential and
The number of friction and counter plates shown in remove the following components:
the illustration is typical only. The actual number of
plates is determined by the axle variant. 5.1. Trunnion pins.
Important: The crownwheel and pinion are matched 5.2. Side gears.
and should be renewed as a pair if either one is 5.3. Bevel gears.
damaged or excessively worn. The two halves of
the differential housing are also matched as are the 5.4. Spherical washers.
differential side gears and bevel gears, do not use 5.5. Pressure plates.
unmatched halves or gears.
5.6. Counter plates.
Disassemble 5.7. Friction plates.
1. Use a heavy duty socket to remove the verbus- 5.8. Shims.
ripp bolts. Discard the bolts.
6. Make a note of the relative positions of the
2. Remove the crownwheel. friction plates, counter plates and spacers before
disassembly, they must be installed in the same
positions.

Figure 50. Limited Slip Differential (LSD)

E
F
H
J
K
N P
A M

G K
C J
H
G

A Verbus-ripp bolts B Crownwheel

C Bolts D Differential assembly case
E Differential assembly case F Shims
G Shims H Counter plates
J Friction plates K Pressure plates

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00 - General

L Side gears M Trunnion pins

N Bevel gears P Thrust washers

27 - 58 9823/0100-1 27 - 58

Assembly
1. Install the following components into the
crownwheel half of the differential assembly:
1.1. Trunnion pins.
1.2. Side gears with pressure plates.
1.3. Counter plates.
1.4. Friction plates.
1.5. Bevel gears.
5. Measure and record the end float of the side
gear.
6. Turn the differential assembly over and repeat
steps 4 and 5 for the second side gear.
7. Disassemble the differential assembly.
8. Add shims to give an end float between the
specified range.
Length/Dimension/Distance: 0.1 –0.2 mm
8.1. Shimming must be carried out whenever
the differential is dismantled, however, the
end float 0.1 and 0.2 mm (0.004 and
0.008 in) can be exceeded on previously
27 - 59
27 - Driveline
24 - Differential
00 - General
1.6. Thrust washers.
2. Do not install the shims at this stage.
3. Align the two halves of the differential assembly
with the bolts. Make sure that the marks made
during disassembly are aligned.
4. Use a DTI (or feeler gauges), with two
screwdrivers or suitable levers, gently apply
pressure to prise the side gear away from the
trunnion pins.
Figure 51.
assembled differential as this is only an
initial setting figure which allows for bedding
in.
8.2. Select the minimum number of shims to
give the correct thickness.
9. Do the steps 4 to 6 again.
10. If the end float is correct, tighten bolts to the
correct torque value.
11. Install the crownwheel with new verbus-ripp
bolts.
12. Tighten the verbus-ripp bolts to the correct torque
value.
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Table 22. Torque Values

Item Nm
1
(1)
94
1
(2)
200
3 56
(1) The torque value is applicable for the 55 Series drivehead.
(2) The torque value is applicable for the 80 Series drivehead.

(For: Limited Slip Differential (LSD)) 8. Remove the roll pins and then remove the
castellated nuts.
Special Tools
Description Part No. Qty. 9. Remove and discard the bearing cups.
Bearing Press 892/00179 1
10. Remove the bearing cones. Discard the
Drive Coupling 892/00812 1 bearings.
Spanner
Adaptor 992/07608 1 11. Remove the differential assembly from the
Bearing Adaptor 992/07609 1 drivehead when the bearings have been
removed from both sides.
Consumables 12. Use the service tool to remove the drive flange.
Description Part No. Size
Special Tool: Drive Coupling Spanner (Qty.: 1)
JCB Multi-Gasket 4102/1212 0.05 L
13. Remove the pinion and the collapsible spacer.
As the drivehead cannot be disassembled while
installed on the machine, we recommend that the 14. Remove the oil seal and pinion tail bearing.
complete axle is removed.
15. Remove the pinion head bearing cone from the
WARNING! A raised and badly supported machine pinion.
can fall on you. Position the machine on a firm, level
surface before raising one end. Ensure the other 16. Remove the pinion head bearing cap along with
end is securely chocked. Do not rely solely on the its shims 2.
machine hydraulics or jacks to support the machine 17. Use a heavy duty socket to remove the verbus-
when working under it. Disconnect the battery, to ripp bolts. Discard the bolts.
prevent the machine being started while you are
beneath it. 18. Remove the bolt 2.

Disassemble 19. Put marks on the two halves of the differential

housing before disassembly to make sure of
1. Drain the oil from the axle hubs. correct assembly.

2. Remove the following components from both the 20. Remove the capscrews.
hubs:
21. Disengage the two halves of the differential and
2.1. Planet gear carrier. remove the following components:
2.2. Brake pressure plate. 21.1. Trunnion pins.
2.3. Brake friction plates. 21.2. Side gears.
2.4. Brake counter plates. 21.3. Planet gears.
3. Remove the driveshaft. 21.4. Thrust washers.

4. Remove the propshaft. 21.5. Pressure plates.

21.6. Counter plates.
5. Drain the oil from the differential casing.
21.7. Friction plates.
6. Remove the bolts 1.
21.8. Shims.
7. Lift the drivehead carrier from the casing.
22. Inspect the condition and security of the bushes.

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24 - Differential
00 - General

22.1. Note: Later type differential assemblies the differential case halves are machined
are not installed with the bushes, instead, so that they support the driveshafts.

Figure 52.

AA
R M
N
L
H
T
G1 Q S
S Q
T

K
G2
J X

AE

AB
C
AD

AC
D1
F C
E
Y
Z
W

F
U
AA A B D2

A Bolt 1 B Drivehead carrier

C Roll pin D1 Castellated nut 1
D2 Castellated nut 2 E Bearing cup
F Bearing cone G1 Differential case half
G2 Differential case half H Verbus-ripp bolt
J Crownwheel K Bolt 2

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00 - General

L Trunnion pin M Planet gear

N Thrust washer P Side gear
Q Shim 1 R Counter plate
S Friction plate T Pressure plate
U Stake nut V Washer
W Drive flange X Pinion
Y Collapsible spacer Z Oil seal
AA Pinion tail bearing AB Pinion head bearing cone
AC Pinion head bearing cap AD Shim 2
AE Bush

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Assemble 4. Attach the two halves of the differential assembly

Make sure all bearings are lightly oiled before
installation and setting. Make sure that the bearings
are rotated when they are being set.
1. Install the following components into the
crownwheel half of the differential assembly:
with the bolts 2. Make sure the marks made
during disassembly are aligned.
5. Use a DTI (or feeler gauges), with two
screwdrivers or suitable levers, gently apply
pressure to prise the side gear away from the
trunnion pins.

1.1. Trunnion pins. Figure 54.

1.2. Side gears with pressure plates.
1.3. Counter plates.
1.4. Friction plates.
1.5. Planet gears.
1.6. Thrust washers.
2. The counter plates and friction plates should be
installed alternatively, as shown. However, some
axles which incorporate differential assemblies
containing 9-friction faces require a unique
configuration. Before assembling these parts,
identify the correct configuration for your
machine.
Figure 53.
S R

6. Measure and record the end float of the side

gear.
S 7. Turn the differential assembly over and do the
steps 5 and 6 for the second side gear.
8. Disassemble the differential assembly.
9. Add shims to give an end float between the
specified range.
9.1. For new plates.
T R Dimension: 0.1 –0.2 mm
9.2. For old plates.
S
Dimension: 0.2 –0.5 mm
10. Do the steps 5 to 7 again.
11. If the end float is correct, tighten the bolts to the
correct torque value.
12. Install the crownwheel with new verbus-ripp
bolts.
T R
13. Tighten the verbus-ripp bolts to the correct torque
R Counter plate value.
S Friction plate
T Pressure plate 14. Measure the pinion depth setting.
3. Do not install the shims 1 at this stage.

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15. Install a new pinion head bearing cone into the 30. Adjust castellated nut 2 until there is no end-float
pinion with suitable press and adaptors. and no pre-load. Make sure that the bearings are
bedded in by rotating in each direction.
Special Tool: Bearing Press (Qty.: 1)
Special Tool: Adaptor (Qty.: 1) 31. Tighten castellated nut 2 by a further 4
Special Tool: Bearing Adaptor (Qty.: 1) castellations to set pre-load. Make sure that the
correct backlash is maintained.
16. Install the new collapsible spacer onto the pinion.
32. Install the roll pins.
17. Apply oil on the pinion head bearing and install
the pinion in the housing. 33. Apply sealant to the mating surfaces of the drive
head carrier and the axle casing.
17.1. Before you install the pinion, make sure
that the pinion matches the crownwheel. Consumable: JCB Multi-Gasket
18. Apply oil on the pinion tail bearing. 34. Install the drivehead carrier to the axle casing
with the crownwheel towards the long driveshaft.
19. Use a suitable drift and tap the tail bearing into
its position in the housing. 35. Install the bolts 1.
20. Put a new oil seal into the housing. 36. Tighten the bolts 1 to the correct torque value.
20.1. Lubricate the seal lips. 37. Assemble the driveshafts and hub assemblies.
21. Install the drive flange with a new stake nut and 38. Fill the hubs and the differential with the correct
washer. grade of oil.
22. Tighten the stake nut into the collapsible spacer 39. Install the propshaft.
until the end float is almost zero, and then
measure the seal drag torque. 40. Fill the hubs and the differential with the correct
grade of oil.
22.1. The seal drag torque should be within the
specified range. Table 23. Torque Values
Torque: 0.4 –0.75 N·m Item Description Nm
A Bolt 1 56
23. Continue to tighten the stake nut to collapse the
spacer to get a rolling torque of the specified K Bolt 2 56
range. H Verbus-ripp bolt 94
Torque: 1.7 –2.8 N·m
23.1. Rotate the flange in each direction to bed
in the bearings before measuring.
23.2. Note: If the specified rolling torque is
exceeded, the collapsible spacer will be
distorted. Replace the spacer and start
again.
24. Stake the nut when the pre-load is correct.
25. Install the differential assembly (without the
bearings) into the drivehead.
26. Install the bearing cones onto the spigots.
27. Apply oil on the bearings and install the bearing
cups and the castellated nuts.
28. Do not install the roll pins at this stage.
29. Adjust castellated nut 1 on the crownwheel side
until you get a backlash value within the specified
range.
Length/Dimension/Distance: 0.13 –0.2 mm

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27 - Hub

Contents Page No.

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

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Notes:

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00 - General Introduction
Introduction .................................................... 27-67 The hub is the part of the axle where the wheel
Component Identification ............................... 27-68 is mounted and where the axle shaft (if installed)
Drain and Fill ................................................. 27-70 passes through.
Calibrate ........................................................ 27-73
Some hubs are not driven and rotate due to motion
Disassemble and Assemble .......................... 27-74 of the machine and some driven hubs may also have
reduction gearing installed.

The hub may also be designed to allow steering of

the wheels and/or incorporate brakes.

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Component Identification

Unit Identification Main Component Identification

The axle serial number is stamped on the unit Figure 57.
identification plate as shown. When you make an
order for parts replacement, always give the details
G H
mentioned on the unit identification plate. In the case
of gear replacements, always check the part number
stamped on the gear, and the number of teeth.

Figure 55. A

A J

K
D
A Identification plate
Figure 56. L
E

F M

Table 24.
Item no Description
A Annulus ring
B Planet gear assembly
(x3)
C Thrust pad
D Sun gear
A Identification plate E Planet gear carrier
F Wheel stud (x5)
G Bearing carrier
H Hub swivel
J Driveshaft
K Oil seal
L Wheel bearing (inner)
M Wheel bearing (outer)

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Sectional Drawing

Figure 58.

13 10 7 11 5 3 4 57 1

12
14
8 18
16
15
17

20

19

23

26 9 22 24 25

Item no Description
Table 25. 17 Thrust pad
Item no Description 18 Driveshaft
1 Swivel hub 19 Sun gear
3 Bearing (taper roller) 20 Circlip (external)
4 Oil seal 22 O-ring
5 Bearing carrier 23 Drain plug
7 Annulus carrier 24 Bearing
8 Dowels 25 Oil seal
9 Bolt Verbus-ripp 26 Spacer (55 Series hub
only)
10 Annulus ring
57 Cover plate
11 Circlip (internal)
12 Planet gear
13 Planetary hub carrier
14 Bearing
15 Circlip (L-shaped)
16 Circlip (external)

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Drain and Fill

Check the hub oil level of one wheel at a time. 4. Apply the park brake.
Complete the steps below to check the hub oil.
5. Set the transmission to the neutral position.
1. Make the machine safe. Refer to (PIL 01-03).
6. Lower the attachments to the ground.
2. Set the machine level with the wheels above the
ground. 7. Stop the engine and remove the ignition key.

2.1. Use suitable lifting equipment to lift the
machine axles to the same level.
3. Set the hub oil level mark to the horizontal
position.
3.1. Turn the wheel manually to get the hub oil
level mark to the horizontal position.
3.2. The specified tolerance is permitted above
or below the oil level mark horizontal
position.
Length/Dimension/Distance: 5 mm
Figure 59.
A 12.1. To Make sure you use the correct torque
B
E
8. Clean the area around the hub plug.
9. Remove the hub plug.
10. Check the oil level of the hub.
10.1. The hub oil level must be level with the
bottom surface of the plug hole.
10.2. If necessary, add the correct axle oil. Refer
to (PIL 75).
11. Clean the plug before you install it.
12. Install the hub plug and tighten to the correct
torque.
tightening information, identify the correct
axle for your machine. Refer to Figure 60.
and Refer to Figure 61.
12.2. Make sure you identify the correct plug for
your machine. Then use the related torque
information. Refer to Figure 62. and Refer
to Figure 63.

D C

A Wheel
B Hub
C Plug
D Level mark
E Tolerance 5 mm

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

A
B

A Axle drain plug 1 location

Table 26. JCB Axles With Inboard Brakes

Type of Differential Plug In- Hub Plug Installed Hub Plug Torque (Nm)
stalled on Your Machine
Axle drain plug 1 with hexagonal Taper plug (3/4 in NPSF) 50
head and bonded washer
Axle drain plug 1 with tapered plug Taper plug (3/4 in BSP) 80

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

D

D Drain plug E Axle drain plug 2 location

Table 27. Axles With Braked Hubs

Type of Differential Plug In- Hub Plug Installed Hub Plug Torque (Nm)
stalled on Your Machine
Axle drain plug 2 with hexagonal Plug (M22) 37.5
head and bonded washer
Axle drain plug 2 with tapered plug Taper plug (3/4 in BSP) 80

Figure 62. Hexagonal Head Plug and

Bonded Washer (Prior to January 2011)

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00 - General

Figure 63. Taper Plug (If in-

stalled) (January 2011 Onwards)

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00 - General

Calibrate

Refer to the relevant Disassemble and Assemble

procedure (PIL 27-27).

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Disassemble and Assemble

Special Tools Figure 64.

Description Part No. Qty. F
Heavy Duty Socket 892/00333 1
19mm A/F x 3/4 in D
Drive G
Wheel Hub Service Kit 892/01092 1 B
Reaction Plate M14 998/M1374 4
Studs
Reaction Plate 998/M1375 1

Disassemble
WARNING A raised and badly supported
machine can fall on you. Position the machine
on a firm, level surface before raising one end.
Ensure the other end is securely chocked. Do
not rely solely on the machine hydraulics or jacks
to support the machine when working under it.
Disconnect the battery, to prevent the machine
being started while you are beneath it.
The illustrations in this procedure show the axle
removed from the machine but the hubs can be
disassembled without removing the axle. Refer to
Figure 70.
1. Drain the oil from the hub.
2. Remove the screws.
3. Remove the planet gear carrier from the bearing
carrier.
4. Remove and discard the O-ring.
5. Remove the planet gears only if they are
damaged. Note: Planet gears can only be
replaced as an assembly which contains the
gear, bearing, and two L-shaped circlips. Refer
to Figure 64. and Refer to Figure 69.
B Planet gear carrier
D Planet gear
G Driveshaft thrust pad
F External circlip 1
5.1. Remove the external circlip 1.
5.2. Remove the planet gear.
5.3. The driveshaft thrust pad is drilled and
tapped for removal purposes. Use a
suitable M6 screw to extract the thrust pad
from inside the planet gear carrier.
6. Remove the external circlip 2.
7. Remove the sun gear from the driveshaft.
8. To remove the verbus-ripp bolts it is necessary
to remove the spacer (if installed). Rotate the
spacer with a suitable drift to align the holes in
the spacer with the space between the bolts.
9. Use two dowels and two heel bars to remove the
spacer as shown. Refer to Figure 65.

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Figure 65. 11.2. Install the four M14 studs and nuts on
the annulus carrier. Some annulus carriers
J have two tapped holes for use with jacking
K screws. Use two high grade M14 bolts
as jacking screws to remove the annulus
carrier.
Special Tool: Reaction Plate (Qty.: 1)
Special Tool: Reaction Plate M14 Studs
(Qty.: 4)
11.3. Engage the reaction plate.
AF 11.4. Adjust the studs to maintain a clearance
between the reaction plate and the
H driveshaft.
11.5. Install a three leg puller. Engage the puller
legs through the holes in the annulus
carrier.

H External circlip 2 11.6. Use the puller to remove the annulus

J Spacer carrier along with the annulus ring from the
K Verbus-ripp bolt axle stub shaft.
AF Sun gear 11.7. Make sure that the dowels remain either
in the annulus carrier or in the stub shaft.
10. Remove the verbus-ripp bolts with a heavy duty Note: It is normal for fretting to occur on
socket. the mating surfaces between the axle stub
Special Tool: Heavy Duty Socket 19mm A/F x 3/4 shaft and annulus carrier. Do not attempt
in Drive (Qty.: 1) to repair it.

10.1. Note: the verbus-ripp bolts are very tight
and care must be taken not to distort the
bolt heads. Use an extension bar as short
as possible. Discard the verbus-ripp bolts
after removal.
12. Remove the internal circlip to separate the
annulus ring from the annulus carrier.
13. Remove the outer wheel bearing and the bearing
carrier as follows:

11. Remove the annulus carrier along with the 13.1. Attach the legs of the bearing puller
annulus ring as follows: Refer to Figure 66. onto two diametrically opposite wheel
studs and put the reaction tube over the
Figure 66. driveshaft. Refer to Figure 67.
Special Tool: Wheel Hub Service Kit (Qty.:
1)
AG 13.2. The reaction tube must be used otherwise
damage to the driveshaft and driveshaft
bearings will occur.
AJ
13.3. On five wheel stud axles, the modified
wheel studs from the Wheel Hub Service
Kit must be used. Bolt to two diametrically
opposite holes provided on the bearing
carrier.
13.4. Slowly turn the screw until the bearing
AH carrier and the outer wheel bearing are
released from the axle stub shaft.
AG M14 studs and nuts 13.5. If the wheel hub starts to rotate use a
AH Reaction plate suitable bar to prevent further rotation.
AJ 3 Leg puller
13.6. If the screw becomes hard to turn, tap the
11.1. Put marks on the stub shaft and annulus back of the bearing carrier with a soft faced
carrier to identify their relative angular mallet to help release the bearing.
position during installation.

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Figure 67. 15. Remove the inner wheel bearing as follows:

Refer to Figure 69.
W Y
Figure 69.

X
Q
Q Bearing carrier W
W Reaction tube
X Screw
Y Bar
W Reaction tube
14. Remove and discard the outer part of the X Screw
combination oil seal by cutting the outer seal with
a sharp chisel. Take care not to damage the seal 15.1. Clamp the plates around the inner wheel
seat on the axle stub shaft. Refer to Figure 68. bearing.

Figure 68. 15.2. Attach the puller rods and put the reaction
tube over the driveshaft.
15.3. The reaction tube must be used otherwise
damage to the driveshaft and driveshaft
bearings will occur.
Z
15.4. Slowly turn the screw until the inner wheel
bearing is released from the axle stub
shaft.
15.5. Remove and discard the inner part of the
combination oil seal.
16. If installed do not remove the dirt shield.

T Combination oil seal

Z Chisel

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Figure 70.

F
D
V
E P
V

C N
L
B

J K
AF
G T

R U

S
A

A Screw B Planet gear carrier

C O-ring D Planer gear
E Bearing F External circlip 1
G Driveshaft thrust pad H External circlip 2
J Spacer K Verbus-ripp bolt
L Annulus carrier M Annulus ring
N Internal circlip P Dowel
Q Bearing carrier R Outer wheel bearing
S Inner wheel bearing T Combination oil seal
U Dirt shield (If installed) V L-shaped circlip
AF Sun gear

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Assemble Figure 73.

1. Install the outer wheel bearing cup into the AA

bearing carrier.
2. Install the inner wheel bearing cup and cone into
the bearing carrier.
3. Use the seal dolly 892/00891 from the Wheel
Hub Service Kit to install a new combination oil
seal. The seal dolly has two sides 'A' and 'B' B
marked for identification. Do not lubricate the
seal before installation. Refer to Figure 71.
Figure 71. Q

AA
A

Q Bearing carrier
AA Seal dolly
5. Install the seal on the dolly.
B
6. Use a soft-faced mallet to drive the seal squarely
AA Seal dolly into the bearing carrier until the dolly flange is up
against the carrier. Refer to Figure 74.
4. Make sure you use the correct side of the seal
dolly as follows: Figure 74.
4.1. For axles with a steel dirt shield use side 'A'
of the seal dolly. Refer to Figure 72.
Figure 72. AA
AA U

A
Q Bearing carrier
AA Seal dolly
7. Attach the bearing press extension shaft onto the
Q
end of the axle stub with four verbus-ripp bolts.
Refer to Figure 75.
Figure 75.

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

K Verbus-ripp bolts

27 - 78 9823/0100-1 27 - 78

8. Lightly apply oil on the inner wheel bearing cone.
9. Position the bearing carrier (complete with inner
bearing) onto the axle stub over the extension
shaft.
10. Assemble the bearing press as shown. Refer to
Figure 76.
Figure 76.
R AC
AD
AB
R Outer wheel bearing
AB Handle
AC Thrust washers (x2)
AD Reaction tube
11. Slide the reaction tube over the extension shaft
(the wide opening towards the bearing).
12. Make sure that the bearing and bearing carrier
are properly positioned against the axle stub.
13. Attach the handle and make sure that the
thrust bearing is installed between the two thrust
washers.
14. Slowly turn the handle to press the inner wheel
bearing correctly into position, then remove the
handle and reaction tube.
15. Install the outer wheel bearing cone into the
bearing carrier.
16. Assemble the reaction tube and handle onto the
extension shaft.
17. Slowly turn the handle to press the outer bearing
correctly into position until the free play is
removed.
18. Remove the handle and reaction tube.
19. Assemble the annulus ring onto the annulus
carrier and then install the internal clip.
20. Make sure that the dowels are correctly installed.
21. Attach the annulus assembly to the axle stub
shaft in the same angular position based on the
marks made during installation.
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22. Install the new verbus-ripp bolts.
23. Do not tighten the verbus-ripp bolts at this stage.
24. Measure the seal drag rolling force:
Figure 77.
BB
BA
BA Cord
BB Spring balance
24.1. Install the planet gear carrier.
24.2. Do not install the sun gear.
24.3. Wrap a cord around the planet gear carrier
flange and attach a spring balance to it as
shown. Refer to Figure 77.
24.4. Pull the spring balance so that the hub
rotates, do this several times to let the seal
bed in and record the reading.
24.5. Remove the planet gear carrier.
25. Tighten the verbus-ripp bolts to the correct torque
value.
26. Measure the rolling force:
26.1. Install the planet gear carrier.
26.2. Do not install the sun gear.
26.3. Wrap a cord around the planet gear carrier
flange and attach a spring balance to it as
shown.
26.4. Pull the spring balance so that the hub
rotates and record the reading.
26.5. To calculate the rolling force, subtract
the seal drag force (24.4) from the value
obtained in the step 26.4.
26.6. The rolling force should be within the
specified range.
Torque: 2 –22 N·m
26.7. If the values are outside the limits specified
then check if the seal is installed correctly,
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and/or replace the wheel bearings if 30.1. Note: The sun gear must be installed with
necessary. the 1.5mm x 45° chamfer inboard.
26.8. Remove the planet gear carrier. 31. Install a new O-ring, and then install the planet
gear carrier onto the bearing carrier. Make sure
27. Press the driveshaft thrust pad (chamfered side
that the two tapped holes are in line with those
faces downwards) into the recess in the planet
on the bearing carrier.
gear carrier.
32. Do not strike the centre of the planet gear
28. Install the new planet gears in the position of any
carrier during installation as this may dislodge the
that were removed during disassembly. Refer to
driveshaft thrust pad.
Figure 77.
33. Apply sealant to the threads of the screws. Refer
28.1. Important: Make sure that you install the
to Figure 80.
planet gears in the correct orientation.
Install the large radius end of the bearing Figure 80.
over the pin first. Refer to Figure 78.
Q
Figure 78.

AE
A

A Screw
AE Large radius end 34. Install the screw to attach the planet gear carrier.
28.2. Secure the planet gears with external 35. Tighten the screws to the correct torque value.
circlip 1.
36. Fill the hub with the correct grade oil.
Figure 79.
F Table 28. Torque Values
Item Nm
D
G A 56
B K 320

B Planet gear carrier

D Planet gear
G Driveshaft thrust pad
F External circlip 1
29. Install the spacer (If installed).
30. Install the sun gear onto the driveshaft and
secure with the external circlip 2.

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47 - Propshaft

Contents Page No.

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

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00 - General
Introduction ....................................................
Check (Condition) ..........................................
Lubricate ........................................................
Remove and Install .......................................
Introduction
27-83 The propeller shaft or propshaft is usually the shaft
27-84 that connects the gearbox to the differential or
27-84 drivehead.
27-85
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.

27 - 83 9823/0100-1 27 - 83

Check (Condition)
1. Make the machine safe. Refer to (PIL 01-03).
2. Check the propshaft tube for damage or cracks.
3. Check the centre bearing (if installed) for
security, cracks or damage.
4. Check the universal joints for security, cracks
or damage. Make sure that there is no play in
the joint and that grease points are present (if
installed).
5. Check the sliding joints for security, cracks or
damage. Make sure that there is no play in
the joint and that grease points are present (if
installed).
6. Check any sensor or sensor ring for security,
cracks or damage (if installed).
7. Make sure the correct fasteners are installed and
tightened to the correct torque.
8. Renew any defective component as needed.
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00 - General
Lubricate
1. Make the machine safe. Refer to (PIL 01-03).
2. Make sure you have the correct grease.
Refer to: PIL 75-00-00.
3. Use a grease gun to lubricate the universal joint
grease points until fresh grease appears past the
seals of all four bearings in each joint.
3.1. If grease does not appear, push the
propshaft away from the bearing that
grease does not appear from and grease
again.
3.2. If grease still does not appear, remove and
examine the bearing. Renew if necessary.
Refer to: PIL 27-47-00.
4. Remove any excess grease.
27 - 84
 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 81.
Figure 82.

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.

27 - 85 9823/0100-1 27 - 85
 27 - Driveline
47 - Propshaft
00 - General

Table 29. Torque Values

Item Nm
A 75–85
C 118

27 - 86 9823/0100-1 27 - 86
 27 - Driveline
51 - Driveshaft

51 - Driveshaft

Contents Page No.

27-51-00 General ........................................................................................................................... 27-89

27-51-15 Shaft Hub Side ............................................................................................................... 27-93

27 - 87 9823/0100-1 27 - 87
Notes:

27 - 88 9823/0100-1 27 - 88
 27 - Driveline
51 - Driveshaft
00 - General

00 - General
Introduction .................................................... 27-89
Component Identification ............................... 27-90
Disassemble and Assemble .......................... 27-92
Introduction
The driveshaft is a mechanical component for
transmitting torque and rotation, usually used to
connect other components of the driveline that
cannot be connected directly because of distance
or the need to allow for relative movement between
them.

27 - 89 9823/0100-1 27 - 89
 27 - Driveline
51 - Driveshaft
00 - General

Component Identification

Main Component Identification

Figure 83.

1 2 3 4

Item Description
4 Axle arm
Table 30.
5 Driveshaft
Item Description
6 Bearing (taper roller)
1 Hub swivel
7 Trunnion (lower)
2 Trunnion (upper)
3 Bearing (taper roller)

27 - 90 9823/0100-1 27 - 90
 27 - Driveline
51 - Driveshaft
00 - General

Sectional Drawing

Figure 84.

1 2 3 4 5 6 7 8

5 9

Table 31.
Item Description
1 Bearing (needle roller)
2 Circlip (internal)
3 Oil seal
4 Spacer
5 Grease nipple
6 Seal
7 Trunnion
8 Bearing (taper roller)
9 Retaining bolt

27 - 91 9823/0100-1 27 - 91
 27 - Driveline
51 - Driveshaft
00 - General

Disassemble and Assemble

Refer to Front Driveshaft, Shaft Hub Side (PIL

27-51-15).

27 - 92 9823/0100-1 27 - 92
 27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side

15 - Shaft Hub Side Calibrate

Consumables
Calibrate ........................................................ 27-93
Description Part No. Size
Disassemble and Assemble .......................... 27-95
JCB Threadlocker 4101/0250 0.01 L
and Sealer (Medium 4101/0251 0.05 L
Strength)

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

When you assemble, select the correct thickness

shim and check the bearing pre-load as follows:

1. Locate the hub swivel and install the bottom

trunnion.
2. Apply JCB Threadlocker to the bottom trunnion
bolts.
Consumable: JCB Threadlocker and Sealer
(Medium Strength)
3. Tighten the bolts to the specified torque value.
Torque: 98 N·m
4. Install the top trunnion and finger tighten the top
trunnion bolts.
5. Attach a spring balance to the track rod swivel
and note the reading. Refer to Figure 85.
Figure 85. Measuring the swivel turning force

6. Tighten the top trunnion bolts to stop end float

but not the bearing pre-load, so that there is no
increase in the spring balance reading.
7. Measure the gap at the top trunnion and subtract
1 mm (0.040 in) to give the shim thickness
(bearing pre-load). Refer to Figure 86.

27 - 93 9823/0100-1 27 - 93
 27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side

Figure 86. Measuring the top trunnion gap

8. Remove the top trunnion and install the correct

shim.
9. Install the top trunnion.
10. Apply JCB Threadlocker to the top trunnion bolts.
Consumable: JCB Threadlocker and Sealer
(Medium Strength)
11. Tighten the bolts to the specified torque value.
Torque: 98 N·m
12. Check that the spring balance reading which
should be 4.5 kgf (10lbf) more than the reading
mentioned in the step 5.

Table 32. Example of shim thickness calculation

Gap 1.55 mm
Subtract 1 mm
Shim Thickness 0.55 mm

27 - 94 9823/0100-1 27 - 94
 27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side

Disassemble and Assemble

Special Tools 3. Mark the position of the top and bottom trunnions.
Description Part No. Qty. Remove the bolts and remove the trunnions.
Impulse Extractor 892/00224 1 4. Remove the hub swivel.
Bearing Removal Tool 892/00225 1
Adaptor 993/59500 1 5. To easily remove the trunnions, pump grease
through the grease nipple.
Consumables Consumable: Special HP Grease
Description Part No. Size
JCB Threadlocker 4101/0250 0.01 L 6. If it is necessary to replace, remove the top and
and Sealer (Medium bottom trunnion oil seals and bearings.
4101/0251 0.05 L
Strength) 7. Use an adaptor with a slide hammer tool to
Special HP Grease 4003/2020 0.5 kg remove the driveshaft oil seal1 and the needle
4003/2017 0.4 kg roller bearing from the hub swivel.
4003/2006 12.5 kg Special Tool: Impulse Extractor (Qty.: 1)
4003/2005 50 kg Special Tool: Adaptor (Qty.: 1)
8. Remove the driveshaft from the axle.
Disassembly
9. Prise out the driveshaft oil seal 2 from the axle
The hub assembly must be removed before you ram.
attempt to remove the hub swivel and driveshaft.
Refer to the applicable axle hub removal procedure. 10. Use a tool (892/00225) to remove the drive shaft
inner bearing.
1. Disconnect the track rod and steering cylinder
Special Tool: Bearing Removal Tool (Qty.: 1)
from the axle steer knuckles.
11. If there has been a component failure, remove
2. The top and bottom trunnions are the same.
all traces of debris from the axle and clean the
magnetic drain plug.

27 - 95 9823/0100-1 27 - 95
 27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side

Figure 87.

20 Trunnions 21 Trunnion bolts

23 Hub swivel 24 Trunnions seals
25 Bearing 26 Driveshaft
27 Drive shaft seal 28 Needle roller bearing
30 Driveshaft inner oil seal 31 Circlip
32 Driveshaft inner bearing

27 - 96 9823/0100-1 27 - 96
 27 - Driveline
51 - Driveshaft
15 - Shaft Hub Side

Assembly 19. Connect the track rod and steering cylinder to the
axle steer knuckles.
1. Tap the driveshaft inner bearing into the position
in the axle case. Table 33. Torque Values

2. Install a new driveshaft oil seal 2. Apply grease Item Description Nm

between the lips of the seal. 21 Trunnion bolts 98
Consumable: Special HP Grease
3. Tap the driveshaft needle roller bearing into the
position in the hub swivel driveshaft bore.
4. Install new driveshaft oil seal 1. Apply grease
between the lips of the seal.
Consumable: Special HP Grease
5. Instal the spacer.
6. Install the driveshaft. Carefully locate the end into
the splines of the differential gears.
7. Push the new trunnion oil seals into the position
followed by the bearings.
8. Apply grease on the bearing and the oil seal
before you install them to the axle.
Consumable: Special HP Grease
9. In the following step, take care not to damage the
trunnion oil seals when you tighten the trunnion
bolts.
10. Previous axles have a shim installed under the
top trunnion. Where a shim is installed follow the
calibration procedure.
11. Locate the hub swivel and install the top and
bottom trunnions.
12. Apply JCB Threadlocker to threads of trunnion
bolts.
Consumable: JCB Threadlocker and Sealer
(Medium Strength)
13. First finger tighten all of the bolts then
sequentially tighten them to bring the two
trunnions together.
14. Tighten the bolts to the correct torque value.
15. Make sure that the swivel rotates smoothly on its
trunnions.
16. Stiff movement may result if seals have become
displaced and damaged during assembly.
17. Make sure that the grease nipple is clear and not
damaged, replace as necessary.
18. Tighten the nipple to the specified torque value.
Torque: 56 N·m

27 - 97 9823/0100-1 27 - 97
Notes:

27 - 98 9823/0100-1 27 - 98
 30 - Hydraulic System
Contents Page No.

30-15 Cylinder / Ram

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

9823/0100-1
2017-07-18
Notes:

9823/0100-1
2017-07-18
 30 - Hydraulic System
15 - Cylinder / Ram

15 - Cylinder / Ram

Contents Page No.

30-15-00 General ............................................................................................................................. 30-3

30-15-34 Steering ............................................................................................................................ 30-7
30-15-99 Seal Kit ........................................................................................................................... 30-17

30 - 1 9823/0100-1 30 - 1
Notes:

30 - 2 9823/0100-1 30 - 2

00 - General
Introduction ......................................................
Health and Safety ...........................................
Check (Condition) ............................................
Check (Operation) ...........................................
30 - 3
30 - Hydraulic System
15 - Cylinder / Ram
00 - General
Introduction
30-3 A hydraulic cylinder ram is a mechanical actuator
30-4 that is used to give a single directional force
30-5 through a single action stroke. It is used in many
30-6 applications, the cylinder gets the power from
pressurised hydraulic oil. The hydraulic cylinder
consists of a cylinder barrel, in which a piston
connected to a piston rod moves back and forth.
The barrel is closed on one end by the cylinder
cap and the other end by the cylinder head where
the piston rod comes out of the cylinder. The piston
has sliding rings and seals. The piston divides the
inside of the cylinder into two chambers, the bottom
chamber (cap end) and the piston rod side chamber
(rod end / head end).
9823/0100-1 30 - 3

Health and Safety
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose
service line has been vented before connecting or
removing hoses. Make sure the engine cannot be
started while the hoses are open.
Lifting Equipment
You can be injured if you use incorrect or faulty lifting
equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all
local regulations.
WARNING! A raised and badly supported machine
can fall on you. Position the machine on a firm, level
surface before raising one end. Ensure the other
end is securely chocked. Do not rely solely on the
machine hydraulics or jacks to support the machine
when working under it. Disconnect the battery, to
prevent the machine being started while you are
beneath it.
Precautions for Installation
1. Precautions when installing the ram on the
machine.
1.1. When installing and removing from the
machine, suspend the ram safely.
1.2. Suspending the ram by the piping is not only
dangerous, but can also cause damage to
the cylinder.
1.3. Secure the piston rod with a band. It is very
dangerous if the rod extends unexpectedly.
Also, the rod can be damaged and become
unusable.
2. Welding after installing the ram may result in
damage.
2.1. If electric welding is done even at a point
away from the ram, there may be sparking
inside the ram and it will become necessary
to replace the ram with a new one.
3. When painting the machine, mask the ram. If
paint adheres to the rod surface or to the wiper
ring and the ram is operated, the wiper ring will
not function properly and foreign matter and paint
can easily enter the ram. This will cause damage
to the seals, drastically shortening the life of the
ram.
4. Install the ram only when it is clean.
30 - 4 9823/0100-1
30 - Hydraulic System
15 - Cylinder / Ram
00 - General
Caution During Use
1. Use only under designated conditions.
1.1. If hydraulic oil other than the designated oil
is used, the seals quickly degenerate and
become damaged. If the relief valve is set at
a value higher than specified, it may cause
ram damage and is dangerous.
1.2. In high temperature environments (approx.
90°C and above) or low temperature
environments (below -20°C), seals quickly
become damaged. Special seal materials
are necessary so check to see if the ram
that you are using is suitable or not.
1.3. The number one cause of ram oil leakage is
rod damage. Be careful not to damage the
rod.
2. Warm up sufficiently before beginning work.
2.1. In cold conditions the rod seals may
be frozen, so if the ram is operated at
maximum pressure and maximum speed,
the seals will be damaged.
2.2. There is a large amount of air in a new
ram or one which has been left for a long
time, so the ram will not operate smoothly.
Also, if pressure is applied suddenly without
bleeding the air, high temperatures will be
generated due to adiabatic compression
and the seals may burn.
2.3. Before beginning work, always move the
ram at full stroke with no load and expel air
from the cylinder.
3. When stopping or storing, do it at a safe and fixed
position.
3.1. The installed ram cannot maintain the same
position for a long period of time, because
the oil inside the ram may leak and the
hydraulic oil volume decreases as it cools.
Stop or store the machine in a safe and
fixed position.
Maintenance, Inspection Points
1. Carry out daily maintenance and inspection.
1.1. The key point for correct long-term
ram function is daily maintenance and
inspection. Carry out maintenance and
inspection so that the ram functions fully at
all times. Always remove any mud, water,
dust or oil film adhering to the rod and
keep it in normal condition. However, when
cleaning the wiper ring and seals, do not get
them wet with water but wipe clean with a
rag. To prevent rust forming during storage,
the amount of exposed ram piston rod
30 - 4

should be kept to a minimum. If leaving for
more than one week, apply a light coating
of suitable grease or petroleum jelly to the
exposed part of the ram piston rod.
2. Use genuine JCB parts when replacing parts.
2.1. If parts other than genuine JCB parts
are used, the desired results may not be
obtained. Use only genuine JCB parts.
3. Caution during dismantling and reassembly.
3.1. Dismantling the ram while it is still installed
on the machine can be dangerous as
unexpected movements of the machine can
occur. Remove the ram from the machine
and then dismantle.
3.2. If reassembled with dirty hands, foreign
matter can enter the ram causing a shorter
life span and also the other hydraulic
equipment may be damaged. Reassemble
in a clean state.
3.3. Follow the instructions in the diagrams
regarding torque tightening for screwed
parts. If the torque is too high or too low, it
can cause damage.
30 - 5 9823/0100-1
30 - Hydraulic System
15 - Cylinder / Ram
00 - General
Check (Condition)
Maintenance and Inspection
1. Always do the daily maintenance and inspection
of the hydraulic rams.
1.1. The key point for the correct long
term ram function is daily maintenance
and inspection. Do the maintenance and
inspection to operate the rams satisfactorily.
1.2. Always remove any mud, water, dust or oil
film adhering to the rod and keep the ram in
normal condition.
1.3. Do not use water when you clean the wiper
ring and seals, use a rag to clean.
1.4. To prevent rust formation during the
machine storage on the ram piston rod, the
amount of exposed time must be kept to a
minimum.
1.5. When you put the machine into storage for
more than one week, apply a light coat of
suitable grease or petroleum jelly to the
exposed part of the ram piston rod.
2. Make sure that the genuine JCB parts are used
when you replace the parts.
2.1. If you used parts other than genuine JCB
parts, the desired results may not be
obtained. JCB recommend you to use only
genuine JCB parts.
3. Take care when you disassemble and assemble
the hydraulic ram.
3.1. If you disassemble the ram on the
machine, it may be dangerous as possible
movements of the ram may occur.
3.2. If you do not obey the cleanliness
procedures during the ram assembling,
foreign matter may enter the ram, and
damage to the ram and other hydraulic
equipments.
3.3. Always obey the cleanliness procedures
when you assemble the hydraulic ram.
3.4. Always obey the correct torque tightening
instructions regarding the screwed parts for
the ram. If the torque value is applied too
high or too low, it may cause damage.
30 - 5
 30 - Hydraulic System
15 - Cylinder / Ram
00 - General

Check (Operation)

Operation
1. The hydraulic ram should only be operated under
the designated conditions.
1.1. If you use oil other than the recommended
hydraulic oil, the seals can quickly
degenerate and become damaged.
1.2. If the relief valve is set at a value higher
than the recommended, it may cause ram
damage and it is dangerous.
1.3. In the higher (approximately 90°C and
above) or lower (below -20°C) temperature
work environments, the seals quickly
become damaged.
1.4. To get the desired operation of the ram
in these work environment, the seals are
made from special materials.
1.5. The basic cause of ram oil leakage is rod
damage.
1.6. Be careful when you handle the ram rod
which must not be damaged.
2. Operate the engine at idle speed to get the
desired normal temperature of the hydraulic oil,
before you start the ram operation.
2.1. In cold conditions the rod seals may be
frozen, and if you operate the ram at
maximum pressure and speed, the seals
will be damaged.
2.2. A new ram has a large amount of trapped
air which may have been left for a long
time, if you operate such a ram, it will not
operate smoothly. If you apply pressure
suddenly without bleeding the air from the
ram, high temperatures will be generated
and the seals will burn.
2.3. Before you operate the ram, always move
the ram at full stroke with no load and bleed
air from the ram cylinder.
3. When you stop the ram operation, do it at a safe
and fixed position.
3.1. The installed ram cannot maintain the same
position for a long period of time, because
the oil inside the ram may leak and the
hydraulic oil volume decreases as it cools.
Keep the machine in a safe and fixed
position.

30 - 6 9823/0100-1 30 - 6
 30 - Hydraulic System
15 - Cylinder / Ram
34 - Steering

34 - Steering Component Identification

Component Identification ................................. 30-7
Bleed ............................................................. 30-10
Remove and Install ....................................... 30-10
Disassemble and Assemble .......................... 30-12

30 - 7 9823/0100-1 30 - 7
 30 - Hydraulic System
15 - Cylinder / Ram
34 - Steering

Figure 88.

11 10
1
13 9
4
5
6
7

3 8

12

1 End cap 2 Piston rod assembly

3 Lock ring 4 Wear ring 1
5 Seal 6 Wear ring 2
7 Piston head 8 Seal
9 O-ring 10 Seal

30 - 8 9823/0100-1 30 - 8
 30 - Hydraulic System
15 - Cylinder / Ram
34 - Steering

11 Seal 12 Bearing bush - rod eye end

13 Bearing bush - rod eye end

30 - 9 9823/0100-1 30 - 9
 30 - Hydraulic System
15 - Cylinder / Ram
34 - Steering

Bleed Remove and Install

WARNING A raised and badly supported
Whenever any hydraulic steering component is machine can fall on you. Position the machine
disconnected or removed from the system, you must on a firm, level surface before raising one end.
be bleed as follows: Ensure the other end is securely chocked. Do
not rely solely on the machine hydraulics or jacks
With the engine running, follow this procedure in to support the machine when working under it.
the order shown, you must not alter the order of Disconnect the battery, to prevent the machine
selections and operations. being started while you are beneath it.
1. Select 2 Wheel Steer.
Removal and Install
1.1. Turn steering wheel to left, until front wheels
are fully locked to the left. The axle may be installed with either a single or twin
1.2. Turn steering wheel to right, until front cylinder system.
wheels are fully locked to the right.
Removal
2. Select 4 Wheel Steer.
1. Make the machine safe.
2.1. Turn steering wheel to left, until front wheels Refer to: PIL 01-03.
are fully locked to the left.
2. Disconnect and cap all the hydraulic hoses to
3. Select 2 Wheel Steer. prevent loss of fluid and ingress of dirt.
3.1. Turn steering wheel to full right lock. 3. Make sure to label or mark the hoses for
3.2. Turn steering wheel to full left lock. identification and correct installation.
3.3. Turn steering wheel to full right lock. 4. Remove the locking bolts and pivot pins.
4. Select 4 Wheel Steer. 5. Remove the steering cylinders from the machine.
4.1. Turn steering wheel to left, until the front
wheels are fully locked to the left.
5. Select 2 Wheel Steer.
5.1. Turn steering wheel to fully right lock.
5.2. Turn steering wheel to fully left lock.
5.3. Turn steering wheel to fully right lock.
6. Select 4 Wheel Steer.
6.1. Turn steering wheel to left, until front wheels
are fully locked to the left.
7. Select 2 Wheel Steer.
7.1. Turn steering wheel to full right lock.
7.2. Turn steering wheel to full left lock.
7.3. Turn steering wheel to full right lock.
8. Select 4 Wheel Steer.
8.1. Turn steering wheel to left, until the front
and rear wheels are fully locked.

30 - 10 9823/0100-1 30 - 10
 30 - Hydraulic System
15 - Cylinder / Ram
34 - Steering

Figure 89.

D
C

A Bolt
B Pivot pin
C Pin
D Ring

Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
steps.
2. Apply anti-seize paste to the pivot pins, to
facilitate subsequent removal.
3. After connecting the hoses, check the hydraulic
fluid level.
3.1. If necessary, top up as required.

30 - 11 9823/0100-1 30 - 11
 30 - Hydraulic System
15 - Cylinder / Ram
34 - Steering

Disassemble and Assemble

Special Tools 1. Make the machine safe.

Description Part No. Qty. Refer to: PIL 01-03.
Temperature Probe 892/00285 1
Ram Piston Nut 993/99512 1 2. Disassemble the cylinder ram in the numerical
Removal Installation sequence.
Spanner 55mm A/F 3. Put the cylinder assembly on a clean workbench.
Ram Piston Nut 993/99513 1
Removal Installation 4. Use the special spanner to loosen the end cap
Spanner 60mm A/F assembly and remove the piston rod assembly
Ram Piston Nut 993/99514 1 from the cylinder.
Removal Installation Special Tool: Ram Piston Nut Removal
Spanner 65mm A/F Installation Spanner 55mm A/F (Qty.: 1)
Ram Piston Nut 993/99515 1 Special Tool: Ram Piston Nut Removal
Removal Installation Installation Spanner 60mm A/F (Qty.: 1)
Spanner 70mm A/F Special Tool: Ram Piston Nut Removal
Ram Piston Nut SSP0046 1 Installation Spanner 65mm A/F (Qty.: 1)
Removal Installation Special Tool: Ram Piston Nut Removal
Spanner 80mm A/F Installation Spanner 70mm A/F (Qty.: 1)
Special Tool: Ram Piston Nut Removal
Ram Piston Nut SSP0047 1
Installation Spanner 80mm A/F (Qty.: 1)
Removal Installation
Special Tool: Ram Piston Nut Removal
Spanner 95mm A/F
Installation Spanner 95mm A/F (Qty.: 1)
Consumables 5. Position the piston rod assembly on bench in
Description Part No. Size place of cylinder.
Cleaner/Degreaser 4104/1557 0.4 L
- General purpose 6. Remove the seal and wear rings from the piston
solvent based parts head.
cleaner
7. Remove the locking ring.
Special HP Grease 4003/2020 0.5 kg
4003/2017 0.4 kg 8. Heat the piston head (180-210 °C) to degrade the
4003/2006 12.5 kg Loctite between piston head and rod.
4003/2005 50 kg 8.1. Use the surface temperature probe to check
the temperature.
Disassemble and Assemble (without Special Tool: Temperature Probe (Qty.: 1)
Dowel) 8.2. Do not exceed 300 °C or the Loctite will
CAUTION If air or hydraulic pressure is used to char, causing thread pick-up.
force out the piston assembly, ensure that the end
cap is securely installed. Severe injury can be 9. Use special spanner to remove the piston head
caused by a suddenly released piston rod. from rod.
CAUTION To avoid burning, wear personal 10. Remove end cap from the piston rod and remove
protective equipment when handling hot the seals and O-ring.
components. To protect your eyes, wear goggles
when using a brush to clean components. 11. Make sure that the metal components are free
from scoring, nicks and burrs.
Disassemble
Refer to Figure 90.

30 - 12 9823/0100-1 30 - 12
 30 - Hydraulic System
15 - Cylinder / Ram
34 - Steering

Figure 90.

11 10
1
13 9
4
5
6
7

3 8

12

1 End cap 2 Piston rod assembly

3 Lock ring 4 Wear ring 1
5 Seal 6 Wear ring 2
7 Piston head 8 Seal
9 O-ring 10 Seal

30 - 13 9823/0100-1 30 - 13

11 Seal
13 Bearing bush - rod eye end
11.1. A damaged rod will impair the life of the
gland seal.
Assemble
1. Use a wire brush and clean the threads of piston
rod, piston head, end cap and cylinder.
2. Use cleaner/ degreaser to make sure that all the
threads are free from grease, hydraulic oil and
old Loctite.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
2.1. Allow 15 minutes for the solvent to dry
before applying Loctite.
3. Make sure that all lubricants used during
assembly, do not come into contact with Loctite.
4. Install the seals into the end cap, then install
the end cap into the piston rod. Refer to Seal
Installation procedure.
Refer to: PIL 30-15-99.
5. Apply Loctite Activator to threads of piston rod,
end cap and cylinder. All Activator to dry for 15
minutes before bringing into contact with Loctite.
5.1. Make sure that the Loctite or Activator are
not allowed to contact seals, bearing rings
or o-rings.
6. Apply Loctite 262 to all threads of piston rod.
Install O-ring in piston head, lubricating only
the O-ring with Mobil HP222 grease. Install and
tighten the piston head to the correct torque
value. Install a new locking ring.
Consumable: Special HP Grease
7. Install a new seal and wear rings to piston head.
8. Position the cylinder on a clean workbench and
install the rod assembly into the cylinder.
9. Apply Loctite 932 to thread of end cap, install a
new O-ring and tighten torque the end cap into
the cylinder.
9.1. If hydraulic cylinder contacts uncured
Loctite a weakening of the bond will result.
Cure times vary according to the ambient
temperature and type of Activator used. The
following approximate cure time applies at
20 °C and is the minimum period between
the assembly and filling the cylinder with oil.
9.2. Loctite 262 or 932 with Activator - 1 hour.
30 - 14 9823/0100-1
30 - Hydraulic System
15 - Cylinder / Ram
34 - Steering
12 Bearing bush - rod eye end
10. When operating in cold weather conditions,
which is consistently below freezing. It is
recommended that the cylinders are operated
slowly to their full extent before commencing
normal working.
Disassemble and Assemble (with
Dowelled Piston Head)
Disassemble
Refer to Figure 90.
1. Make the machine safe.
Refer to: PIL 01-03.
2. Put the cylinder assembly on a clean workbench.
3. Use the special spanner to loosen the end cap
assembly and remove the piston rod assembly
from the cylinder.
Special Tool: Ram Piston Nut Removal
Installation Spanner 55mm A/F (Qty.: 1)
Special Tool: Ram Piston Nut Removal
Installation Spanner 60mm A/F (Qty.: 1)
Special Tool: Ram Piston Nut Removal
Installation Spanner 65mm A/F (Qty.: 1)
Special Tool: Ram Piston Nut Removal
Installation Spanner 70mm A/F (Qty.: 1)
Special Tool: Ram Piston Nut Removal
Installation Spanner 80mm A/F (Qty.: 1)
Special Tool: Ram Piston Nut Removal
Installation Spanner 95mm A/F (Qty.: 1)
4. Position the piston rod assembly on the
workbench in place of the cylinder.
5. Extract the dowel from the piston head, using a
metric screw threaded into the extractor hole.
6. Use special spanner to remove the piston head
from rod.
7. Remove gland bearings and end cap from piston
rod and remove seals and back-up rings. Refer
to Seal Installation procedure.
Refer to: PIL 30-15-99.
7.1. Make sure that the metal components are
free from scoring, nicks and burrs.
7.2. A damaged rod will impair the life of the
gland seal.
Assemble
1. Use a wire brush and clean the threads of piston
rod, piston head, end cap and cylinder.
30 - 14

2. Use cleaner/ degreaser to make sure that all the
threads are free from grease, hydraulic oil and
old Loctite.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
2.1. Allow 15 minutes for the solvent to dry
before applying Loctite.
3. Make sure that all lubricants used during
assembly, do not come into contact with Loctite.
4. Install seal into end cap first, followed by circlip.
Insert seal and back-up ring into the end cap.
Refer to Seal Installation procedure.
Refer to: PIL 30-15-99.
4.1. Install the external O-ring.
5. Use sleeve, overleaf, installed over piston rod
threads to protect the seals from damage and
the threads from oil and grease. Install the gland
bearing into the end cap and push the assembly
over the sleeve onto the rod.
6. Apply Loctite Activator to threads of end cap and
cylinder. Allow the Activator to dry for 15 minutes
before bringing into contact with Loctite.
7. Do not allow the Loctite or Activator to contact
the seals, bearing rings or O-rings.
Installation of Locking Dowel to Piston head/rod
as follows:
1. Install O-ring into piston head.
2. Install the piston head to piston rod and tighten
to the correct torque value.
3. New cylinder shaft and piston head installed.
3.1. If both are required, the following procedure
should be followed:
3.2. Drill though piston head into piston rod. Use
an undersized diameter drill first as a guide
and then drill with the correct size diameter
drill to suit.
3.3. Remove all swarf and contamination. Insert
the dowel into drilled hole, make sure
tapped extractor hole is to the outside.
Table 34. Drilling Details for Piston Head Retention (all diameters in mm)
Cylinder Size Dowel Size Guide Drill
90 x 50 80 x 25 5 24
100 x 60
110 x 60 120 x 30 8 28
110 x 65
30 - 15 9823/0100-1
30 - Hydraulic System
15 - Cylinder / Ram
34 - Steering
4. New piston head installed on a pre-drilled piston
rod.
4.1. Drill and dowel both the piston head and
piston rod at 90 °C from the existing drilled
dowel hole in the piston rod. Follow the
above procedures at step 3.
5. New piston rod installed to a pre-drilled piston
head. Refer to Table 34.
5.1. Use the pre-drilled in the piston head. Care
must be taken not to elongate the existing
hole in the piston head.
5.2. Use a drill the same diameter as the pre-
drilled hole in the piston head to make a
'centre mark' in the piston rod. Do not drill
the piston rod at this stage.
5.3. Use an undersized diameter drill as a guide
and drill into the piston rod to the required
depth. make sure the drill has centred
correctly on the center mark.
5.4. Use the correct side diameter drill to suit the
dowel and drill to the required depth.
5.5. Remove all swarf and contamination, insert
the dowel.
6. Position cylinder on workbench and install rod
assembly into cylinder.
7. Apply Loctite 932 to first three threads of cylinder,
tighten the end cap to the correct torque value.
7.1. If hydraulic oil contacts uncured Loctite
a weakening of the bond will result.
Cure times vary according to the ambient
temperature and type of Activator used. The
following approximate sure times apply at
20 and are the minimum periods between
assembly and filling the cylinder with oil.
7.2. Loctite 262 or 932 with Activator - 1 hour.
8. When operating in cold weather conditions,
which is consistently below freezing. It is
recommended that the cylinders are operated
slowly to their full extent before commencing
normal working.
Guide Drill Dowel Drill Dowel Drill
Depth Depth
8.02/8.10 27/28
12.02/12.10 32/33
30 - 15
 30 - Hydraulic System
15 - Cylinder / Ram
34 - Steering

Cylinder Size Dowel Size Guide Drill Guide Drill Dowel Drill Dowel Drill
Depth Depth
120 x 65 120 x 35 8 33 12.02/12.10 37/38
130 x 75

Table 35. Torque Values

Item Description Nm
1 End cap 678
7 Piston head 405

30 - 16 9823/0100-1 30 - 16
 30 - Hydraulic System
15 - Cylinder / Ram
99 - Seal Kit

99 - Seal Kit Figure 91.

Remove and Install

Special Tools
Description Part No. Qty.
Ram Protection Sleeve 892/00167 1
(90mm rod diameter)
Ram Seal Installation 892/00334 1 A Ram seal installation tool
Tool B Pins
Ram Protection Sleeve 892/01016 1 1.2. Open the seal installation tool and insert
(25mm rod diameter) the new rod seal. Install the seal behind the
Ram Protection Sleeve 892/01017 1 two front pins but in front of the rear pin as
(30mm rod diameter) shown.
Ram Protection Sleeve 892/01018 1 Figure 92.
(40mm rod diameter)
Ram Protection Sleeve 892/01019 1
(50mm rod diameter)
Ram Protection Sleeve 892/01020 1
- Slew (50mm rod
diameter)
Ram Protection Sleeve 892/01021 1
(60mm rod diameter)
Ram Protection Sleeve 892/01022 1
- Slew (60mm rod
diameter)
A Rod seal
Ram Protection Sleeve 892/01023 1
(65mm rod diameter) 1.3. Later ram end caps and piston heads
Ram Protection Sleeve 892/01024 1 have metric threads. The seals are also
(70mm rod diameter) different, make sure that the correct seals
Ram Protection Sleeve 892/01025 1 are installed. On metric threaded rams,
(75mm rod diameter) make sure that the seals are installed the
correct way around, as shown.
Ram Protection Sleeve 892/01026 1
(80mm rod diameter) Figure 93.
Ram Seal Assembly 892/01027 1
Tool

Remove
1. Remove and discard the old seals.
Refer to: PIL 30-15-00.

Install
1. Install new rod seals:
A Inner seal
1.1. Use the ram seal installation tool to install B Outer seal
rod seals, the size (diameter) and position
of pins is determined by the diameter and 1.4. Close the tool. The seal must form a
radial width of the rod seal being installed. reniform (kidney shape).
The pins are screwed into threaded holes
in the tool body, the spacing of the holes is
designed to suit small or large diameter rod
seals.
Special Tool: Ram Seal Installation Tool
(Qty.: 1)

30 - 17 9823/0100-1 30 - 17
 30 - Hydraulic System
15 - Cylinder / Ram
99 - Seal Kit

Figure 94. Special Tool: Ram Protection Sleeve - Slew

(60mm rod diameter) (Qty.: 1)
Special Tool: Ram Protection Sleeve
(65mm rod diameter) (Qty.: 1)
Special Tool: Ram Protection Sleeve
(70mm rod diameter) (Qty.: 1)
Special Tool: Ram Protection Sleeve
(75mm rod diameter) (Qty.: 1)
Special Tool: Ram Protection Sleeve
1.5. Before you install the rod seals, check that (80mm rod diameter) (Qty.: 1)
the seal grooves are free of contamination Special Tool: Ram Protection Sleeve
and sharp edges. (90mm rod diameter) (Qty.: 1)

1.6. Locate the seal in the end cap groove. Figure 96.
When the seal is in position, open the tool
to release the seal. Make sure the seal is
correctly installed in its grooved and remove
the tool.
Figure 95.

A Protection Sleeve (various sizes)

2. Install new head piston seals.
2.1. Use the Piston seal assembly tool to lever
the inner seal into the piston head seal
groove. Do not let the seal twist. There are
identification marks on the outer diameter
1.7. Install the rod wiper seal into the seal of the seal, make sure that the marks are
groove. Make sure that the seal is correctly visible and the seal is free to rotate, if not
installed as shown. Note: Some rod wipers, remove the seal and retry.
i.e. power track rod, may use a metal
encased seal which is pressed into the Special Tool: Ram Seal Assembly Tool
housing. Care must be taken to make sure (Qty.: 1)
that the seal is square before it is pressed Figure 97.
in.
1.8. A special sleeve must be used to protect
the rod seals from damage, when installing
the end cap on to the piston rod. There are
various sizes of sleeve, make sure you use
the correct size sleeve and also make sure
that the hexagon on the end cap is towards
the eye end of the rod.
Special Tool: Ram Protection Sleeve
(25mm rod diameter) (Qty.: 1)
Special Tool: Ram Protection Sleeve
(30mm rod diameter) (Qty.: 1)
Special Tool: Ram Protection Sleeve
(40mm rod diameter) (Qty.: 1)
Special Tool: Ram Protection Sleeve
(50mm rod diameter) (Qty.: 1)
Special Tool: Ram Protection Sleeve - Slew A Piston seal assembly tool
(50mm rod diameter) (Qty.: 1) B Inner seal
Special Tool: Ram Protection Sleeve C Outer seal
(60mm rod diameter) (Qty.: 1)

30 - 18 9823/0100-1 30 - 18
 30 - Hydraulic System
15 - Cylinder / Ram
99 - Seal Kit

2.2. Use the same procedure to install the outer

seal as stated for the inner seal. Check that
the external grooves are visible.
2.3. Make sure that the O-ring is installed into
the internal seal groove on the piston head.
Screw the piston head on to the thread of
the piston rod and tighten to the correct
torque value.
Refer to: PIL 30-15-00.
2.4. Install the piston head retaining dowel.
Refer to: PIL 30-15-00.
2.5. Install wear rings, rotate the wear rings so
that the piston retention dowel is covered by
the wear ring, not as shown at C.
Figure 98.

A Outer wear ring

B Inner wear ring
C Incorrect installation
3. Install the piston rod and head assembly into the
cylinder.
3.1. Insert the piston/rod assembly into the
cylinder ram. Align the rod and head
assembly until parallel with the cylinder ram
then push the assembly into the cylinder.
3.2. Install the end cap and assemble the ram
assembly.
Refer to: PIL 30-15-00.

30 - 19 9823/0100-1 30 - 19
Notes:

30 - 20 9823/0100-1 30 - 20
 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

9823/0100-1
2017-09-22
Notes:

9823/0100-1
2017-09-22
 72 - Fasteners and Fixings
00 - Fasteners and Fixings

00 - Fasteners and Fixings

Contents Page No.

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

72 - 1 9823/0100-1 72 - 1
Notes:

72 - 2 9823/0100-1 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
manufactured using an improved type of corrosion
resistant finish. This type of finish is called Dacromet
and replaces the original Zinc and Yellow Plating
used on earlier machines. The two types of fasteners
can be readily identified by colour and part number
suffix. Refer to Table 1. Fastener Types.
Table 36.
Fastener Type Colour Part Number
Suffix
Zinc and Yellow Golden Finish Z (e.g.
1315/3712Z)
Dacromet Mottled Silver D (e.g.
Finish 1315/3712D)
Note: As the Dacromet fasteners have a lower torque
setting than the Zinc and Yellow fasteners, the torque
figures used must be relevant to the type of fastener.
A Dacromet bolt should not be used in conjunction
with a Zinc or Yellow plated nut, as this could
change the torque characteristics of the torque
setting further. For the same reason, a Dacromet nut
should not be used with a Zinc or Yellow plated bolt.
All bolts used on JCB machines are high tensile and
must not be replaced by bolts of a lesser tensile
specification.
Dacromet bolts, due to their high corrosion
resistance are used in areas where rust could
occur. Dacromet bolts are only used for external
applications. They are not used in applications
such as gearbox or engine joint seams or internal
applications.
JCB Fasteners (After September 2017)
Torque and Angle Tightening
Insufficient pre-load of a bolted joint can cause
major problems, such as cylinder head warp, leaking
gasket joints etc. There are several methods of
achieving an accurate pre-load of a bolted joint, the
two main methods used on the JCB engine are:
• Torque Control Tightening - Using a torque
meter to control the torque is the most
popular means of controlling pre-load, and
in the majority of instances this method is
adequate. It should be noted that with this
process, the majority of the torque is used
to overcome friction, therefore slight variations
in the frictional conditions can lead to large
changes in the bolt pre-load.
• Angle Control Tightening - Where a more
precise pre-load is required, the torque and
angle tightening method is used. The bolt
is tightened to a predetermined torque (this
may be done in stages), and then as a
final sequence, the bolt is tightened to a
predetermined angle - this method of tightening
the bolts results in a smaller variation in the
final pre-load. It is critical that the predetermined
tightening angle is accurately achieved, failure
to tighten accurately to the specified angle could
result in the bolt pre-load being incorrect - this
will lead to eventual failures. It is good practice
to replace all bolts that have been tightened
using the torque + angle procedure.
Tightening Method
The following example explains the recommended
torque and angle procedure. A torque angle gauge
should be used for accuracy, but as a visual check,
the bolts can be match marked as described below.

1. Tighten the bolt to the specified torque (specified

Table 37. 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 99.
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 9823/0100-1 72 - 3
 72 - Fasteners and Fixings
00 - Fasteners and Fixings
00 - General

Figure 99.

0°

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

this instance the additional torque angle is 90°.
This line must be marked the specified angle in
a clockwise direction (to further tighten the bolt).
Refer to Figure 100.
Figure 100.

+90°

4. In some instances, angle torque tightening can

be specified in two stages, for instance in this
example, the first angle quoted is 90° and then a
second angle of 180°. The additional 180° angle
is from the LAST tightened position. Refer to
Figure 101.
Figure 101.

+180°

+90°

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

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

72 - 4 9823/0100-1 72 - 4
 72 - Fasteners and Fixings
03 - Screws

03 - Screws

Contents Page No.

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

72 - 5 9823/0100-1 72 - 5
Notes:

72 - 6 9823/0100-1 72 - 6
 72 - Fasteners and Fixings
03 - Screws
00 - General

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

Table 38. Up to September 2017

Type 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 39. 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 9823/0100-1 72 - 7
 72 - Fasteners and Fixings
03 - Screws
00 - General

Technical Data

Table 40. 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 9823/0100-1 72 - 8
 72 - Fasteners and Fixings
06 - Bolts

06 - Bolts

Contents Page No.

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

72 - 9 9823/0100-1 72 - 9
Notes:

72 - 10 9823/0100-1 72 - 10
 72 - Fasteners and Fixings
06 - Bolts
00 - General

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

Table 41. Up to September 2017

Type 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 42. 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 102.

72 - 11 9823/0100-1 72 - 11
 72 - Fasteners and Fixings
06 - Bolts
00 - General

Technical Data Table 45. 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 43. 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 46. 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 44. 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 47. 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 9823/0100-1 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 48. 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 9823/0100-1 72 - 13
Notes:

72 - 14 9823/0100-1 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

9823/0100-1
2018-01-17
Acronyms Glossary

PTFE Polytetrafluoroethylene

9823/0100-1
2018-01-17
 75 - Consumable Products
00 - Consumable Products

00 - Consumable Products

Contents Page No.

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

75 - 1 9823/0100-1 75 - 1
Notes:

75 - 2 9823/0100-1 75 - 2

00 - General
Health and Safety ........................................... 75-3
Technical Data ................................................. 75-5
75 - 3 9823/0100-1
75 - Consumable Products
00 - Consumable Products
00 - General
Health and Safety
Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves
to prevent skin contact. Wash skin contaminated with
oil thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear personal protective equipment.
Hold a piece of cardboard close to suspected
leaks and then examine the cardboard for signs of
fluid. If fluid penetrates your skin, get medical help
immediately.
Hygiene
JCB lubricants are not a health risk when used
correctly for their intended purposes.
However, excessive or prolonged skin contact can
remove the natural fats from your skin, causing
dryness and irritation.
Low viscosity oils are more likely to do this, so take
special care when handling used oils, which might be
diluted with fuel contamination.
Whenever you are handling oil products you must
maintain good standards of care and personal and
plant hygiene. For details of these precautions we
advise you to read the relevant publications issued
by your local health authority, plus the following.
Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled
containers.
Waste Disposal
CAUTION It is illegal to pollute drains, sewers
or the ground. Clean up all spilt fluids and/or
lubricants.
Used fluids and/or lubricants, filters and
contaminated materials must be disposed of in
accordance with local regulations. Use authorised
waste disposal sites.
All waste products must be disposed of in
accordance with all the relevant regulations.
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 9823/0100-1 75 - 4
 75 - Consumable Products
00 - Consumable Products
00 - General

Technical Data

Table 49. Lubricants and Capacities

Item Capacity Fluid/ Lubricant International Spec-
ification
Litres UK Gals
Axle - SD55/NT 8.0 1.76 Q8 EL3857/ Mobil API GL4,
Housing Fluid 424 M2C41B/134D,
F M1135/M1141/
M1143
Hubs (x2) SD55 2.0 0.44 Q8 EL3857 SAE90 / API GL4,
(Brakes) Mobil Fluid 424 M2C41B/134D,
MF M1135/M1141/
M1143
SD40 (No Brakes) 1.0 0.22 Q8 T35 SAE90 / API-GL5, MIL-
SD55 (No Brakes) 1.8 0.40 Mobilube HD90 L2105C
SD70 (No Brakes) 2.0 0.44
Grease points - - Mobil HP222 Mobil HP222
Brake system - - Mobil DTE 11M
(1)
ISO VG 15
(1) Caution: Do not use ordinary brake fluid (J1703).

Important: Q8 EL3857/ Mobil 424 should always

be used for axles installed with brakes. For axles
without brakes Q8 T35 SAE90/ Mobilube HD90 or
Q8 EL3857/ Mobil Fluid 424 can be used.

Important: For axles with limited slip differential, Q8

EL3857/ Mobil Fluid 424 must be used.

75 - 5 9823/0100-1 75 - 5
 75 - Consumable Products
09 - Fluids

09 - Fluids

Contents Page No.

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

75 - 6 9823/0100-1 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 9823/0100-1 75 - 7
 75 - Consumable Products
10 - Locking Fluids

10 - Locking Fluids

Contents Page No.

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

75 - 8 9823/0100-1 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 9823/0100-1 75 - 9
 75 - Consumable Products
10 - Locking Fluids
00 - General

Technical Data

Table 50. 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 9823/0100-1 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 9823/0100-1 75 - 11
 75 - Consumable Products
14 - Solvents and Primers

14 - Solvents and Primers

Contents Page No.

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

75 - 12 9823/0100-1 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 9823/0100-1 75 - 13
 75 - Consumable Products
14 - Solvents and Primers
00 - General

Technical Data

Table 51. 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 9823/0100-1 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 9823/0100-1 75 - 15
 75 - Consumable Products
15 - Adhesive

15 - Adhesive

Contents Page No.

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

75 - 16 9823/0100-1 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 9823/0100-1 75 - 17
 75 - Consumable Products
15 - Adhesive
00 - General

Technical Data

Table 52. 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 9823/0100-1 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 9823/0100-1 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 9823/0100-1 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 9823/0100-1 75 - 21
 75 - Consumable Products
16 - Sealant

16 - Sealant

Contents Page No.

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

75 - 22 9823/0100-1 75 - 22

00 - General
Introduction .................................................... 75-23
Technical Data ............................................... 75-24
75 - 23 9823/0100-1
75 - Consumable Products
16 - Sealant
00 - General
Introduction
All sealants should be used at all times in line
with the manufacturer’s recommendations. Sealants
are used mainly for the sealing of screwed joints,
sealing flanges and flat surfaces and where gap
filling properties are required.
Types of Sealant
Various types of sealant are specified in JCB
Standards:
1. Those for the sealing of screwed joints.
2. Sealants for joining flanges and flat surfaces.
(Flange size and likelihood of dismantling
require consideration when selecting this type of
sealant).
3. Sealants for use where gap filling properties are
required. (The gap dimensions, joint movement
if any, type of materials being joined and
aesthetic appearance require consideration
when selecting this type of sealant).
Approved Sealants
The table shown in Technical Data are the approved
sealants available to use on JCB machines. The
table also provides basic details to help with selection
of sealants. More up to date information can be found
on the manufacturer’s website.
75 - 23
 75 - Consumable Products
16 - Sealant
00 - General

Technical Data

Table 53. 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 9823/0100-1 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 9823/0100-1 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 9823/0100-1 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 9823/0100-1 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 9823/0100-1 75 - 28
 78 - After Sales
Contents Page No.

78-24 Maintenance Schedules

78-24-00 General ............................................................................................................................. 78-3
78-24-03 Maintenance Intervals ...................................................................................................... 78-5
78-24-06 Pre-start Cold Checks, Service Points and Fluid Levels .................................................. 78-6
78-24-09 Functional Tests and Final Inspection .............................................................................. 78-7
78-81 Clothing and Personal Protective Equipment (PPE)
78-81-00 General ............................................................................................................................. 78-9
78-93 Special Tools
78-93-00 General ........................................................................................................................... 78-11
78-93-03 Parts List ........................................................................................................................ 78-12
78-96 Units of Measurement
78-96-00 General ........................................................................................................................... 78-27

9823/0100-1
2018-05-18
Notes:

9823/0100-1
2018-05-18
 78 - After Sales
24 - Maintenance Schedules

24 - Maintenance Schedules

Contents 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 9823/0100-1 78 - 1
Notes:

78 - 2 9823/0100-1 78 - 2

00 - General
Introduction ...................................................... 78-3
Operation ......................................................... 78-4
78 - 3 9823/0100-1
78 - After Sales
24 - Maintenance Schedules
00 - General
Introduction
WARNING Maintenance must be done only by
suitably qualified and competent persons.
Before doing any maintenance make sure the
machine is safe, it must be correctly parked on
solid, level ground.
To prevent anyone starting the engine, remove
the ignition key. Disconnect the battery (by means
of the battery isolator if installed) when you are
not using electrical power. If you do not take these
precautions you could be killed or injured.
A badly maintained machine is a danger to
the operator and the people working around the
operator. Make sure that the regular maintenance
and lubrication tasks listed in the service schedules
are done to keep the machine in a safe and efficient
working condition.
To ensure the correct functioning of the engine
and emissions control system all operation and
maintenance must be conducted in accordance
with the instructions in this manual. Incorrect
operation, maintenance or repair of the engine
and emissions control system may lead to reduced
product life, loss of performance or malfunctions.
It is the machine owner's responsibility to ensure
maintenance is conducted properly in accordance
with the requirements in this manual.
Apart from the daily tasks, the schedules are based
on the machine running hours. Keep a regular
check on the hourmeter readings to correctly gauge
the service intervals. When there is no hourmeter
installed, use the calendar equivalents to determine
the service intervals.
Do not use a machine which is due for a service.
Make sure any defects found during the regular
maintenance checks are corrected immediately.
More frequent checks of engine components than
the engine manufacturer recommends do not
invalidate emissions warranty.
78 - 3
 78 - After Sales
24 - Maintenance Schedules
00 - General

Operation

The schedules show the service tasks which must be

done and their intervals.

The services must be done at either the hourly

interval or the calendar equivalent, whichever occurs
first.

The intervals given in the schedules must not

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

Table 54.
Service task can be completed by a
competent operator. Details of how to
complete the service task are given in
the Operator's Manual.
We recommend that a Service Engi-
neer completes the service task. De-
tails of how to complete the service
task are given in the Service Manual.

78 - 4 9823/0100-1 78 - 4
 78 - After Sales
24 - Maintenance Schedules
03 - Maintenance Intervals

03 - Maintenance Intervals

Introduction

Table 55.
Interval (h) Calendar Equivalent
10 Daily
50 Weekly
500 Six months
1000 Yearly
2000 Two years

78 - 5 9823/0100-1 78 - 5
 78 - After Sales
24 - Maintenance Schedules
06 - Pre-start Cold Checks, Service Points and Fluid Levels

06 - Pre-start Cold Checks, Service

Points and Fluid Levels

Introduction

Table 56. AXLES and STEERING

Component Operation 10 50 100
(1)
500 1,000 2,000
Axle oil lev- Check
el (include
Hubs when
applicable)
(3)

Axle oil (in- Change

clude Hubs
when ap-
plicable)
Drive shafts Security/
Grease
Steer axle Check
movement/
Shimming
(4)

Axle pivot Grease

and steering
joints
(2)

Cylinders Check
- Chrome
condition
(1) Important: First 100 hours Service only, to be completed by your Distributor.
(2) Important: Mobil HP222 Grease must be used at 500 hours intervals. If an alternative grease is used, the
service interval must be reduced to 50 hours/ weekly.
(3) Important: Check for leaks every 50 hours, check level if leaking.
(4) Important: Jobs which should be done by a specialist.

Check generally for leaks on all systems, for

example, hydraulic, axles etc. If a leak is evident find
the source and repair as required. Make sure that
the system is topped up with the recommended fluid
after repair.

Faults in the braking system must be rectified

immediately. Make sure that the correct fluid is used
and all equipment is clean and free from water
contamination. Under no circumstances should
water be allowed to enter the braking system.

78 - 6 9823/0100-1 78 - 6
 78 - After Sales
24 - Maintenance Schedules
09 - Functional Tests and Final Inspection

09 - Functional Tests and Final

Inspection

Introduction

Table 57. Functional Test and Final Inspection

Component Operation 10 50 100 500 1,000 2,000
(1)

AXLES and STEERING

Steering modes - Operation Check
Wheel nut torque Check
Steer phasing
(2)
Check
Steer cylinders - Balance
(2)
Check
Steer circuit pressure
(2)
Check
(1) Important: First 100 Hours service only, to be completed by your Distributor.
(2) Important: Jobs which should be done only by a Specialist person.

Important: Check generally for leaks on all systems,

for example, hydraulics, axles etc. If a leak is evident
find the source and repair as required. Make sure that
the system is topped up with the recommended fluid
after repair.

Important: Faults in the braking system must be

rectified immediately. Make sure the correct fluid
is used and all equipment is clean and free
from water contamination. Under no circumstances
should water be allowed to enter the braking system.

78 - 7 9823/0100-1 78 - 7
 78 - After Sales
81 - Clothing and Personal Protective Equipment (PPE)

81 - Clothing and Personal Protective Equipment (PPE)

Contents Page No.

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

78 - 8 9823/0100-1 78 - 8
 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 9823/0100-1 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

78 - 10 9823/0100-1 78 - 10
 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.

78 - 11 9823/0100-1 78 - 11
 78 - After Sales
93 - Special Tools
03 - Parts List

03 - Parts List Introduction

Introduction .................................................... 78-12
Component Identification ............................... 78-14

27 - Driveline

Tool Category Part No. Description Qty. Comments

General Tool 892/00179 Bearing Press 1
Special Tool 892/00224 Impulse Extractor 1
Special Tool 892/00225 Bearing Removal Tool 1
General Tool 892/00333 Heavy Duty Socket 1
19mm A/F x 3/4 in
Drive
Special Tool 892/00812 Drive Coupling Spanner 1
General Tool 892/00822 Splined Bolt Socket 1
Special Tool 892/00918 Setting Tool Kit 1
Special Tool 892/01092 Wheel Hub Service Kit 1
Special Tool 921/52600 Spacer Kit 1
Special Tool 921/53300 Spacer Kit 1
Special Tool 921/M0229 Shim Kit 1
Special Tool 992/07608 Adaptor 1
Special Tool 992/07609 Bearing Adaptor 1
Special Tool 993/59500 Adaptor 1
General Tool 993/70111 Torque Wrench 1
(10-100Nm)
Special Tool 997/11000 Support Bracket 1
Special Tool 998/M1374 Reaction Plate M14 4
Studs
Special Tool 998/M1375 Reaction Plate 1

30 - Hydraulic System

Tool Category Part No. Description Qty. Comments

Special Tool 892/00167 Ram Protection Sleeve 1
(90mm rod diameter)
Special Tool 892/00285 Temperature Probe 1
Special Tool 892/00334 Ram Seal Installation 1
Tool
Special Tool 892/01016 Ram Protection Sleeve 1
(25mm rod diameter)
Special Tool 892/01017 Ram Protection Sleeve 1
(30mm rod diameter)
Special Tool 892/01018 Ram Protection Sleeve 1
(40mm rod diameter)
Special Tool 892/01019 Ram Protection Sleeve 1
(50mm rod diameter)
Special Tool 892/01020 Ram Protection Sleeve 1
- Slew (50mm rod
diameter)
Special Tool 892/01021 Ram Protection Sleeve 1
(60mm rod diameter)

78 - 12 9823/0100-1 78 - 12
 78 - After Sales
93 - Special Tools
03 - Parts List

Tool Category Part No. Description Qty. Comments

Special Tool 892/01022 Ram Protection Sleeve 1
- Slew (60mm rod
diameter)
Special Tool 892/01023 Ram Protection Sleeve 1
(65mm rod diameter)
Special Tool 892/01024 Ram Protection Sleeve 1
(70mm rod diameter)
Special Tool 892/01025 Ram Protection Sleeve 1
(75mm rod diameter)
Special Tool 892/01026 Ram Protection Sleeve 1
(80mm rod diameter)
Special Tool 892/01027 Ram Seal Assembly 1
Tool
Special Tool 993/99512 Ram Piston Nut 1
Removal Installation
Spanner 55mm A/F
Special Tool 993/99513 Ram Piston Nut 1
Removal Installation
Spanner 60mm A/F
Special Tool 993/99514 Ram Piston Nut 1
Removal Installation
Spanner 65mm A/F
Special Tool 993/99515 Ram Piston Nut 1
Removal Installation
Spanner 70mm A/F
Special Tool SSP0046 Ram Piston Nut 1
Removal Installation
Spanner 80mm A/F
Special Tool SSP0047 Ram Piston Nut 1
Removal Installation
Spanner 95mm A/F

78 - 13 9823/0100-1 78 - 13
 78 - After Sales
93 - Special Tools
03 - Parts List

Component Identification

Special Tool - 892/00167 - Ram Protection Sleeve (90mm rod diameter)

General Tool - 892/00179 - Bearing Press

Special Tool - 892/00224 - Impulse Extractor

78 - 14 9823/0100-1 78 - 14
 78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool - 892/00225 - Bearing Removal Tool

Special Tool - 892/00285 - Temperature Probe

General Tool - 892/00333 - Heavy Duty Socket 19mm A/F x 3/4 in Drive

Special Tool - 892/00334 - Ram Seal Installation Tool

78 - 15 9823/0100-1 78 - 15
 78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool - 892/00812 - Drive Coupling Spanner

PTO coupling spanner for yoke type couplings.

General Tool - 892/00822 - Splined Bolt Socket

Special Tool - 892/00918 - Setting Tool Kit

Item Part No. Description Qty.
1a 892/01164 Adaptor (PS760 - 1
1 1a 2004)
1b 892/01165 Sleeve (PS760 - 1
2004)
1c 892/01163 Support Bracket 1
(PS760 - 2004)
1b 1d 998/11350 Adaptor 1
1e 998/11351 Sleeve (40 series 1
drivehead - front
1c axles)
1e 998/11352 Sleeve (40 series 1
drivehead - rear
axles)

1d 1e

Special Tool - 892/01016 - Ram Protection Sleeve (25mm rod diameter)

78 - 16 9823/0100-1 78 - 16
 78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool - 892/01017 - Ram Protection Sleeve (30mm rod diameter)

Special Tool - 892/01018 - Ram Protection Sleeve (40mm rod diameter)

Special Tool - 892/01019 - Ram Protection Sleeve (50mm rod diameter)

Special Tool - 892/01020 - Ram Protection Sleeve - Slew (50mm rod diameter)

78 - 17 9823/0100-1 78 - 17
 78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool - 892/01021 - Ram Protection Sleeve (60mm rod diameter)

Special Tool - 892/01022 - Ram Protection Sleeve - Slew (60mm rod diameter)

Special Tool - 892/01023 - Ram Protection Sleeve (65mm rod diameter)

Special Tool - 892/01024 - Ram Protection Sleeve (70mm rod diameter)

78 - 18 9823/0100-1 78 - 18
 78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool - 892/01025 - Ram Protection Sleeve (75mm rod diameter)

Special Tool - 892/01026 - Ram Protection Sleeve (80mm rod diameter)

Special Tool - 892/01027 - Ram Seal Assembly Tool

7m m
11o

20m m 10m m

5m m

mm
R3

110m m
175m m

3o
R
1.
4m
m

78 - 19 9823/0100-1 78 - 19
 78 - After Sales
93 - Special Tools
03 - Parts List

Special Tool - 892/01092 - Wheel Hub Service Kit

A 5

1
6
8, 9
7

2 10
3
4

B
13,23 15
19,20

14

C 16

18
17
8
21
Item Part No. Description Qty.
A Bearing Puller 1
B Bearing Press 1
C Seal Dolly - 1
comprises:
1 998/M5626 Puller Beam 1
2 998/1067 Clamp Plates 1
3 1315/3731Z Bolt M16 x 220mm 2
4 1370/0601Z Nut M16 2
5 998/10614 Reaction Tube 1
6 998/10624 Modified Wheel 2
Stud
7 1370/0701Z Puller Leg 2
8 1370/0701 Nut M20 4
9 1420/0012Z Washer M20 4
10 998/10610 Rod 2
11 1370/0401Z Nut M12 2
12 1420/0009Z Washer M12 2
13 998/10608 Bearing Centre 1
Puller

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

Item Part No. Description Qty.

14 1315/3414Z Bolt M10 1
15 1370/0301Z Nut M10 1
16 Reaction Tube 1
(same part as item
5)
17 998/10616 Handle Nut 1
18 1315/3833Z Bolt M20 2
19 445/12303 Washer 2
20 917/02800 Bearing 1
21 892/00891 Seal Dolly 1
22 998/10609 Bearing Installation 1
Tube
23 998/M5629 Bearing Centre 1
Puller (87 Series)

Special Tool - 921/52600 - Spacer Kit

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

Item Part No. Description Qty.

1 921/52628 Spacer 12.60mm 1
thick
2 921/52629 Spacer 12.65mm 1
thick
3 921/52630 Spacer 12.7mm 1
thick
4 921/52601 Spacer 12.75mm 1
thick
5 921/52602 Spacer 12.80mm 1
thick
6 921/52603 Spacer 12.85mm 1
thick
7 921/52604 Spacer 12.9mm 1
thick
8 921/52605 Spacer 12.95mm 1
thick
9 921/52606 Spacer 13.00mm 1
thick
10 921/52607 Spacer 13.05mm 1
thick
11 921/52608 Spacer 13.10mm 1
thick
12 921/52609 Spacer 13.15mm 1
thick
13 921/52610 Spacer 13.20mm 1
thick
14 921/52611 Spacer 13.25mm 1
thick
15 921/52612 Spacer 13.30mm 1
thick
16 921/52613 Spacer 13.35mm 1
thick

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

Item Part No. Description Qty.

17 921/52614 Spacer 13.40mm 1
thick
18 921/52615 Spacer 13.45mm 1
thick
19 921/52616 Spacer 13.50mm 1
thick
20 921/52617 Spacer 13.55mm 1
thick
21 921/52618 Spacer 13.60mm 1
thick
22 921/52619 Spacer 13.65mm 1
thick
23 921/52620 Spacer 13.70mm 1
thick
24 921/52621 Spacer 13.75mm 1
thick
25 921/52622 Spacer 13.80mm 1
thick
26 921/52623 Spacer 13.85mm 1
thick
27 921/52624 Spacer 13.90mm 1
thick
28 921/52625 Spacer 13.95mm 1
thick
29 921/52626 Spacer 14.00mm 1
thick
30 921/52627 Spacer 14.20mm 1
thick

Special Tool - 921/53300 - Spacer Kit

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

Item Part No. Description Qty.

1 921/53322 Spacer 13.55mm 1
thick
2 921/53323 Spacer 13.575mm 1
thick
3 921/53324 Spacer 13.6mm 1
thick
4 921/53325 Spacer 13.625mm 1
thick
5 921/53301 Spacer 13.65mm 1
thick
6 921/53302 Spacer 13.675mm 1
thick
7 921/53303 Spacer 13.7mm 1
thick
8 921/53304 Spacer 13.725mm 1
thick
9 921/53305 Spacer 13.75mm 1
thick
10 921/53306 Spacer 13.775mm 1
thick

78 - 22 9823/0100-1 78 - 22
 78 - After Sales
93 - Special Tools
03 - Parts List

Item Part No. Description Qty.

11 921/53307 Spacer 13.80mm 1
thick
12 921/53308 Spacer 13.825mm 1
thick
13 921/53309 Spacer 13.850mm 1
thick
14 921/53310 Spacer 13.875mm 1
thick
15 921/53311 Spacer 13.90mm 1
thick
16 921/53312 Spacer 13.925mm 1
thick
17 921/53313 Spacer 13.950mm 1
thick
18 921/53314 Spacer 13.975mm 1
thick
19 921/53315 Spacer 14.00mm 1
thick
20 921/53316 Spacer 14.025mm 1
thick
21 921/53317 Spacer 14.050mm 1
thick
22 921/53318 Spacer 14.075mm 1
thick
23 921/53319 Spacer 14.10mm 1
thick
24 921/53320 Spacer 14.125mm 1
thick
25 921/53321 Spacer 14.150mm 1
thick

Special Tool - 921/M0229 - Shim Kit

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

Item Part No. Description Qty.

1 921/M0230 Shim 0.15mm thick 1
2 921/M0231 Shim 0.2mm thick 1
3 921/M0232 Shim 0.25mm thick 1
4 921/M0233 Shim 0.5mm thick 1
5 921/M0234 Shim 1.0mm thick 1

Special Tool - 992/07608 - Adaptor

Special Tool - 992/07609 - Bearing Adaptor

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

Special Tool - 993/59500 - Adaptor

General Tool - 993/70111 - Torque Wrench (10-100Nm)

Special Tool - 993/99512 - Ram Piston Nut Removal Installation Spanner 55mm A/F

Special Tool - 993/99513 - Ram Piston Nut Removal Installation Spanner 60mm A/F

Special Tool - 993/99514 - Ram Piston Nut Removal Installation Spanner 65mm A/F

Special Tool - 993/99515 - Ram Piston Nut Removal Installation Spanner 70mm A/F

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

Special Tool - 997/11000 - Support Bracket

Special Tool - 998/M1374 - Reaction Plate M14 Studs

Special Tool - 998/M1375 - Reaction Plate

Special Tool - SSP0046 - Ram Piston Nut Removal Installation Spanner 80mm A/F

Special Tool - SSP0047 - Ram Piston Nut Removal Installation Spanner 95mm A/F

78 - 25 9823/0100-1 78 - 25
 78 - After Sales
96 - Units of Measurement

96 - Units of Measurement

Contents Page No.

78-96-00 General ........................................................................................................................... 78-27

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

00 - General Table 63. Flow

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 64. Area
Standard Units Measurement Convert to Multiply by
(unit)
Table 58. 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 65. Torque
Table 59. 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 66. Pressure
Yard (yd) 1.094 Measurement Convert to Multiply by
Kilometre (km) Mile (mile) 0.621 (unit)
Bar Pound force/ 14.5
Table 60. Mass inch² (psi)
Measurement Convert to Multiply by Table 67. 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 61. Speed lon
Measurement Convert to Multiply by Table 68. 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 62. Volume Table 69. 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 70. 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)

78 - 27 9823/0100-1 78 - 27
 78 - After Sales
96 - Units of Measurement
00 - General

Table 71. Current

Measurement (unit)
Ampere (A)

Table 72. Voltage

Measurement (unit)
Volt (V)

Table 73. Noise Levels

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

78 - 28 9823/0100-1 78 - 28