This service manual provides instructions for disassembling and assembling the master clutch on a loader. The summary describes:
1) Special tools are required to remove the clutch pack retainers and install a mandrel and locking plates during disassembly and assembly.
2) The cover is removed after installing jacking bolts and lifting eyes. Seals and gaskets are then removed from the cover and housing.
3) Locking plates are installed to secure the clutch assembly while removing bolts to lift out the drum, hub and pressure plate assembly.
This service manual provides instructions for servicing the valves on a loader engine. It includes identification of valve components, operation descriptions, specifications, and procedures for adjusting, removing, and installing valves. The manual outlines using special tools and setting the engine to specific positions to access different valves. It describes measuring and adjusting valve clearances when the engine is cold. Removal and installation procedures note inspecting components and installing new valve stem seals.
Jcb tm420 telescopic wheel loader service repair manual sn 2454001 and upfusjjfksekmme
This service manual section provides instructions for removing and installing the master clutch, as well as disassembling and assembling it. The master clutch controls gear changes in the transmission. Removal involves using jacking bolts and threaded lifting eyes to detach the clutch cover and drum. Assembly is the reverse of disassembly, replacing worn parts as needed and applying the specified torques. Special tools like retainers and a mandrel are required for some steps.
Jcb 509 42 telescopic handler service repair manual sn from 1402020 and upfdjjsekksemxs
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine components, including the engine, brake system, hydraulic system, electrical system, and driveline. The section summarized provides instructions for removing and installing the front and rear cases of the semi-automatic gearbox. The process requires using various special tools and consumables, checking clutch shaft end floats, and applying sealants and threadlocker to fasteners.
JCB JS160W WHEELED EXCAVATOR Service Repair Manual SN:2584081fujdfjjskekmwem
This service manual provides instructions for servicing wheeled excavators including models JS145W, JS160W, and JS20 MH. The manual contains sections covering the entire machine systems from the engine, brakes, and hydraulics to the operator station, electrical system, and attachments. Specific chapters provide procedures for maintenance, removal and installation of components, including the flywheel, oil pump, engine mounts, and oil cooler. Safety warnings are included throughout and technical illustrations supplement the text.
Jcb 4160 fastrac service repair manual sn from 2184000 onwardsfisjejfskemmd
This service manual provides instructions for servicing the timing gears of Fastrac agricultural tractors models 4160, 4190, and 4220. The summary includes:
- The timing gears are located inside a case at the flywheel end of the engine and ensure the camshaft operates the valves at the correct times relative to the crankshaft.
- There are three main types of timing gear assemblies: narrow without power take-off, broad with light duty power take-off, and broad with heavy duty power take-off.
- Timing gear removal and installation procedures are provided, including removing the front cover, idler gear, and timing gear case. Cleaning and applying sealant is
Still r70 20 fork truck service repair manualfhjsekfksemert
The document provides information about a workshop manual for STILL trucks models 7032-34/38-40/48-50. It includes sections on the chassis frame and counterweight, driver's cab, steer axle, power axle, and other components. The power axle section describes the power axle components, including the double reduction spur-type gearbox, D.C. electric motor, and long axle housing. It also provides maintenance instructions and torque specifications for power axle components.
Jcb 550 140 telescopic handler service repair manual sn from 2902000 onwardsfisjejfskemmd
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Jcb 533 105 telescopic handler service repair manual sn from 2460601 onwardsudfjdfjjskekemm
This service manual provides instructions for servicing the engine of a Loadall rough terrain variable reach truck. It contains sections covering the general operation of the engine as well as procedures for adjusting valve clearances, removing and installing valves, and identifying engine components. The summary focuses on servicing the engine valves, which includes adjusting clearances when the engine is cold using indicator pins to locate specific valves, and removing valves using a spring compressor after removing the collets, retainer, and spring.
This service manual provides instructions for servicing the valves on a loader engine. It includes identification of valve components, operation descriptions, specifications, and procedures for adjusting, removing, and installing valves. The manual outlines using special tools and setting the engine to specific positions to access different valves. It describes measuring and adjusting valve clearances when the engine is cold. Removal and installation procedures note inspecting components and installing new valve stem seals.
Jcb tm420 telescopic wheel loader service repair manual sn 2454001 and upfusjjfksekmme
This service manual section provides instructions for removing and installing the master clutch, as well as disassembling and assembling it. The master clutch controls gear changes in the transmission. Removal involves using jacking bolts and threaded lifting eyes to detach the clutch cover and drum. Assembly is the reverse of disassembly, replacing worn parts as needed and applying the specified torques. Special tools like retainers and a mandrel are required for some steps.
Jcb 509 42 telescopic handler service repair manual sn from 1402020 and upfdjjsekksemxs
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine components, including the engine, brake system, hydraulic system, electrical system, and driveline. The section summarized provides instructions for removing and installing the front and rear cases of the semi-automatic gearbox. The process requires using various special tools and consumables, checking clutch shaft end floats, and applying sealants and threadlocker to fasteners.
JCB JS160W WHEELED EXCAVATOR Service Repair Manual SN:2584081fujdfjjskekmwem
This service manual provides instructions for servicing wheeled excavators including models JS145W, JS160W, and JS20 MH. The manual contains sections covering the entire machine systems from the engine, brakes, and hydraulics to the operator station, electrical system, and attachments. Specific chapters provide procedures for maintenance, removal and installation of components, including the flywheel, oil pump, engine mounts, and oil cooler. Safety warnings are included throughout and technical illustrations supplement the text.
Jcb 4160 fastrac service repair manual sn from 2184000 onwardsfisjejfskemmd
This service manual provides instructions for servicing the timing gears of Fastrac agricultural tractors models 4160, 4190, and 4220. The summary includes:
- The timing gears are located inside a case at the flywheel end of the engine and ensure the camshaft operates the valves at the correct times relative to the crankshaft.
- There are three main types of timing gear assemblies: narrow without power take-off, broad with light duty power take-off, and broad with heavy duty power take-off.
- Timing gear removal and installation procedures are provided, including removing the front cover, idler gear, and timing gear case. Cleaning and applying sealant is
Still r70 20 fork truck service repair manualfhjsekfksemert
The document provides information about a workshop manual for STILL trucks models 7032-34/38-40/48-50. It includes sections on the chassis frame and counterweight, driver's cab, steer axle, power axle, and other components. The power axle section describes the power axle components, including the double reduction spur-type gearbox, D.C. electric motor, and long axle housing. It also provides maintenance instructions and torque specifications for power axle components.
Jcb 550 140 telescopic handler service repair manual sn from 2902000 onwardsfisjejfskemmd
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Jcb 533 105 telescopic handler service repair manual sn from 2460601 onwardsudfjdfjjskekemm
This service manual provides instructions for servicing the engine of a Loadall rough terrain variable reach truck. It contains sections covering the general operation of the engine as well as procedures for adjusting valve clearances, removing and installing valves, and identifying engine components. The summary focuses on servicing the engine valves, which includes adjusting clearances when the engine is cold using indicator pins to locate specific valves, and removing valves using a spring compressor after removing the collets, retainer, and spring.
Jcb 510 56 telescopic handler service repair manual sn from 1402020 and upfujdjjksekmem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual covers removing and installing the semi-automatic gearbox, which involves separating the front and rear cases. Key steps include removing clutch and shaft assemblies, checking clutch shaft end float tolerances, applying sealant and threadlocker, and using special tools for installation. The manual provides diagrams and specifies torque values for reassembly. Consumable products like sealant and threadlocker are listed.
Jcb 509 42 telescopic handler service repair manual sn from 1402020 and upfujjdfjjskekmm
This service manual provides instructions for servicing and repairing loadall trucks. It contains sections covering the machine systems and components. The section summarized provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing clutch shaft assemblies in the correct order, checking clutch shaft end floats, and applying threadlocker to bolts. Consumables like gasket material and threadlocker are listed.
Jcb 506 36 telescopic handler service repair manual sn from 1402020 and upufjjdjkskemem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual covers removing and installing the semi-automatic gearbox, which involves separating the front and rear cases. Key steps include removing clutch and shaft assemblies, checking clutch shaft end float tolerances, installing new seals, and applying threadlocker and liquid gasket. Special tools and consumables like an end float setting tool kit and JCB threadlocker are required.
Jcb 510 56 telescopic handler service repair manual sn from 1402020 and upfujjdfjjskekmm
This service manual provides instructions for servicing and repairing loadall trucks. It contains sections covering various vehicle systems and components. The section summarized provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing clutch shaft assemblies in the correct order, checking clutch shaft end floats, and applying threadlocker to fasteners. Consumables like gasket material and threadlocker are listed.
Jcb 507 42 telescopic handler service repair manual sn from 1402020 and upudfjjsjekkemm
This service manual provides instructions for servicing and repairing loadall trucks. It contains sections covering various vehicle systems. The section summarized details the process for removing and installing the front and rear cases of the semi-automatic gearbox. Key steps include separating the cases, removing internal components like clutches and shafts in the proper sequence, and reassembling the cases while ensuring correct clutch shaft end float is achieved. Special tools and consumables like threadlocker and gasket material are listed. End float measurements for the input and reverse shafts are to be taken and must fall within the specified range.
Jcb 512 56 telescopic handler service repair manual sn from 1402020 and upfujdjjksekmem
This service manual provides instructions for servicing and repairing loadall trucks. It contains sections covering various vehicle systems and components. The section summarized details the process for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing clutch shaft assemblies in the correct order, checking clutch shaft end floats, and applying threadlocker to attachment bolts. Special tools are required for tasks like measuring end float.
Jcb 512 56 telescopic handler service repair manual sn from 1402020 and upfujjdfjjskekmm
This service manual provides instructions for servicing and repairing loadall trucks. It contains sections covering the machine systems and components. The section summarized provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing clutch shaft assemblies in the correct order, checking clutch shaft end floats, and applying threadlocker to bolts. Consumables like gasket material and threadlocker are listed.
Jcb 509 42 telescopic handler service repair manual sn from 1402020 and upfujdjjksekmem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual covers removing and installing the semi-automatic gearbox, which involves separating the front and rear cases. Key steps include removing clutch and shaft assemblies, checking clutch shaft end float tolerances, applying sealant and threadlocker, and using special tools for installation. The manual provides diagrams and specifies torque values for reassembly. Consumable products like sealant and threadlocker are listed.
Jcb 512 56 telescopic handler service repair manual sn from 1402020 and upfjsjefskekfmme
This document provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing internal components like clutch assemblies in the proper sequence, and checking clutch shaft end float to ensure correct assembly. Consumables like threadlocker and gasket material should be used, and special tools are required to measure end float within the specified range.
Jcb 510 56 telescopic handler service repair manual sn from 1402020 and upufjdjjksekmem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine components, including the engine, brake system, hydraulic system, electrical system, and driveline. The section summarized provides instructions for removing and installing the front and rear cases of the semi-automatic gearbox. The process requires using various special tools and consumables, checking clutch shaft end floats, and applying sealants and threadlocker to fasteners.
Jcb 509 42 telescopic handler service repair manual sn from 1402020 and upfjjsekksemmer
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine components, including the engine, brake system, hydraulic system, electrical system, and driveline. The section on the semi-automatic gearbox provides instructions for removing and installing the gearbox, checking clutch shaft end floats, and installing new seals and gaskets. Special tools and consumable products like threadlocker and gasket material are listed.
Jcb 506 36 telescopic handler service repair manual sn from 1402020 and upfjjsjeskkekem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine, attachments, body, operator station, engine, brakes, steering, driveline, hydraulics, and electrical systems. When servicing the semi-automatic gearbox, procedures are provided for removing and installing internal components like clutches and cases, checking clutch end float, and installing seals and gaskets. Special tools and consumables are listed that may be required for the work.
Jcb 507 42 telescopic handler service repair manual sn from 1402020 and upregdfcgvdgvf
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine components, including the engine, brake system, hydraulic system, electrical system, and driveline. The section summarized provides instructions for removing and installing the front and rear cases of the semi-automatic gearbox. The process requires using various special tools and consumables, checking clutch shaft end floats, and applying sealants and threadlocker to fasteners.
Jcb 507 42 telescopic handler service repair manual sn from 1402020 and upfjjsjeusekkekm
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine components, including the engine, brake system, hydraulic system, electrical system, and driveline. The section summarized provides instructions for removing and installing the front and rear cases of the semi-automatic gearbox. The process requires using various special tools and consumables, checking clutch shaft end floats, and applying sealants and threadlocker to fasteners.
Jcb 509 42 telescopic handler service repair manual sn from 1402020 and upfjskekazswdmme
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine systems including the engine, brakes, steering, hydraulics, electrical system, and driveline. The driveline section provides step-by-step instructions for removing and installing the front and rear gearbox cases, checking clutch shaft end floats, and installing internal components like clutches, gears, and seals. Special tools and consumable products like sealants and gaskets are listed.
Jcb 507 42 telescopic handler service repair manual sn from 1402020 and upfhshefjjskefkem
This document provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing internal components like clutch assemblies in the proper sequence, and checking clutch shaft end float to ensure correct assembly. Consumables like threadlocker and gasket material should be used, and special tools are required to measure end float within the specified range.
Liebherr r906 1449 classic hydraulic excavator service repair manualfjjsiefksekm
The document is a service manual for Liebherr hydraulic excavators. It contains 18 sections that provide technical specifications, maintenance guidelines, and instructions for repairing and servicing various engine, hydraulic, electrical, and other components of the excavators. The manual is intended to assist customer support services and includes symbols to identify safety warnings and notes for procedures. It also provides guidelines for how the manual is structured and indexed.
Liebherr lh110 m 1227 (tier4f) hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that discusses the mounting of standard and fine thread clamping nuts, and mounting clamping nuts on suspensions with swing brakes. It includes figures showing the components of differential cylinders and shock absorbers, and tables listing recommended corrosion inhibitors and base coats and paints from Liebherr. The manual instructs the reader to click on a link to access the complete manual.
Liebherr lh110 c 1228 (tier4f) hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that discusses the mounting of standard and fine thread clamping nuts, and mounting clamping nuts on suspensions with swing brakes. It includes figures showing the components of differential cylinders and shock absorbers, and tables listing recommended corrosion inhibitors and base coats and paints from Liebherr. The manual instructs the reader to click on a link to access the complete manual.
Liebherr lh60 m timber hydraulic excavator service repair manualfjjsiefksekm
This document provides safety warnings and instructions for operating a hydraulic excavator. It outlines hazards associated with the machine and stresses the importance of following safety precautions to prevent injury. Specific dangers are indicated by warning signs on the machine. The document also defines the designated use of the excavator as loosening, picking up, transporting, and dumping materials while following technical safety guidelines. Any other uses are considered not in accordance with safe operation of the machine.
Liebherr lh40 c 1527 (tier4f) hydraulic excavator service repair manualfjjsiefksekm
This document contains figures and tables describing components of differential cylinders, shock absorbers, and hydraulic cylinders. It discusses mounting of standard and fine thread clamping nuts, and adjusting swing brakes. The document also includes a table of corrosion inhibitors recommended by Liebherr and another table listing base coats and paints from Liebherr available in aerosol cans. It encourages the reader to download a complete manual by clicking on a provided link.
Liebherr lh35 1201 hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that was printed on December 25, 2019 at 21:58. It contains instructions and diagrams for mounting different clamping nuts, adjusting swing brakes, and identifying components of hydraulic cylinders and shock absorbers that are at risk for corrosion. It also includes tables listing recommended corrosion inhibitors and paints from Liebherr for protecting hydraulic cylinder components from corrosion.
More Related Content
Similar to Jcb tm320 telescopic wheel loader service repair manual sn 2681926 and up
Jcb 510 56 telescopic handler service repair manual sn from 1402020 and upfujdjjksekmem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual covers removing and installing the semi-automatic gearbox, which involves separating the front and rear cases. Key steps include removing clutch and shaft assemblies, checking clutch shaft end float tolerances, applying sealant and threadlocker, and using special tools for installation. The manual provides diagrams and specifies torque values for reassembly. Consumable products like sealant and threadlocker are listed.
Jcb 509 42 telescopic handler service repair manual sn from 1402020 and upfujjdfjjskekmm
This service manual provides instructions for servicing and repairing loadall trucks. It contains sections covering the machine systems and components. The section summarized provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing clutch shaft assemblies in the correct order, checking clutch shaft end floats, and applying threadlocker to bolts. Consumables like gasket material and threadlocker are listed.
Jcb 506 36 telescopic handler service repair manual sn from 1402020 and upufjjdjkskemem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual covers removing and installing the semi-automatic gearbox, which involves separating the front and rear cases. Key steps include removing clutch and shaft assemblies, checking clutch shaft end float tolerances, installing new seals, and applying threadlocker and liquid gasket. Special tools and consumables like an end float setting tool kit and JCB threadlocker are required.
Jcb 510 56 telescopic handler service repair manual sn from 1402020 and upfujjdfjjskekmm
This service manual provides instructions for servicing and repairing loadall trucks. It contains sections covering various vehicle systems and components. The section summarized provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing clutch shaft assemblies in the correct order, checking clutch shaft end floats, and applying threadlocker to fasteners. Consumables like gasket material and threadlocker are listed.
Jcb 507 42 telescopic handler service repair manual sn from 1402020 and upudfjjsjekkemm
This service manual provides instructions for servicing and repairing loadall trucks. It contains sections covering various vehicle systems. The section summarized details the process for removing and installing the front and rear cases of the semi-automatic gearbox. Key steps include separating the cases, removing internal components like clutches and shafts in the proper sequence, and reassembling the cases while ensuring correct clutch shaft end float is achieved. Special tools and consumables like threadlocker and gasket material are listed. End float measurements for the input and reverse shafts are to be taken and must fall within the specified range.
Jcb 512 56 telescopic handler service repair manual sn from 1402020 and upfujdjjksekmem
This service manual provides instructions for servicing and repairing loadall trucks. It contains sections covering various vehicle systems and components. The section summarized details the process for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing clutch shaft assemblies in the correct order, checking clutch shaft end floats, and applying threadlocker to attachment bolts. Special tools are required for tasks like measuring end float.
Jcb 512 56 telescopic handler service repair manual sn from 1402020 and upfujjdfjjskekmm
This service manual provides instructions for servicing and repairing loadall trucks. It contains sections covering the machine systems and components. The section summarized provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing clutch shaft assemblies in the correct order, checking clutch shaft end floats, and applying threadlocker to bolts. Consumables like gasket material and threadlocker are listed.
Jcb 509 42 telescopic handler service repair manual sn from 1402020 and upfujdjjksekmem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual covers removing and installing the semi-automatic gearbox, which involves separating the front and rear cases. Key steps include removing clutch and shaft assemblies, checking clutch shaft end float tolerances, applying sealant and threadlocker, and using special tools for installation. The manual provides diagrams and specifies torque values for reassembly. Consumable products like sealant and threadlocker are listed.
Jcb 512 56 telescopic handler service repair manual sn from 1402020 and upfjsjefskekfmme
This document provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing internal components like clutch assemblies in the proper sequence, and checking clutch shaft end float to ensure correct assembly. Consumables like threadlocker and gasket material should be used, and special tools are required to measure end float within the specified range.
Jcb 510 56 telescopic handler service repair manual sn from 1402020 and upufjdjjksekmem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine components, including the engine, brake system, hydraulic system, electrical system, and driveline. The section summarized provides instructions for removing and installing the front and rear cases of the semi-automatic gearbox. The process requires using various special tools and consumables, checking clutch shaft end floats, and applying sealants and threadlocker to fasteners.
Jcb 509 42 telescopic handler service repair manual sn from 1402020 and upfjjsekksemmer
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine components, including the engine, brake system, hydraulic system, electrical system, and driveline. The section on the semi-automatic gearbox provides instructions for removing and installing the gearbox, checking clutch shaft end floats, and installing new seals and gaskets. Special tools and consumable products like threadlocker and gasket material are listed.
Jcb 506 36 telescopic handler service repair manual sn from 1402020 and upfjjsjeskkekem
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine, attachments, body, operator station, engine, brakes, steering, driveline, hydraulics, and electrical systems. When servicing the semi-automatic gearbox, procedures are provided for removing and installing internal components like clutches and cases, checking clutch end float, and installing seals and gaskets. Special tools and consumables are listed that may be required for the work.
Jcb 507 42 telescopic handler service repair manual sn from 1402020 and upregdfcgvdgvf
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine components, including the engine, brake system, hydraulic system, electrical system, and driveline. The section summarized provides instructions for removing and installing the front and rear cases of the semi-automatic gearbox. The process requires using various special tools and consumables, checking clutch shaft end floats, and applying sealants and threadlocker to fasteners.
Jcb 507 42 telescopic handler service repair manual sn from 1402020 and upfjjsjeusekkekm
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine components, including the engine, brake system, hydraulic system, electrical system, and driveline. The section summarized provides instructions for removing and installing the front and rear cases of the semi-automatic gearbox. The process requires using various special tools and consumables, checking clutch shaft end floats, and applying sealants and threadlocker to fasteners.
Jcb 509 42 telescopic handler service repair manual sn from 1402020 and upfjskekazswdmme
This service manual provides instructions for servicing Loadall rough terrain variable reach trucks with model numbers 506-36, 507-42, 509-42, 510-56, and 512-56. The manual contains sections covering the machine systems including the engine, brakes, steering, hydraulics, electrical system, and driveline. The driveline section provides step-by-step instructions for removing and installing the front and rear gearbox cases, checking clutch shaft end floats, and installing internal components like clutches, gears, and seals. Special tools and consumable products like sealants and gaskets are listed.
Jcb 507 42 telescopic handler service repair manual sn from 1402020 and upfhshefjjskefkem
This document provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing internal components like clutch assemblies in the proper sequence, and checking clutch shaft end float to ensure correct assembly. Consumables like threadlocker and gasket material should be used, and special tools are required to measure end float within the specified range.
Similar to Jcb tm320 telescopic wheel loader service repair manual sn 2681926 and up (16)
Liebherr r906 1449 classic hydraulic excavator service repair manualfjjsiefksekm
The document is a service manual for Liebherr hydraulic excavators. It contains 18 sections that provide technical specifications, maintenance guidelines, and instructions for repairing and servicing various engine, hydraulic, electrical, and other components of the excavators. The manual is intended to assist customer support services and includes symbols to identify safety warnings and notes for procedures. It also provides guidelines for how the manual is structured and indexed.
Liebherr lh110 m 1227 (tier4f) hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that discusses the mounting of standard and fine thread clamping nuts, and mounting clamping nuts on suspensions with swing brakes. It includes figures showing the components of differential cylinders and shock absorbers, and tables listing recommended corrosion inhibitors and base coats and paints from Liebherr. The manual instructs the reader to click on a link to access the complete manual.
Liebherr lh110 c 1228 (tier4f) hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that discusses the mounting of standard and fine thread clamping nuts, and mounting clamping nuts on suspensions with swing brakes. It includes figures showing the components of differential cylinders and shock absorbers, and tables listing recommended corrosion inhibitors and base coats and paints from Liebherr. The manual instructs the reader to click on a link to access the complete manual.
Liebherr lh60 m timber hydraulic excavator service repair manualfjjsiefksekm
This document provides safety warnings and instructions for operating a hydraulic excavator. It outlines hazards associated with the machine and stresses the importance of following safety precautions to prevent injury. Specific dangers are indicated by warning signs on the machine. The document also defines the designated use of the excavator as loosening, picking up, transporting, and dumping materials while following technical safety guidelines. Any other uses are considered not in accordance with safe operation of the machine.
Liebherr lh40 c 1527 (tier4f) hydraulic excavator service repair manualfjjsiefksekm
This document contains figures and tables describing components of differential cylinders, shock absorbers, and hydraulic cylinders. It discusses mounting of standard and fine thread clamping nuts, and adjusting swing brakes. The document also includes a table of corrosion inhibitors recommended by Liebherr and another table listing base coats and paints from Liebherr available in aerosol cans. It encourages the reader to download a complete manual by clicking on a provided link.
Liebherr lh35 1201 hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that was printed on December 25, 2019 at 21:58. It contains instructions and diagrams for mounting different clamping nuts, adjusting swing brakes, and identifying components of hydraulic cylinders and shock absorbers that are at risk for corrosion. It also includes tables listing recommended corrosion inhibitors and paints from Liebherr for protecting hydraulic cylinder components from corrosion.
Liebherr lh30 1210 hydraulic excavator service repair manualfjjsiefksekm
The document is a technical manual that was printed on December 25, 2019 at 21:58. It contains diagrams and tables related to hydraulic cylinders and corrosion prevention. Figures 1-4 illustrate components of cylinders and their assembly while Tables 1-2 list recommended corrosion inhibitors and paints from Liebherr. The manual instructs the reader to click on a link to access the complete document.
Liebherr er 902 hydraulic excavator service repair manualfjjsiefksekm
The document is a service manual that provides technical data, maintenance guidelines, and information on systems for hydraulic excavators models ER 900-942. It covers general information, tools, the engine, coupling and splitterbox, hydraulic system, hydraulic components, electrical system, swing gear, swing ring, travel gear, track components, undercarriage and uppercarriage attachments, cab heater and air conditioning. The manual is intended to assist with maintenance and repairs for the excavator models.
Liebherr a912 compact 1506 tier4f hydraulic excavator service repair manualfjjsiefksekm
This document contains figures and tables describing components of mechanical devices like clamping nuts, differential cylinders, and shock absorbers. It discusses parts that are at risk of corrosion and recommends corrosion inhibitors and paints from Liebherr to protect those parts. The document encourages downloading a complete manual for more information.
Liebherr a910 compact 1505 tier4f hydraulic excavator service repair manualfjjsiefksekm
This document contains figures and tables describing components of mechanical devices like clamping nuts, differential cylinders, and shock absorbers. It identifies parts that are at risk of corrosion and recommends corrosion inhibitors and paint coatings from Liebherr to protect those parts. The document encourages downloading a complete manual for more information.
Jcb 1253, 1202, 1553, 1554 liftall service repair manual from 6600001 to 6600785fjjsiefksekm
This document provides service information for the Liftall 1253/1202/1553/1554, including sections covering general information, identification, load charts, torque specifications, service tools, and numerical lists of tools. It contains specifications, diagrams, and instructions to aid technicians in servicing and repairing these machines.
Jcb 1253, 1202, 1553, 1554 liftall service repair manual from 2087061 to 2089561fjjsiefksekm
The document is a service manual for the Liftall 1253/1202/1553/1554 machines. It contains sections covering general information such as machine identification, load charts, torque specifications, and service tools. It also includes sections specific to the body and framework, electrics, hydraulics, and engine of the machines. The manual provides information and specifications to assist with maintenance and repair of the Liftall models.
Jcb 540 140 telescopic handler service repair manual sn from 2460601 onwardsfjjsiefksekm
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Jcb 535 v140 telescopic handler service repair manual sn from 2902000 onwardsfjjsiefksekm
This service manual provides instructions for servicing the loadall rough terrain variable reach truck. It contains sections on the machine systems including the engine, fuel system, cooling system, brake system, hydraulic system and electrical system. The section summarized focuses on servicing the engine valves and connecting rod big-end bearings. It provides removal and installation instructions, component identification diagrams, and technical specifications for the valves and instructions to check the big-end bearings for wear. Safety information is also provided to ensure the work is performed correctly.
Jcb 531 70 tier 4 telescopic handler service repair manual sn from 2336575 on...fjjsiefksekm
This document provides service and repair instructions for fuel injectors in JCB Loadall vehicles. It describes injector components and identification, includes a check procedure using diagnostic tools, and outlines removal and installation steps. Special tools are required for tasks like leak testing and installing injector seals. Torque specifications are provided for tightening injector clamps and sleeves.
Jcb 526 56 tier 4 telescopic handler service repair manual sn from 2902000 on...fjjsiefksekm
This document provides service and repair instructions for fuel injectors in JCB Loadall vehicles. It describes injector components and identification, includes a check procedure using diagnostic tools, and outlines removal and installation steps. Special tools are required for tasks like leak testing and installing injector seals. Torque specifications are provided for tightening injector clamps and sleeves.
Jcb 506 36 telescopic handler service repair manual sn from 1402020 and upfjjsiefksekm
This document provides instructions for removing and installing the front case of a semi-automatic gearbox. Key steps include separating the front and rear cases, removing and installing various clutch shaft assemblies in the proper sequence, and checking clutch shaft end float to ensure correct assembly tolerances. Special tools and consumables like threadlocker and gasket material are required.
Jcb 411 ht, 413s, 417ht wheel loader service repair manual from 2095872 to 20...fjjsiefksekm
This service manual provides instructions for servicing JCB machines 411HT, 413S, and 417HT. It contains sections on various machine systems including the engine, fuel and exhaust systems, cooling system, brake system, hydraulic system, and electrical system. The section on the fuel and exhaust system includes subsections that provide introductions, component identifications, check procedures, and removal/installation steps for the inlet manifold, outlet manifold, and general exhaust system components. Safety precautions are outlined regarding working with hot or hazardous exhaust components.
Jcb 270 skid steer loader service repair manual sn from 2675500 to 2675700fjjsiefksekm
This service manual provides instructions for servicing skid steer loaders and their engines. It details removing and installing the engine bedplate, which acts as the main strength component and maintains alignment of internal engine parts. The multi-step procedure requires cleaning and applying sealant to the bedplate and crankcase mating surfaces before reinstalling with new bolts and following torque specifications. Special tools like templates and wrenches are listed to correctly complete the removal and installation.
Jcb 270 skid steer loader service repair manual sn from 2478301 to 2478700fjjsiefksekm
This service manual provides instructions for servicing JCB skid steer loaders and their components. It contains sections on machine systems and components including the engine, fuel system, cooling system, brakes, hydraulics and electrical system. The section summarized here provides instructions for removing and installing the crankshaft from the engine. It describes cleaning and inspecting the crankshaft, lists the required tools and consumables, and outlines the step-by-step removal and installation procedures. Precautions are given to handle the heavy crankshaft safely and ensure proper lubrication when reassembled.
Understanding Catalytic Converter Theft:
What is a Catalytic Converter?: Learn about the function of catalytic converters in vehicles and why they are targeted by thieves.
Why are They Stolen?: Discover the valuable metals inside catalytic converters (such as platinum, palladium, and rhodium) that make them attractive to criminals.
Steps to Prevent Catalytic Converter Theft:
Parking Strategies: Tips on where and how to park your vehicle to reduce the risk of theft, such as parking in well-lit areas or secure garages.
Protective Devices: Overview of various anti-theft devices available, including catalytic converter locks, shields, and alarms.
Etching and Marking: The benefits of etching your vehicle’s VIN on the catalytic converter or using a catalytic converter marking kit to make it traceable and less appealing to thieves.
Surveillance and Monitoring: Recommendations for using security cameras and motion-sensor lights to deter thieves.
Statistics and Insights:
Theft Rates by Borough: Analysis of data to determine which borough in NYC experiences the highest rate of catalytic converter thefts.
Recent Trends: Current trends and patterns in catalytic converter thefts to help you stay aware of emerging hotspots and tactics used by thieves.
Benefits of This Presentation:
Awareness: Increase your awareness about catalytic converter theft and its impact on vehicle owners.
Practical Tips: Gain actionable insights and tips to effectively prevent catalytic converter theft.
Local Insights: Understand the specific risks in different NYC boroughs, helping you take targeted preventive measures.
This presentation aims to equip you with the knowledge and tools needed to protect your vehicle from catalytic converter theft, ensuring you are prepared and proactive in safeguarding your property.
What Could Be Behind Your Mercedes Sprinter's Power Loss on Uphill RoadsSprinter Gurus
Unlock the secrets behind your Mercedes Sprinter's uphill power loss with our comprehensive presentation. From fuel filter blockages to turbocharger troubles, we uncover the culprits and empower you to reclaim your vehicle's peak performance. Conquer every ascent with confidence and ensure a thrilling journey every time.
Implementing ELDs or Electronic Logging Devices is slowly but surely becoming the norm in fleet management. Why? Well, integrating ELDs and associated connected vehicle solutions like fleet tracking devices lets businesses and their in-house fleet managers reap several benefits. Check out the post below to learn more.
Expanding Access to Affordable At-Home EV Charging by Vanessa WarheitForth
Vanessa Warheit, Co-Founder of EV Charging for All, gave this presentation at the Forth Addressing The Challenges of Charging at Multi-Family Housing webinar on June 11, 2024.
Welcome to ASP Cranes, your trusted partner for crane solutions in Raipur, Chhattisgarh! With years of experience and a commitment to excellence, we offer a comprehensive range of crane services tailored to meet your lifting and material handling needs.
At ASP Cranes, we understand the importance of reliable and efficient crane operations in various industries, from construction and manufacturing to logistics and infrastructure development. That's why we strive to deliver top-notch solutions that enhance productivity, safety, and cost-effectiveness for our clients.
Our services include:
Crane Rental: Whether you need a crawler crane for heavy lifting or a hydraulic crane for versatile operations, we have a diverse fleet of well-maintained cranes available for rent. Our rental options are flexible and can be customized to suit your project requirements.
Crane Sales: Looking to invest in a crane for your business? We offer a wide selection of new and used cranes from leading manufacturers, ensuring you find the perfect equipment to match your needs and budget.
Crane Maintenance and Repair: To ensure optimal performance and safety, regular maintenance and timely repairs are essential for cranes. Our team of skilled technicians provides comprehensive maintenance and repair services to keep your equipment running smoothly and minimize downtime.
Crane Operator Training: Proper training is crucial for safe and efficient crane operation. We offer specialized training programs conducted by certified instructors to equip operators with the skills and knowledge they need to handle cranes effectively.
Custom Solutions: We understand that every project is unique, which is why we offer custom crane solutions tailored to your specific requirements. Whether you need modifications, attachments, or specialized equipment, we can design and implement solutions that meet your needs.
At ASP Cranes, customer satisfaction is our top priority. We are dedicated to delivering reliable, cost-effective, and innovative crane solutions that exceed expectations. Contact us today to learn more about our services and how we can support your project in Raipur, Chhattisgarh, and beyond. Let ASP Cranes be your trusted partner for all your crane needs!
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
EV Charging at MFH Properties by Whitaker JamiesonForth
Whitaker Jamieson, Senior Specialist at Forth, gave this presentation at the Forth Addressing The Challenges of Charging at Multi-Family Housing webinar on June 11, 2024.
2. 27 - Driveline
06 - Semi-Automatic Gearbox
12 - Clutch - Ratio
27 - 126 9813/6850-2 27 - 126
12 - Clutch - Ratio
Disassemble and Assemble
Special Tools
Description Part No. Qty.
Circlip Assembly Tool 998/11334 1
Main shaft clutch
Disassembly
The numerical sequence is a guide to the
disassembly procedure.
1. Remove and discard the O-ring seals 1.
2. To check the clutch plates.
2.1. Remove the circlip1 from the clutch drum.
2.2. Lift off the thick pressure counter plate then
the seven friction plates and seven counter
plates.
3. Remove and check the roller bearing race. If
necessary discard it.
4. Use either the circlip assembly tool or a tube of
suitable diameter to install over the top spring
cup.
Special Tool: Circlip Assembly Tool (Qty.: 1)
Figure 567.
A
A Tube
5. Cut out a small portion of the tube, to allow
access, to release the circlip 2.
6. With the clutch drum located in the press,
compress the spring sufficiently to allow the
circlip 2 to be released.
7. When the circlip 2 is released, remove it from the
shaft with the spring cup, spring and the lower
spring cup.
8. If necessary the clutch operating piston may be
removed by compressed air blown through the
drilling in the end of the clutch shaft.
9. Remove and discard the clutch piston O-ring seal
2 and seal 3.
3. 27 - Driveline
06 - Semi-Automatic Gearbox
12 - Clutch - Ratio
27 - 127 9813/6850-2 27 - 127
Figure 568.
B
R
S
M
Q
P
N
K
G
F
D
C
L
J
H
E
Table 242.
Item Description
B Circlip 1
C Thick pressure counter
plate
D Friction plate
E Counter plate
F Roller bearing race
Item Description
G Upper spring cup
H Circlip 2
J Spring
K Lower spring cup
L Piston
M Clutch shaft
N O-ring seal 2
4. 27 - Driveline
06 - Semi-Automatic Gearbox
12 - Clutch - Ratio
27 - 128 9813/6850-2 27 - 128
Item Description
P O-ring seal 3
Q Housing
R Gallery port
S O-ring seal 1
Assembly
Assembly is the opposite of the disassembly
procedure with the following precautions.
1. Install the new clutch piston O-ring seals 2 and
seal 3 to the piston.
2. Lubricate the new seals and push the piston into
the housing by hand.
3. Put the lower spring cup over the central spigot
of the piston.
4. Replace the spring and the top spring cup.
5. Keep the circlip 2 on the top cup ready for
installation.
6. Use the tube with a cutout to compress the
spring.
7. Locate the cutout to give access for circlip 2.
8. Install the circlip 2 and make sure that it is seated
correctly in the groove.
9. New clutch friction plates must be soaked in oil
before assembly.
10. Install the first counter plate to the clutch drum
followed by the friction plate.
11. Alternately install all fourteen plates.
12. Use a scrap splined drive hub to align the splines
of the friction plates.
13. Install the thick counter plate at the top of the
assembly followed by the circlip 1.
14. Check the free play clearance of the clutch plates
and it must be within the specified limit.
Dimension: 3 –3.5 mm
15. You can adjust the clearance by either changing
the thick pressure plate from 6.0mm (0.24in)
thick version to 6.5mm (0.26in) thick or by
the addition of a shim counter plate installed
immediately under the thick pressure plate.
16. Once the clutch is assembled completely then
apply compressed air to the gallery port in the
end of the shaft to check the clutch operation.
Ratio Clutches
Disassembly
1. For the remaining two ratio clutches follow the
same disassembly procedure as above.
2. The only difference is the retention of the support
taper roller bearing which for each clutch is held
in place by a machined cap.
Assembly
1. Clutch 1 and clutch 2 assembly.
1.1. Use a mandrel to carefully push the taper
bearing 1 into its position.
1.2. Rotate the roller cage as the bearing is
pushed into place to make sure that the
mandrel does not foul and distort the cage.
1.3. Put the new O-ring seal 4 into the grooves
in the cap 1.
Figure 569.
W
V
U
T
X
T Taper bearing 1
U O-ring sea l4
V Cap 1
W Capscrews 1
X O-ring seals 5
1.4. Two capscrews 1 hold the cap 1 in place.
1.5. Tighten the capscrews 1 to the correct
torque value.
1.6. Put two new O-ring seals 5 into the groves
in cap 1.
5. 27 - Driveline
06 - Semi-Automatic Gearbox
12 - Clutch - Ratio
27 - 129 9813/6850-2 27 - 129
2. Clutch 3 and clutch 4 assembly.
2.1. Use a mandrel to carefully push the taper
bearing 2 into its position.
2.2. Rotate the roller cage as the bearing is
pushed into the place to make sure that the
mandrel does not foul and distort the cage..
2.3. Put the new O-ring seal 6 into the grooves
in the cap 2.
Figure 570.
Y
Z
AA
AC
AB
Y Taper bearing 2
Z O-ring seal 6
AA Cap 2
AB Capscrews 2
AC O-ring seals 7
2.4. Two capscrews 2 hold the cap 2 in place.
2.5. Tighten the capscrews 2 to the correct
torque value.
2.6. Put two new O-ring seals 7 into the groves
in cap 2.
Table 243. Torque Values
Item Description Nm
W Capscrews1 18
AB Capscrews2 45
6. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 130 9813/6850-2 27 - 130
13 - Clutch - Master
Remove and Install ..................................... 27-130
Disassemble and Assemble ........................ 27-136
Remove and Install
Special Tools
Description Part No. Qty.
Clutch Pack Retainers 892/01048 2
Mandrel 892/01050 1
Locking Plates 892/01052 2
Consumables
Description Part No. Size
JCB Multi-Gasket 4102/1212 0.05 L
Remove
1. Put the gearbox on a suitable manipulator.
Rotate the gearbox until the clutch is in the top
position.
2. Remove all the cover attaching bolts and then
install the M10 jacking bolts1 (x3).
3. Screw all the jacking bolts evenly until the cover
is clear of its spigot.
Figure 571.
G
A
BC
E
B
F
D
A Cover attaching bolts (x18)
B M10 jacking bolts1 (x3)
C Cover
D M10 threaded lifting eye (x2)
E Oil seal2
F Cover O-ring seal
G O-ring1 seal
4. Install the M10 threaded lifting eyes to lift the
cover.
7. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 131 9813/6850-2 27 - 131
5. Carefully lift off the cover and make sure that you
keep it square to the housing.
6. Make sure that you remove and discard all the
O-ring1 seals.
7. Remove the jacking bolt.
8. Remove and discard the cover O-ring seal.
9. Prise out and discard the oil seal2 carefully and
make sure that the seal housing in the cover is
not damaged.
10. Install the special locking plates to prevent the
clutch assembly from rotating.
Special Tool: Locking Plates (Qty.: 2)
Figure 572.
AH
H
J
K
L
A Cover attaching bolts (x18) H Special screws
J Clutch assembly K Special locking plate
L Housing
11. Use the cover attaching bolts and the special
screws that are supplied with the locking plates,
to lock the clutch assembly to the housing.
12. Remove all the clutch drum bolts.
8. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 132 9813/6850-2 27 - 132
Figure 573.
M
N
P Q
M Clutch drum bolts (x12)
N Plug1
P M8 threaded lifting eye (x2)
Q Clutch drum
13. Remove the locking plate.
14. Install the M8 threaded lifting eyes to the clutch
drum.
15. Attach suitable lifting equipment to the clutch
drum.
16. Carefully remove the clutch drum, hub and the
pressure plate assembly.
17. Install the special pack retainers to the clutch
plate carrier.
Special Tool: Clutch Pack Retainers (Qty.: 2)
Figure 574.
R
U
T
S
V
R Special pack retainers (x2)
S Clutch plates
T Thrust washer1
U Plate carrier
V Thrust washer2
18. Remove the carrier together with the clutch
plates and the thrust washer1.
19. Remove the thrust washer2.
20. Remove the button head capscrews.
21. Remove the oil baffle plate.
22. Rotate the drum carrier to align the five holes with
countersunk capscrews.
23. Remove the countersunk capscrews.
9. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 133 9813/6850-2 27 - 133
Figure 575.
Y
M
W
M
Z
L
X
Z
AA
AB
M Clutch drum bolts (x12)
L Housing
W Button head capscrews (x5)
X Oil baffle plate
Y Countersunk capscrews
Z JCB multigasket
AA Drum carrier
AB M10 jacking bolts2 (x3)
24. Install the M10 jacking bolts2 and jack the drum
carrier to remove it from the housing.
25. Make sure that you install the drum bolts that
will assist you to lift the drum carrier clear of the
housing.
26. The drum carrier will be removed completely with
the PTO (Power Take-Off) input gear and the
bearing.
27. It is not necessary to remove the clutch housing
unless it is damaged or the PTO/splitter gearbox
needs to be disassembled.
Figure 576.
L
Z
AD
AC
AB
L Housing
Z JCB multigasket
AB Verbus-ripp bolts (x12)
AC O-ring2
AD Cross drilling blanking plug2
28. The clutch house removal.
28.1. Remove and discard all the Verbus-ripp
bolts.
28.2. Use a soft faced hammer to separate the
housing from the PTO/splitter gearbox.
28.3. Remove the clutch housing.
29. After you remove the clutch from the housing
there will be three main sub assemblies.
29.1. Remove the Clutch drum, hub and
pressure plate sub-assembly. Refer to
Figure 577.
10. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 134 9813/6850-2 27 - 134
Figure 577.
29.2. Remove the clutch plates and plate carrier
sub-assembly. Refer to Figure 578.
Figure 578.
29.3. Remove the clutch drum carrier and input
gear PTO sub-assembly.
Figure 579.
Install
Installation is the opposite of the removal procedure
but make sure that additionally you follow the
instructions below.
1. If it is necessary to replace the clutch housing
with a new one then make sure that the cross
drilling blanking plug2 is installed to the new
housing.
2. Tighten the plug2 to the correct torque value.
3. Make sure that the oil feed cross drillings are
clear.
4. Carefully clean all the traces of the sealing
compound from the clutch and the smoothshift
gearbox housing mating surfaces.
5. Lightly lubricate with oil and install a new O-ring2.
6. Apply even beads of JCB Multigasket to the
Smoothshift Gearbox housing (around the outer
diameter and around each threaded bolt hole).
Consumable: JCB Multi-Gasket
7. Make sure that you install new Verbus-ripp bolts.
8. Tighten the Verbus-ripp bolts to the correct
torque value.
9. Make sure that the clutch components are
carefully checked for any signs of wear or
damage.
10. If any of the friction or counter plates are
damaged or if any of the friction plates are
excessively worn (thickness less than 3.5 mm or
oil grooves less than 0.1 mm deep) replace the
complete set of plates.
11. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 135 9813/6850-2 27 - 135
11. Make sure that the new friction plates are soaked
in transmission oil before you install them.
12. Check the thrust washer2 for any signs of wear.
13. If the thickness (3.9mm) or the outside diameter
(110.0mm) is less then the mentioned value then
install a new thrust washer2.
14. Before you install the new thrust washer2 soak it
in the transmission oil for at least an hour.
15. Do not apply any kind of thread locking
compound to any of the bolts or screws.
16. Tighten the plug1s to the correct torque value to
prevent oil gallery leakage.
17. It is not possible to locate the clutch drum over
the clutch plates and carrier assembly inside the
housing.
18. First sub-assemble the components on the
bench and then use the retainers to hold the
assembly together.
19. Before you replace the drum, plates, carrier and
hub assembly install the two guide pins to the
M10 threaded holes in the drum carrier.
20. Use a special mandrel to install the new oil seal2.
Special Tool: Mandrel (Qty.: 1)
21. If the clutch plates are replaced with new ones,
check to make sure that the clutch is disengaged
before installing the cover 2.
22. Lightly apply oil and install a new O-ring1 and the
cover O-ring.
Table 244. Torque Values
Item Description Nm
A Cover attaching bolt 56
M Clutch drum bolt 52
W Button head capscrews 12
Y Countersunk capscrews 38
N Plug1(Black) 22
N Plug1(Gold) 12
AB Verbus-ripp bolt 75
AD Cross drilling blanking plug2 15
12. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 136 9813/6850-2 27 - 136
Disassemble and Assemble
Special Tools
Description Part No. Qty.
Peg Socket 892/01045 1
Mandrel 892/01046 1
Clutch Jig 892/01047 1
Clutch Pack Retainers 892/01048 2
Guide Rods 892/01049 2
Slide Hammer Kit 993/68100 1
Consumables
Description Part No. Size
4101/0250 0.01 LJCB Threadlocker
and Sealer (Medium
Strength)
4101/0251 0.05 L
Master Clutch- Clutch Drum and Hub
Disassembly
1. Remove the lubrication nozzles.
2. Remove the bolts.
3. Remove the release springs and the spring
pillars then discard the springs.
4. Remove the oil baffle plate from the locating
dowel 1.
5. Remove the pressure plate.
6. Make sure that you do not lose the dowel 1 and
dowel 2
7. Remove the piston from the drum.
8. Use M6 bolt (x2) and suitable levers to help in
removal of the piston.
9. Remove and discard the outer seal from the
piston.
10. Remove the socket head capscrews (x8).
11. Use a suitable bar to prevent drum rotation.
12. Use a soft faced hammer to tap out the hub from
the drum.
13. Remove and discard the O-ring 1 from the drum.
14. Remove the circlip.
15. Use a suitable drift to tap out the blanking disc
together with the inner bearing.
16. Remove and discard the O-ring 2.
17. Remove and discard the iron sealing ring.
18. Remove and discard the inner piston seal from
the hub.
19. Do not remove the outer bearing unless it is to be
replaced with a new one.
20. At the time of removal the bearing can be
damaged. When the bearing is removed it must
be replaced.
21. To remove the outer bearing, screw in two jacking
bolts at their correct location on the hub.
22. If the bronze bush is to be replaced, then remove
it with a suitable puller and slide hammer.
Special Tool: Slide Hammer Kit (Qty.: 1)
13. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 137 9813/6850-2 27 - 137
Figure 580.
A
H
K
L
K
H
Y
X
B
V
N
Q
R
P
L
Z
Z
T
S
U
Y
W
D
C
E
F
L
J
M
W
G
14. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 138 9813/6850-2 27 - 138
Table 245.
Item Description
A Lubrication nozzles
B Bolts
C Springs
D Spring pillars
E Oil baffle plate
F Pressure plate
G Piston
H Drum
J Outer seal
K Socket head capscrews
(x8)
L Hub
M O-ring 1
N Circlip
P Blanking disc
Q Inner bearing
R O-ring 2
S Sealing ring
Item Description
T Inner piston seal
U Outer bearing
V Bronze bush
W M8 bolt (x2)
X Dowel 1
Y Dowel 2
Z Jacking bolts (x2)
Assembly
Assembly is the opposite of the disassembly
procedure but additionally follow the steps below.
1. Check that the oil feed slots and drillings are
clear.
2. Check the condition of the pressure plate, if it is
excessively scored then replace with a new one.
3. If it is necessary to replace the pressure plate,
dowel 1 and dowel 2 must be installed to the plate
before assembly.
15. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 139 9813/6850-2 27 - 139
Figure 581.
A
H
K
X
B
Y
Y
W
D
C
E
F
L
J
M
W
G
A Lubrication nozzles B Bolts
C Springs D Spring pillars
E Oil baffle plate F Pressure plate
G Piston H Drum
J Outer seal K Socket head capscrews (x8)
L Hub M O-ring 1
W M8 bolt (x2) X Dowel 1
Y Dowel 2
4. The larger dowel 2 must be tapped into the blind
holes on one face of the plate and the smaller
dowel 1 must be tapped onto the through holes
on the opposite face so that they reach through
the plate but do not protrude.
5. Check the faces of the drive tangs on the drum
and if you find any small burrs then carefully use
a file to remove the small burrs.
6. Check the pressure relief ball valve in the piston,
the ball should be free to move against its spring.
7. Check the pressure relief valve for leakage.
Refer to Figure 582.
7.1. Put a drop of paraffin in the orifice of the
valve.
16. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 140 9813/6850-2 27 - 140
Figure 582.
AC
AC Valve orifice
7.2. There should not be any leakage on the
other side of the ball.
7.3. If there is leakage then the piston or the
valve assembly must be replaced with a
new one.
8. If the bronze bush is to be replaced then make
sure that the oil grooves must align with the oil
feed drillings in the hub.
9. Use a suitable mandrel to push the bush until it
is 0.5mm below the end face of the hub.
Special Tool: Mandrel (Qty.: 1)
10. Lubricate and install a new O-ring 1 to the drum.
11. Align the oil feed holes in the hub with the oil feed
slots in the drum. Refer to Figure 583.
Figure 583.
12. Keep the hub square to the drum to avoid
damage to the O- ring 1.
13. Install the socket head capscrews.
14. Gradually tighten the capscrews to the correct
torque value.
15. Align the threaded holes in the piston with the
guide hole in the hub. Refer to Figure 584.
Figure 584.
LG
AA AB
AB AA
G Piston
L Hub
AA Threaded holes in piston
AB Guide holes in hub
16. Locate the piston inside its groove.
17. Locate the larger dowel (dowel2) pins on the
pressure plate into the drilled holes in the piston.
18. Use a suitable press to push the pressure plate
and the plate will push the piston down.
19. Remove the pressure plate and make sure that
there is no evidence of damaged seals in the
form of small slices of seal material.
20. If damage is suspected, remove the piston, install
new seals and then assemble again.
21. Make sure that the pressure plates are aligned
correctly.
22. Replace the oil baffle plate on the locating dowel
1.
23. Install new springs.
24. Remove any debris that may have been pushed
from the bolt holes into the hub.
25. If the drum and the hub are separated then
the outer bearing and the capscrews must be
replaced with a new one.
26. Before you install the outer bearing make sure
that the spring is installed already.
17. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 141 9813/6850-2 27 - 141
27. Use a suitable press to install the outer bearing
and apply force only on to the inner race.
28. Note that the piston rings cannot be installed
before the outer bearing.
29. Apply one drop of JCB Threadlocker and Sealer
to one or two threads from the end, on the
lubrication nozzles.
Consumable: JCB Threadlocker and Sealer
(Medium Strength)
30. Install new piston rings with extreme care, as the
rings can break very easily.
31. Note the interlocking end of the piston rings.
Figure 585.
V
N
Q
R
P
L
Z
Z
T
S
U
AD
N Circlip P Blanking disc
Q Inner bearing R O-ring 2
S Sealing ring T Inner piston seal
U Outer bearing V Bronze brush
L Hub Z Jacking bolts (x2)
AD Piston ring interlocking end
Table 246. Torque table
Item Description Torque value
A Lubrication nozzles 15 N·m
B Bolts 28 N·m
K Socket head capscrews 85 N·m
Master Clutch- Clutch Plates and Plate
Carrier
Disassembly
1. Remove the friction plates and counter plates
from the plate carrier.
2. The plates can only be removed from one end of
the carrier. There are six friction plates and five
counter plates.
3. If the thrust washer is not removed at the time of
removal then remove it now.
18. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 142 9813/6850-2 27 - 142
Figure 586.
E
H
G
F
C
B
G
D
C
A
B
B
A
Table 247.
Item Description
A Friction plates
B Counter plates
C Plate carrier
D Thrust washer
E Clutch drum and hub as-
sembly
Item Description
F Guide rods
G Threaded hole
H Clutch pack retainers
Assembly
1. Before you assemble the friction and the counter
plates check them for any signs of damage or
wear.
19. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 143 9813/6850-2 27 - 143
2. Friction plates should not be less than 3.5 mm
thick or have oil grooves less than 0.1 mm deep.
If the friction plate thickness is less then 3.5 mm
then it needs to be changed for a new one.
3. Replace the plates in a set, not as a single piece.
4. Check the thrust washer for wear.
5. If the thickness is less than 2.9mm or the outside
diameter is less than 90mm then replace the
thrust washer.
6. Before you install new friction plates and a new
thrust washer soak them in transmission oil for at
least one hour.
7. Start the assembly with a friction plate followed
by a counter plate and so on.
8. Note the correct orientation of oil slots in the
friction plates relative to the plate carrier. Refer
to Figure 587.
Figure 587.
A
C
A Friction plate
C Plate carrier
9. The counter plates should be positioned relative
to the two threaded holes. Refer to Figure 588.
Figure 588.
E
G
F
C
B
G
B Counter plates
C Plate carrier
E Clutch drum and hub assembly
F Guide rods
G Threaded hole
10. It is not possible to replace the clutch drum and
hub assembly inside the clutch housing unless
it is first installed to the plates and plate carrier
assembly.
11. Install the thrust washer to the plate carrier.
12. Install two suitable guide rods to the threaded
holes in the plate carrier.
Special Tool: Guide Rods (Qty.: 2)
13. Use suitable lifting equipment to carefully lower
the drum and hub sub-assembly over the plates.
14. Make sure that the guide rods locate through the
corresponding holes in the drum.
15. Make sure that the drive tangs on the counter
plates engage with the cut-outs in the drum.
16. It may be necessary to rotate the drum and plates
slightly to align them.
17. With the drum and hub fully lowered, remove the
guide rods and install two special pack retainers
to temporarily hold the assembly together.
Special Tool: Clutch Pack Retainers (Qty.: 2)
18. Do not use bolts or screws, mistakenly they may
be left in the place which can make the clutch
inoperative.
20. Thank you very much for
your reading. Please Click
Here. Then Get COMPLETE
MANUAL. NO WAITING
NOTE:
If there is no response to
click on the link above,
please download the PDF
document first and then
click on it.
21. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 144 9813/6850-2 27 - 144
19. The special retainers prevent further assembly
until they are removed.
20. The drum, hub, plates and plate carrier can
now be replaced inside the clutch housing as a
complete assembly.
Refer to: PIL 27-06-13.
21. Remove the special retainers and install plugs to
the holes in the clutch drum.
22. If the clutch plates are replaced, the plate stack
height is changed.
23. If the stack height is too high then the clutch
will be permanently engaged. Do the following
check.
23.1. Assemble the clutch components inside
the housing.
23.2. Do not install the cover.
Figure 589.
J
K
E
L
E Clutch drum and hub assembly
J Cover
K Bolt
L Splitter input shaft
23.3. Make sure that the bolts are tightened and
the splitter input shaft is engaged in the
clutch plate carrier.
23.4. Turn the clutch drum/hub assembly and, at
the same time hold the splitter shaft so it
does not rotate. Some drag is normal.
Master Clutch- Clutch Drum Carrier and
Power Take Off Input gear
Disassembly
1. To remove the stake nut follow the steps below.
1.1. Use a vice and a suitable jig to position the
assembly as shown.
Special Tool: Clutch Jig (Qty.: 1)
22. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 145 9813/6850-2 27 - 145
Figure 590.
A
C
B
D
E
A Stake nut B Input gear
C Drum plate carrier D Clutch jig
E Hacksaw
1.2. To avoid damage to the input gear threaded
shaft, use a hacksaw to carefully cut-away
the staked portion of the collar on the stake
nut. Refer to Figure 591.
Figure 591.
A E
A Stake nut
E Hacksaw
1.3. Make sure that the gear shaft is not
damaged.
1.4. The staked portion can now be easily bent
clear of the shaft. Refer to Figure 592.
23. 27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 146 9813/6850-2 27 - 146
Figure 592.
A
F
A Stake nut
F Bent on the stake
1.5. Use a special peg socket to loosen the
stake nut. The nut is very tight.
Special Tool: Peg Socket (Qty.: 1)
1.6. Make sure that the gear shaft is not
damaged.
1.7. Support the input gear and then remove the
stake nut.
1.8. Remove the gear and the bearing retainer
plate from the drum carrier.
1.9. Discard the stake nut.
2. Use a suitable press to push off the bearing and
then remove the loose bearing rib.
Figure 593.
C
G
H
J
BK
A
Table 248.
Item Description
A Stake nut
B Input gear
C Drum plate carrier
G Gear and bearing retain-
er plate
Item Description
H Bearing
J Bearing rib
K Attaching screw holes