service repair manual

1. Copyright © 2004 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.
World Class
Customer Support
9813-1450-2
Publication No.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Service Manual
Side Engine Loadalls
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
Section M - Electronic Data Systems

2. Section F2 - Transmission
Wheels and Tyres
Removal and Replacement
F2-4 F2-4F-02-03 Issue 01
Removal and Replacement
Front Wheels
Important: The wheel and tyre assembly is heavy. Get the
aid of one more person to remove and replace a wheel.
!MWARNING
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 engine being
started while you are beneath the machine.
GEN-1-1
Removal (one wheel)
1 Park the machine and make it safe. Fit the boom
safety strut. Obey the care and safety procedures.
K Related Topics ( T F2-2)
2 Make sure that the engine cannot be started.
3 Put chocks A under the rear wheels.
4 Loosen the five wheel nuts B by half a turn.
5 Put a jack C under the axle arm. Use the correct jack.
6 Use the jack to lift the machine until the front wheel D
is off the ground.
7 Put chocks E under the axle arm.
8 Hold the wheel D and remove the wheel nuts B.
9 Remove the wheel.
Replacement
Note: Make sure that the mating surfaces of the wheel and
axle hub are clean.
!MWARNING
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.
2-3-2-8
Replacement is the opposite of the removal procedure.
During the replacement procedure do this work also:
– Torque tighten the nuts B.
When the replacement procedure is complete:
– Check the wheel nut torques are correct after every
two hours of machine operation until they stay
correct.
Table 3. Torque Settings
C045590
Fig 1.
Item Nm kgf m lbf ft
B(1)
(1) 550-80 machines
650 66 480
B(2)
(2) Other machines
680 69 500

3. Section F2 - Transmission
Wheels and Tyres
Removal and Replacement
F2-5 F2-5F-02-03 Issue 01
Rear Wheels
Important: The wheel and tyre assembly is heavy. Get the
aid of one more person to remove and replace a wheel.
!MWARNING
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 engine being
started while you are beneath the machine.
GEN-1-1
Removal (one wheel)
1 Park the machine and make it safe. Fit the boom
safety strut. Obey the care and safety procedures.
K Related Topics ( T F2-2)
2 Make sure that the engine cannot be started.
3 Put chocks A under the front wheels.
4 Loosen the five wheel nuts B by half of one turn.
5 Put a jack C under the centre of the rear axle. Use the
correct jack.
6 Use the jack to lift the machine until both rear wheels
are off the ground.
7 Put chocks E under each end of the rear axle.
8 Hold the wheel D and remove the wheel nuts.
9 Remove the wheel.
Replacement
Note: Make sure that the mating surfaces of the wheel and
axle hub are clean.
!MWARNING
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.
2-3-2-8
Replacement is the opposite of the removal procedure.
During the replacement procedure do this work also:
– Torque tighten the nuts B.
When the replacement procedure is complete:
– Check the wheel nut torques are correct after every
two hours of machine operation until they stay
correct.
Table 4. Torque Settings
C045590
Fig 2.
Item Nm kgf m lbf ft
B(1)
(1) 550-80 machines
650 66 480
B(2)
(2) Other machines
680 69 500

4. Section F2 - Transmission
Wheels and Tyres
Removal and Replacement
F2-6 F2-6F-02-03 Issue 01
Wheel Studs
Removal and Replacement
The procedures that follow are for one wheel stud. The
procedures are the same for all the wheel studs.
!MWARNING
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.
2-3-2-8
Removal
1 Remove the wheel from the hub. K Front
Wheels ( T F2-4) K Rear Wheels ( T F2-5)
2 Push out the wheel stud 3-A.
Important: Remove all the wheel studs 3-A and discard
them.
C045650
Fig 3.
Replacement
Important: Examine the wheel stud holes 4-B in the hub
carrier 4-C. If the holes are defective do not use the hub
carrier. Replace the hub carrier with a new one. Refer to
Applications for related axle topics. K Related
Topics ( T F2-2)
1 Put the stud 4-A into the hub carrier hole.
2 Use a nut and washer to pull in the stud 4-A into the
hub carrier 4-C.
3 Examine the stud and make sure it is correctly
installed. If the stud is loose replace the hub carrier 4-
C. Refer to Applications for related axle topics.
K Related Topics ( T F2-2)
C045650-C1
Fig 4.

5. Section F3 - Transmission
Front Axles
Introduction
F3-1 F3-1F-03-10 Issue 01
Front Axles
Introduction
Table 1. Procedure and Specification Variants
This topic contains information about a machine DEVICE. Make sure you are referring to the correct device. Refer to the
applications table.
Descriptions and procedures relate to the device and not related systems. For information about the systems refer to the
relevant topics.
This topic is intended to help you understand what the device does and how it works. Where applicable it also includes
procedures such as removal and replacement and dismantle and assemble.
K Related Topics ( T F3-2)
K Specifications ( T F3-3)
K SD80 3 Piece Steer Drive Axle ( T F3-3)
K Component Identification ( T F3-4)
K Renewing the Pinion Oil Seal ( T F3-6)
K Removal and Replacement - SD80 Fixed Axle ( T F3-7)
K Removal and Replacement - SD80 Pivot Sway Axle ( T F3-9)(1)
(1) Procedure variant. Make sure you refer to the correct procedure.
K Removal and Replacement - SD80 Trunnion Sway Axle ( T F3-12)(1)
K Dismantle, Inspection and Assembly ( T F3-15)
Procedures, Specifications(1)
(1) The table lists procedure and specification variants and the applicable machine models. Use the table to make sure
you refer to the correct information.
Machine Model Application
540-170
5AF
550-140
5AG
540-140
5AL
550-170
5AM
535-125
HiViz
5AN
535-140
HiViz
5AP
540-200
K Removal and Replacement - SD80 Pivot
Sway Axle ( T F3-9)
K Removal and Replacement - SD80
Trunnion Sway Axle ( T F3-12)

6. Section F3 - Transmission
Front Axles
Related Topics
F3-2 F3-2F-03-10 Issue 01
Related Topics
Table 2. Related Topics in This Publication
Table 3. Related Topics in Publication 9803/8610, Transmissions
The table lists other topics in the manual that contain information related to this topic. Refer to the applicable
topics to complete your procedures. Where applicable the text in this section contains cross references to this
page to help you find the correct information. Some machines have different systems and devices. Make sure
you refer to the correct topic, refer to Section 1 - Applications.
Sections Topic Titles Sub Titles
1 Applications ALL
2 ALL (Care and Safety)(1)
(1) You must obey all of the relevant care and safety procedures.
ALL
3 Maintenance ALL
F Applications ALL
F Rear Axles Renewing the Pinion Oil Seal
G Service Brakes SYSTEM Bleeding
H Steering SYSTEM Bleeding
H Steering SYSTEM Re-Phasing
The table lists topics in another manual that contain information related to this topic. Refer to the applicable
topics to complete your procedures. Where applicable the text in this section contains cross references to this
page to help you find the correct information. Some machines have different systems and devices. Make sure
you refer to the correct topics, refer to Designations. K Specifications ( T F3-3)
Sections Section Titles Topic Titles
A Axle Hubs 80 Series Hub
B Axle Hub Swivels and Driveshafts 55 Series Hub Swivel and Driveshaft
C Axle Integral Brakes 70 Series Integral Brakes (3 Piece Axles)
D Axle Drive Heads 80 Series Drive Heads (3 Piece Axles)

7. Section F3 - Transmission
Front Axles
Specifications
F3-3 F3-3F-03-10 Issue 01
Specifications
The axle serial number is stamped on the unit identification
plate A as shown.
Fig 1.
Note: It is essential that the correct ratio axle in
relationship to the gearbox ratio is fitted to the machine. Do
not fit a new axle with a different ratio to the axle being
replaced.
Table 4. SD80 3 Piece Steer Drive Axle
Designations
Hubs 80 Series
Hub swivels and drive shafts 55 Series
Drive head 80 Series 3 piece
Brakes 70 Series Integral Brakes (3 Piece Axles)
Type JCB spiral bevel input with epicyclic hub reduction
Brakes Oil immersed multi-plate discs, located in centre section
Steering Steer rams or power track rod

8. Section F3 - Transmission
Front Axles
Component Identification
F3-4 F3-4F-03-10 Issue 01
Component Identification
The illustration shows a typical 3 piece steer drive front
axle. K Fig 2. ( T F3-5)
The front axle consists of a centre casing (drivehead) and
two axle arms and swivel wheel hubs.
The drivehead houses the differential gearing and two oil-
immersed disc brake units.
The axle arms house the driveshafts. Specially shaped
spider gears in the differential provide `torque
proportioning'. This means that drive power will be kept on
one wheel if the other is slipping.
The wheel hubs are connected to the halfshafts through
universal joints which drive sun-and-planet gears inside
the hubs.
A Yoke connection to propshaft
B Pinion
C Crownwheel
D Differential unit
Note: Items A, B, C and D form the `drive head' part of
the axle.
E Drive shaft
F Universal coupling
G Reduction gear hub
H Steer swivel trunnion bearings
L Inboard oil-immersed multi-plate disc brakes
M Brake actuating piston
N Hydraulic brake lines

9. Section F3 - Transmission
Front Axles
Component Identification
F3-5 F3-5F-03-10 Issue 01
Fig2.TypicalSteerDriveFrontAxle

10. Section F3 - Transmission
Front Axles
Renewing the Pinion Oil Seal
F3-6 F3-6F-03-10 Issue 01
Renewing the Pinion Oil Seal
The front axle pinion oil seal is renewed using the same
procedure as described for the rear axles. K Related
Topics ( T F3-2)

11. Section F3 - Transmission
Front Axles
Removal and Replacement - SD80 Fixed Axle
F3-7 F3-7F-03-10 Issue 01
Removal and Replacement - SD80 Fixed Axle
!MWARNING
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 engine being
started while you are beneath the machine.
GEN-1-1
If the boom is raised, make sure the maintenance strut is
fitted. Obey the care and safety procedures. K Related
Topics ( T F3-2)
K Fig 3. ( T F3-8)
Note: Some machines may have shims installed on the
axle mounts. Make sure to note the position and quantity
of these shims before removal. Make sure to retain the
shims and replace them in the correct position when
replacing the axle. There may be an uneven number of
shims between each side of the axle as the shims are used
to adjust the machine height and make it level.
Removal
1 Disconnect the propshaft coupling from the axle by
unscrewing bolts A.
!MWARNING
When the driveshaft is disconnected the park brake
will no longer function. The machine must be securely
blocked to prevent any machine movement before
disconnecting the driveshaft.
TRANS-1-3
2 Disconnect and plug the hydraulic hoses to the steer
rams/ power track rod.
3 Slacken off the roadwheel retaining nuts C then raise
and support the front end of the machine on axle
stands or blocks positioned under the chassis.
Remove the front roadwheels.
4 Remove the front mudguards. Undo the bracket
retaining nuts E at the steering trunnions.
5 Disconnect the brake hose at the axle. Blank off the
exposed connections.
6 Uncouple the steer proximity switch electrical
connector (if fitted).
7 Support the axle on a trolley jack.
8 Unscrew axle mounting nuts D and remove the bolts
and washers.
9 Lower the axle down from the machine.
10 Remove the axle from the machine.
Replacement
Replacement is the opposite of the removal procedure.
During replacement do this work also:
– Bleed the brake system, see Section G - Brakes.
K Related Topics ( T F3-2)
– Refit the road wheels and carry out the tightness
checks as detailed in Section 3 - Routine
Maintenance. K Related Topics ( T F3-2)
– Bleed the steering system, see Section H - Steering.
K Related Topics ( T F3-2)
– Re-phase the steering system, see Section H -
Steering. K Related Topics ( T F3-2)
– Grease the axle pivot trunnions.
Table 5. Torque Settings
Item Nm kgf m lbf ft
A 78 8 57
B 56 5.7 41
C 680 69 500
D (1)
(1) Dry nuts.
969 99 715
D (2)
(2) Nuts with special dry lubricating film.
600 60 440
E 98 10 72

12. Section F3 - Transmission
Front Axles
Removal and Replacement - SD80 Fixed Axle
F3-8 F3-8F-03-10 Issue 01
Fig 3. SD80 Fixed Axle
E
B
C
A
D

13. Section F3 - Transmission
Front Axles
Removal and Replacement - SD80 Pivot Sway Axle
F3-9 F3-9F-03-10 Issue 01
Removal and Replacement - SD80 Pivot Sway Axle
!MWARNING
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 engine being
started while you are beneath the machine.
GEN-1-1
If the boom is raised, make sure the maintenance strut is
fitted. Obey the care and safety procedures.K Related
Topics ( T F3-2)
Removal K Fig 5. ( T F3-11)
Removal
1 Disconnect the propshaft coupling from the axle by
unscrewing bolts A.
!MWARNING
When the driveshaft is disconnected the park brake
will no longer function. The machine must be securely
blocked to prevent any machine movement before
disconnecting the driveshaft.
TRANS-1-3
2 Disconnect and plug the hydraulic hoses to the steer
rams.
3 Slacken off the roadwheel retaining nuts C then raise
and support the front end of the machine on support
stands or blocks positioned under the chassis.
Remove the front roadwheels.
4 Remove the front mudguards. Undo the bracket
retaining nuts K at the steering trunnions.
5 Disconnect the brake hose at the axle. Blank off the
exposed connections.
6 Uncouple the steer proximity switch electrical
connector (if fitted).
7 Undo bolt D and remove pivot pin E.
8 Undo the sway ram pivot bracket mounting bolts H.
Lift away the bracket.
9 Support the axle on a trolley jack.
10 Undo bolt F and remove pivot pin G.
11 Remove the axle from the machine.
Replacement
Replacing is generally the reverse of the removal
sequence.
Replacement is the opposite of the removal procedure.
During replacement do this work also:
– Bleed the brake system, see Section G - Brakes.
K Related Topics ( T F3-2)
– Adjust the sway sight rod M so that the top of the rod
is in line with the top of the tube L when the machine
is horizontal. To adjust this slacken the locknuts N and
screw the sight rod up or down to the correct position.
Tighten the locknuts when the position is correct.
K Fig 4. ( T F3-10)
– Refit the road wheels and carry out the tightness
checks as detailed in Section 3 - Routine
Maintenance. K Related Topics ( T F3-2)
– Bleed the steering system, see Section H - Steering.
K Related Topics ( T F3-2)
– Re-phase the steering system, see Section H -
Steering. K Related Topics ( T F3-2)
– Grease the axle pivot trunnions.

14. Section F3 - Transmission
Front Axles
Removal and Replacement - SD80 Pivot Sway Axle
F3-10 F3-10F-03-10 Issue 01
C127500
Fig 4.
Table 6. Torque Settings
Item Nm kgf m lbf ft
A 78 8 57
B 56 5.7 41
C 680 69 500
H 969 99 715
K 98 10 72
L
M
N
N

15. Section F3 - Transmission
Front Axles
Removal and Replacement - SD80 Pivot Sway Axle
F3-11 F3-11F-03-10 Issue 01
Fig 5. SD80 Pivot Sway Axle
K
E
D
G
J
A
B
F
H
C

16. Section F3 - Transmission
Front Axles
Removal and Replacement - SD80 Trunnion Sway Axle
F3-12 F3-12F-03-10 Issue 01
Removal and Replacement - SD80 Trunnion Sway Axle
!MWARNING
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 engine being
started while you are beneath the machine.
GEN-1-1
If the boom is raised, make sure the maintenance strut is
fitted. Obey the care and safety procedures.K Related
Topics ( T F3-2)
Removal
1 Disconnect the propshaft coupling from the axle by
unscrewing bolts A.
!MWARNING
When the driveshaft is disconnected the park brake
will no longer function. The machine must be securely
blocked to prevent any machine movement before
disconnecting the driveshaft.
TRANS-1-3
2 Disconnect and plug the hydraulic hoses G to the
power track rod.
3 Slacken off the roadwheel retaining nuts then raise
and support the front end of the machine on support
stands or blocks positioned under the chassis.
Remove the front roadwheels.
4 Remove the front mudguards. Undo the bracket
retaining nuts F at the steering trunnions.
5 Disconnect the brake hose at the axle. Blank off the
exposed connections.
6 Uncouple the steer proximity switch K electrical
connector (if fitted).
7 Undo bolt D and remove pivot pin E.
8 Undo the sway ram pivot bracket mounting bolts H.
Lift away the bracket.
Fig 6.
9 Remove the access plate screws M and lift off the
plate N to get access to the front trunnion bolts.
10 Support the axle on a trolley jack.
11 Undo the six trunnion bolts B and nuts C. The top of
the bolts can be accessed from underneath the boom
as shown at L and below the access cover N.
12 Remove the axle from the machine. Be sure to
retrieve dowels J. If shims are fitted record their
positions. Use some wire to tie the trunnions to the
axle.
C053980
L
M
N

17. Section F3 - Transmission
Front Axles
Removal and Replacement - SD80 Trunnion Sway Axle
F3-13 F3-13F-03-10 Issue 01
Replacement
Replacement is the opposite of the removal procedure.
During replacement do this work also:
– Bleed the brake system, see Section G - Brakes.
K Related Topics ( T F3-2)
– Adjust the sway sight rod Y so that the top of the rod
is in line with the top of the tube X when the machine
is horizontal. To adjust this slacken the locknuts Z and
screw the sight rod up or down to the correct position.
Tighten the locknuts when the position is correct.
K Fig 7. ( T F3-13)
– Make sure you re-fit dowels J together with any shims
in their original positions.
– Make sure that the axle oscillates freely before final
tightening of the fixing bolts.
– Refit the road wheels and carry out the tightness
checks as detailed in Section 3 - Routine
Maintenance. K Related Topics ( T F3-2)
– Bleed the steering system, see Section H - Steering.
K Related Topics ( T F3-2)
– Re-phase the steering system, see Section H -
Steering. K Related Topics ( T F3-2)
– Grease the axle pivot trunnions.
C127500-C1
Fig 7.
Table 7. Torque Settings
Item Nm kgf m lbf ft
A 78 8 57
B 476 48 352
C 476 48 352
H 600 60 440
F 98 10 72
X
Y
Z
Z

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19. Section F3 - Transmission
Front Axles
Removal and Replacement - SD80 Trunnion Sway Axle
F3-14 F3-14F-03-10 Issue 01
Fig 8. SD80 Trunnion Axle
A312090-C2
F
D
B
G
G J
J
C
J
J
E
K
H
A
A

20. Section F3 - Transmission
Front Axles
Dismantle, Inspection and Assembly
F3-15 F3-15F-03-10 Issue 01
Dismantle, Inspection and Assembly
Make sure that you identify the axle sub-assemblies
designations correctly. K Specifications ( T F3-3)
The procedures for dismantling, inspection and assembly
are described in the Transmissions Service Manual.
K Related Topics ( T F3-2)