EXCAVATOR LOADER
SERVICE MANUAL
2D, 2DS, 3, 3C, 3CS, 3D, 700
From machine serial number 55500
Care & Safety
Tecnical Data
Rountine Maintenance
Attachments
Body & Framework
Electircs
Controls
Hydraulics
Transmission
Brakes
Steering
Engine
9803/3200
. . . . . . . . . . . . . . . . . . .1
. . . . . . . . . . . . . . . . . . .2
. . . . . . . . . . . . . . . . . . .3
. . . . . . . . . . . . . . . . . . .A
. . . . . . . . . . . . . . . . . . .B
. . . . . . . . . . . . . . . . . . .C
. . . . . . . . . . . . . . . . . . .D
. . . . . . . . . . . . . . . . . . .E
. . . . . . . . . . . . . . . . . . .F
. . . . . . . . . . . . . . . . . . .G
. . . . . . . . . . . . . . . . . . .H
. . . . . . . . . . . . . . . . . . .K
Issue 5
SERVICE MAIVUAL
РгЫасе
ТЫб о1 ите is published mainly ог the benefit Ы 1СВ Distributor Service Еп9 пеег , Ы соре
are available гогл ]СВ Distributors to individual machine users.
ТЬе тапиа1 is compiled in sections,the first three Ы ,ЫсЬ are numbered апд contain Саге апд
аеу арес1 Ы workshop р rоседи ге, Technical Оаа апд Routine Maintenance. The remaining
sections are alphabetically сое апд деа1 with Dismantling, Overhaul ес., Ы specific components.
Рог Ехатр1 е:—
В
Е
=
=
Воду апд Framework
Hydraulics
А11 sections are listed оп the гоп соег, the bands Ы which coincide with divider сагЁ ог rapid
геегепсе. ЕасЬ individual section а1 о has its о 'п Contents Ра9е.
Реглоа1, Replacement, Dismantling апд АббеглЫу procedures should Ье carried out in ассогапсе
with the sequences Ъо 'п оп the illustrations, paying particular attention Ёо items пое in the
text.
Where гтоге detailed information is necessary, ЁЫ is given in the ех in the оггл Ы step Ьу [ер
instructions.
Left Напд ап Right Напд, 'Ьеге used, are а iewed гогл the геаг Ы the machine.
* Тог
е Settings in this Publication are given а 'глеап' figures ап
тау агу Ьу 3% higher or оиег.
Distributor copies Ы the тапиа1 wi11 Ье continuously updated Ьу the issue Ы Replacement Ра9е .
ТЬее should Ье inserted а the appropriate р1 асе ап the existing ране (if апу ) withdrawn ап
дiscarded.
Where possible, revised information is indicated Ьу ап asterisk (*)against the item concerned, the
ране issue number in the bottom right hand согпег being similarly marked. Where the entire ране
or illustration has Ьееп геГе the asterisk ‚,i11 поЁ Ье used, оп1 у the ране issue number wi11 Ье
raised.
А publication detailing а11 the special оо1 required for the machines is available ерага1е1 у.
9803/3200
issue 2`
SERVICE MANUAL
1-1
1-1
МАСН1NЕ 1ОЕГТ1Е1САТ1О
The following information explains the various serial numbers to Ье found оп the Оаа Р1 ае attached to the machine.
1t is essential that the serial ги. гяЬег аге used to ensure the соггес upply Ы раг
апд to 1осае the соггес ervice
information.
SKIDDED TRANSMISSION MACHINES — Мапиа1 апд /3 build
СЕААВОХ
1СВ MACHINE
SERIAL NO.
SERIAL NO
ТАСТОй
POWER ТАКЕ-ОЕЕ
SERIAL О.
SERIAL NO.
HYDRAULIC POWER
UNIT SERIAL NO.
EiiiGINE
SERIAL NO.
О
СВ Machine Serial Number
e.g.
30111 129564 / З
МАСН1NЕ ТУРЕ АО МАРК
SEQUENTIAL SERIAL NO.
55000-68150
МК11 гапе
100001-124999
апд loaders
125001-199999
МК111 гапуг
BU1LD 1DENTIF1CATION
В1апк—Мапиа1 Transmission
%3
—Тоге сопегег
980313200
lssue 1
SERVICE MANUAL
1-2
1-2
MACHINE IDENTIFICATION
e.g.
Tractor Serial No.
ТРА
384В / 7 / 237580
М11О I ТУРЕ
384В-10 speed, тапиа1 ог torque converter
272В-9 speed, тапиа1 оп1 у.
BUILD ТУРЕ
1— Мапиаl,
апсагс
3—Torque converter,
апсагс
7— Мапиаl, Сеггпап
8—Torque converter, Germaп
9—Р.Т.О. with hydraulics
10— Р.Т.О. е hydraulics
SEQUENTIAL SERIAL N0.
Tractor Serial Г'1о.— СВ Build skid
e.g.
SKI
/
002676
В [)1[ О ТУРЕ
К1—
апсагс
SK2—Germaп/Austrian
ЕО[)Е [\]Т1 А[ SERIAL N0.
Епупе Serial No.
e.g.
498NT / 1897 / 61294
--
ENGINE ТУРЕ
4—Number Ы cylinders
98— Воге in millimetres
ENGINE BUILD LIST N0.
ЕО[)Е[\]ТГА[ SERIAL N0,
9803/3200
Issue 1
SERV 1СЕ MANUAL
MACHINE 1DENT1F1CAT1ON
Р 'ЕАТАА1[\ —/5 build
JСВ MACHINE
сЕААВОХ
SERIAL NO.
SERIAL NO.
ТОН 01)Е
Е АТЕ А
СО
SERIAL NO.
Е
АХI
SERIAL NO.
ENciN1E
О
SERIAL NO.
JСВ N1аснгпе Serial No.
e.g.
3D 111
129564/5
MACHINE ТУРЕ АГО МАНК
1
SEQUENTIAL SERIAL NO
125001-199999-М К111 гапе
В1)110 1DENT1F1CAT10N
/5 Тогсе Сопегег
Engine Serial Nо.
е.9.
498NТ /
2058
/
64878
e.g.
12731
1078
/
1
Е NС1N ЕТУРЕ
4 - Number Ы cylinders
98 - Воге in millimetres
ЕГС1 Г\ Е В1)110 115Т NO.
SEQUENTIAL SERIAL
О.
СеагЬох Serial No.
/
В1Л 10 115Т NO.
BU11_D ОДТЕ
Month апд уеаг
SEQUENTIAL SERIAL NO.
Оег yearly period
Torque Сопыегнег Serial No.
SEQUENTIAL SERIAL NO.
АхIе Serial No.
SEQUENTIAL SERIAL NO.
9803/3200
lssue 1
1
1
САЙЕ AND 6АЕЕТУ
Contents
Contents
9803/3200
Component Removal
2-1
Нoses and Рре5
3-1
Dismantling and АеглЫу
4-1
Вearings
5-1
Pressure Testing
6-1
Suction Strainers
6-1
Training
7-1
1
1
САЙЕ АГЮ ЗАРЕТУ
2-1
2-1
COMPONENT
REMOVAL
есоге а11 moving раг1 Ы the
machine to prevent inadvertent
actions Ьу other personnel
causing dangerous movement
and possible injury.
Рог ехатр1 е: Always set
buckets and shovels оп the
ground or оп adequate supports
before work is commenced.
еег work beneath а machine
unless it is standing оп hard
ground,preferably сопсгее or
tarmacadam. 1f а machine is
lifted to improve accessibility,
aways р1 асе substantial
supports under the main frame
or track frame before work is
commenced.
ir е
о 9►`о jC~
~w.
~'
о~ л
е rёё,
Always check lifting equipment,
slings, chains etc. before
components аге hoisted. Always
use equipment which is
adequate ог the оЬ in hand.
9803/3200
1
е1
САЕЕ AND АЕЕТУ
3-1
1
3-1
НО6ЕЗ AND РIРЕ6
Адау it Ыanking plugs
whenever hoses or pipes are
д isconnected. Serious сагпае
сап occur if dirt or abrasive
material еп1ег the hydraulic
уегл.
Ае the digging equipment оп
the ground, ор the еппе апс
орегае а11 сопго1 levers to vent
апу residual pressure гогп the
hydraulic circuit before hoses
or pipes are disconnected. This
minimises the chance Ы injury
гогп spurting он
hen а
connection is ioosened.
►
4о
Те
e 1еглрега 1 ге Ы асасеп
pipework апд соглропеп1 with
the hand prior to disconnecting
а hose or pipe. 1f the он is
considered too hot for safety,
a11ow sufficient игле for it 1о
соо1 before а connection is
loosened.
9803/3200
1
САЕЕ АГ\1О АЕЕТУ
Аепе Ьо5е5 if апу Ы the following faults
are found.
1 End fitting damaged or leaking.
are dented or crushed, оП
1f hose е1 Ьо
flow is restricted and the speed а which
the service operates wi11 Ье reduced.
сап completely block
Вад I у crushed е1 Ьо
the оН flow and prevent the service from
орега i п
2 Outer covering chafed or cut and wire
reinforcing exposed.
1f а hose remains in service in this condition
аег wi11 веер into the internal wire
reinforcing and cause сопсеа1ед corrosion
and consequent weakening Ы the hose
structure. This тау not Ье аррагеп until
the hose subsequently fails.
3 Outer covering ballooning 1оса11у.
This is caused Ьу failure Ы the hose
structure which allows hydraulic он o
leak internally. ТЬе оН eventually огсеs
its way into the outer layers Ы the Ьо5е'5
construction апд ultimately саые the
hose to Ьыг .
4 Evidence Ы kinking or crushing оп flexiЫe
раг Ы hose.
1f а hose is deformed ра its designed
limits, damage to the internal structure is
caused. This сап геы1 in restriction Ы оН
flow or 1оса1 weakening Ы the hose.
5 Armouring embedded in outer cover.
1f armouring is deformed, internal damage
similar 1о that caused Ьу сгыЫпд or
kinking wiII almost certainly have occured.
6 End fittings displaced.
1f the swaged sleeve Ы ап епд fitting
арреаг o have то 'ед from its original
position, there is а possibility that partial
failure has occured in the агеа where the
51ее \ е grips the flexible раг Ы the hose.
Ultimately the епд fitting wi11 ри11 оН.
9803/3200
1
1
САЙЕ AND ЗАРЕТУ
3-3
3-3
Аепе pipes if апу Ы the
following faults аге found.
1 Сопе damaged ог
1оге .
2 Thread damaged.
3 End fittings аглае ог
leaking.
4 Outer surfaces damaged ог
severely corroded.
k Сам"~
Unsupported hoses ог pipes
must по ouch each other ог
аасеп соглропеп ог chafing
wi11 Ье caused.
у'
::
Loosely соппес each епс ,
settle the hose ог pipe into
position апд tighten connections
Clamps should Ье tightened
sufficiently to retain the hose
ог pipe without causing crushing.
9803/3200
1
1
САЙЕ АГ\Ю ЗАРЕТУ
3-4
1
3-4
1f а hose is connected to
moving согпропеп1, the
согпропеп hould Ье то iед
о"ег the fu11 extent Ы their
travel to check that the ое
does not foul а
is bent.
б
Ное ггш пе"ег Ье twisted
when fitting.
9803/3200
lssue 1
1
САГЕ АПIД 5АРЕТУ
4-1
4-1
oisMANTLING
Et АЗЗЕМВIУ
Thoroughly сеап the exterior
Ы а11 components Ьеоге
дismaпtling. 1f dismantling is
commenced without removing
а component from the machine,
cleanliness is доиЬ1у important
since the service life о а
compoпent is drastically
reduced if dirt or abrasive
гпа [ег is not ехс1 идед а а11
times.
(,; ёi
вв
iё sti
Sometimes components are
дisтапt1ед in adverse
conditions without workshop
facilities being available. 1f
this is necessary, suitable
precautions must Ье taken ю
ргеУеп [ dust ап
irt settling
оп internal раг1, particularly
оп oiled surfaces 4 еге и
i11
Ье retained ап coпtaminate
апу пе оП with which а
component is filled.
с.
1
~
аш нсаге:
Select cleaning ауеп[ and
solvents with саге. The
following are гесоепе ;
Petrol, alcohol, methylate
spirits ап сагЬоп tetrachloride.
А11 these о1 епб еарогае а
гоогп temperature ап
о not
1еае residue.
WA R П11 N G : So lvent type
с1еапег are dangerous when
used in а confined агеа. Avoid
inhalation Ы the vapour or
сопас[ with the skin. Оо not
use пеаг а nake 1 агпе.
9803/3200
1
4-2
САНЕ AГ1D ЗАЕЕТУ
1
4-2
Trichlorethylene ог paint
thinners must not Ье used in
the presence Ы seals and 'О'
rings because they сап severely
damage сег1ап 1уре of rubber.
Еепе 'О' rings, seals and
gaskets, regardless Ы condition,
whenever they are disturbed,
unless instructed otherwise.
Lightly соа 'О rings and
gasket
Г[И hydraulic оН
before fitting, unless
instructed otherwise.
Соа askets with а suitable
jointing solution before fitting,
unless instructed otherwise.
Ргоргеагу solutions which
are compatible with the various
oils used Ьу JCB are given and
are referred 1о where appropriate.
9803/3200
lssue 1
1
САЕЕ АND ЗАЕЕТУ
5-1
1
5-1
6EАFi1NGS
ЕЕМО\1А1
Оо not remove bearings unless
they are to Ье renewed ( ее
1nspection) or unless unavoidable in а dismantlin еср]епсе.
Whenever possible, use а
suitable puller or ехгас1ог to
minimise risk Ы damage to both
the bearing and adjacent раг .
Кеер bearings with loose rings,
ba11s or го11ег а matched
assemblies; they are selectively
assembled and раг до not
interchange from опе bearing
to another.
1NSPECTION
Chec Ъа the bearing has had
атр1 е lubrication and that the
Iubricant has not Ьееп
contam i nated.
Check for discoloration and
signs Ы overheating.
Check the bearing for
excessive с1вагапсе and the
сане ог еаг, cracks and
scuffing. If in doubt regarding
the clearance, compare this
with ап identical пе bearing.
ОТЕ. Journal bearings are
graded Ьу the internal clearance
when пе , this is indicated Ьу
опе, two or three feint circles
marked оп опе ring. Епге
that both Ьеагп are Ы the
агпе grade when comparing
пе
ith о iд.
9803/3200
1
САЙЕ AND
дЕЕТУ
Check the finish Ы the
locating
гасе А & В.
They тау have been lightly
marked оп аегпЫу Ы hould
по Ье polished. Polishing
indicates that the ring hes been
turning relative to its seating—
this is confirmed if the seating
is а1 о polished.
1f bearing rings have Ьееп
turning, the mating раг must
Ье either renewed or built ир
апд machined to their original
sizes.
Check the bearing tracks,
rollers or Ьа!1 for surface
imperfections.
Аепе the пее 1 е roller bearings
if:1 Rollers, саде or rings аге
damaged.
2 Rollers fa11 from са9е.
3 Rollers сап Ье то~ед
noticeably out оТ alignment.
4 The shaft surface is
damaged or огп. 1f this
has occured, shaft particles
wi11 have entered the bearing
and Ьес1 ыегтЁ early failure
is а1 гло inevitable.
1f а bearing is judged to Ье fit
for further еЛсе, it should Ье
carefully washed in clean
solvent and immersed in clean
оП for temporary огаде.
9803/3200
lssue 1
1
САЕЕ АND ЗАЕЕТУ
5-3
FITTI1VG
Bearings are normally а press
fit оп rotating раг1 and а
sliding fit оп static согпропеп1
such а housings.
\1епе'1ег possible fit the
bearing to the rotating раг
first.
Jse а tubular drift or press tool
but ensure that it does по
сопас the ring нр since
damage тау Ье caused.
Bearing оп shaft—Exert
еПог against the inner ring.
Bearing in housing—Exert
е [ог against the outer
ring.
1f а press is по available when
fitting large bearings, it is
рге[егаЫе to either heat the
bearing in hot оП or Ю Неа
the housing rather than use а
large Нагтгпег and drift.
Check that the bearing аЫ
squarely against the locating
face.
Апу peculiarities regarding the
fitting Ы specific bearings are
covered in the арргоргае
аегтЬ1 у sequence.
9803/3200
5-3
1
САВЕ AND ЗАFЕТУ
б-1
I
1
б—'1
851 Р' ТЕ5Т1! Ю
Ensure that there аге по 1еаб
from hoses ог pipework Ьеоге
ргеввиге testing is carried out.
Readings should Ье taken
using а gauge of adequate
pressure гапде for the test,
either liquid filled ог fitted with
а restrictor ог датрег.
Before adjusting а ',а1',е,
unscrew the adjusting screw
1'о ог three turns ю release
апу югаррес dirt.
SUCTION 8ТВА1ГЕ
Thoroughly wash suction
strainers in petrol ог сагЬоп
tetrachloride, using а soft
brush апд air blasting if
necessa гу.
Remove а11 1гасе Ы gummy
deposit. 1t should Ье possible
ю see light through the глеи.
9803/3200
Issue 1
CARE АГЮ ЗАЕЕТУ
1
7-1
7-1
ТВА11111 Ю
Training соге suitable ог
а11 гасеб Ы personnel are held
а ге91аг intervals. Details are
readily available from СВ
еМсе.
9803/3200
2
2
тЕснNIСАL ОАтА
Сопеп 5
Сопеп
9803/3200
Attachments
1-1
В rakes
1-1
Capacities
1-2
Electrical у5 егп
1-3
Е пд I пе
1-3
Нуд rаи 1 ics
1-4
Steering
1-4
Transmission
1-5
Тугез
1-7
Тогсце Settings
2-1
lssue 3
2
2
тЕснNIСАL ОАтА
1-1
1-1
АТТАСНМЕГi Т$
1СВ Roadbreaker
Ритр F1ow Rate а 2000 rev/min.
апд его pressure. (Hamworthy апд Commercial)
Relief Va1ve Settings
—System Relief Уа1 е (Hamworthy)
—8уЁегп Relief Va1ve with combined Dipper
Mounted А Ёас iгтiеп1 (Parker Hannifin)
—Component Relief Уа1 е ([.Н. апс R.H.)
45 litres/min.
10 1)К Ga1/min.
12 US Ga1/min.
138 Ьаг
141 kgf/ст2
2000 1bf/in2
127 Ьаг
103 Ьаг
130 kgf/ст2
105 kgf/ст2
1845 1bf/in2
1500 1bf/in2
1СВ Extending Dipper ]СВ Jaw апд ]СВ Powerbreaker
Ритр Е1о' Rate а 2000 rev/min. апд его
pressure. (Commercial).
45 litres/min.
Relief Уа1 е Settings. (Parker Hannifin)
127 Ьаг
10 1) К Ga1/min.
130 kgf/ст2
12 US Ga1/min.
1845 1bf/in2
Hydraulic Power Take-off
СЗеатЬох Ratio
Output Shaft Diameter
3:1
35тт.
1.375in.
6 splines ю В81495/8АЕ ]718с
F1ow to motor а 1800 engine ге /гтйп. to give
Р.Т.О. реес Ы 530-550 rev/min.
100 litres/min.
22 1)К Ga1/min.
26.5 US Ga1/min.
*ВАКЕ$
Туре
Diameter to т/с по. 129502
from т/с по. 129503
—с гу
—он immersed (from т/с по. 138622/5)
Орегангоп — Мапиа1 апд /3 build
—/5 build
Multiplate disc unit, mounted inboard оп each геаг шнее1
drive shaft.
165тт. х 89тт. (6.5in. х 3.5in.)
178тт. х 102тт. (7in. х 4in.)
Nominal 200тт. (8in.) dia.
Ву оо ог hand via mechanical linkage.
Ву оо ia hydraulics
Parking Brake—/5 build оп1у
Туре
Diameter
Operation
9803 /3200
Disc unit mounted оп 9еагЬох out put shaft
279тт. (11in.)
[еег апд саЫе.
lssue 5'
2
2
ТЕстiсА1ОАТА
1-2
1-2
САРАС1Т1ЕЗ
1itres
1К Ga1
US Ga1
Non-Ьа1апсед Engines-Stee1 Sump
-А11оу Sump
ENGINE О11.-/5 build
9.б
11.0
11.0
11.5
9.1
2.1
2.4
2.4
2.5
2.0
2.5
2.8
2.8
3.0
2.4
СООЫГЮ ЗУЗТЕМ
13.6
3.0
3.6
TORQUE CONVERTER-/3 build
-/5 build
6ЕАРВОХ-10 рееd
-9 рее (Synchro)
20.4
11.0
50.0
56.8
4.5
2.4
11.0
12.5
5.4
2.9
13.2
2.55
57.0
25.0
29.5
68.0
0.56
12.5
5.5
б.5
15.0
0.67
15.0
6.6
7.8
18.0
4.5
1.0
1.2
173.0
159.0
195.0
205.0
177.0
38.0
35.0
43.0
45.0
39.0
45.6
42.0
51.6
54.0
46.8
ENGINE О1L-Мапиа1 ап /3 build
Ва1 апсед Engines - Stee1 Sump
- А11оу Sump
-/5 build
-with hydraulic lift
*О
' Ь Dnу Вгае
-/5 build with Oi1 lmmersed 6rakes
уЕ АХЕ-/5 Ьцс
Е11Е1 ТАГК
8[ Е\Р/ ACTUATOR
20,3,ЗС,3О
HYDRAULIC ЗУЗТЕМ-20,3
-2О83С8
-ЭС
-30
-700
15.0
Гое: The following original ес111 ргпеп engine ,еге fitted with Ьа1 апсег units оп production:
38Т0 engine гогл serial по. 44287
АН 4/98Г\ Т engines.
Balancers тау have Ьееп fitted in service to other engines. Stee1 апд а11оу sumps have Ьееп fitted intermittently.
9803/3200
lssue 6"
2
TECHNICAL ОАТА
1-3
1-3
ELECTRICAL 8У8ТЕПП
Туре
Ва1 егу
А1 егпаог То Engine No. 4/98Г\ Т 2724
Егогп Engine No. 4/98Г\ Т 2725
Sealed
Dynamo
То Machine No. 61767
$ агег Моног
Light ВЫЬз
12 ',о1 negative earth
12 volt
128 amplh
Lucas 18ACR
АС De1co ОГ\460
CAV АС5НЕВ
Lucas С40
Lucas М50
З6/36W
Headlights
Working Lights
Side Lights
еаг Lights
1 ndicators
lnstruments
lnterior
48W
6W
6/21
21W
2.2W
18W
ЕГЮ1 Е
Маке
Туре
регесес Ьу
$' ер Volume
Воге 38Т0
4/98
Stroke 38TD
4/98
Compression Ratio 38ТГ
4/98
Firing Огдег
Va1ve С1еагапсе (1' о ог со1д)
lnfection Timing
38Т D
4/98 $ В1гп Minimec
4/98 CAV D.P.A.
Engine $реес
Idling
Махгтит Revs.
Махгтит по 1оад Revs
ВLМС 4 Cylinder diesel
З8Т
Identifia Ыe Ьу serial
4/98 Г питЬег prefix.
230in3
3.771itres
100 to 100.2тт.3.937 to 3.9738in.
98 to 98.2тт. 3.8583 to 3.859in.
4.7in.
120тт
125тт.
4.921 in.
17.5: 1
16.8: 1
1,3,4,2
0.013in.
О.33тт.
20° В.Т.О.С.
160 В.Т.О.С.
14° В.Т.О.С.
700-720 rev/min.
2000 rev/min.
2200-2220 rev/min.
Г' ое: Еог fи11 details, геfег to Engine Service Мапиа1 ( Юн Service PuЫication мо. 980311200).
9803/3200
lssue 4
2
тЕснпIесАL оАтА
1-4
1-4
НУ®RAULICS
Ритр flow гае а 2000 rev/min. апд maximum pressure.
Ритр Туре
Litres/min.
МасЫпе
т/с Го.
2D,2DS,3
Plessey Сеаг
То 100611
102
From 100612 Hamworthy Сеаг 93
Hamworthy Gear 126.1
3С,3С~,30,700
1) К Ga1/min.
US GaI/min.
22.5
20.5
27.75
27
24.6
33.3
Note: 2О,2О апд 3 machines fitted with ]СВ Roadbreaker ог Hydraulic Роег Тае-оН ле the ЭС уре main
ритр.
Relief Vаiые Operating Рге 5цге5
*Ьаг
Main Relief '/а!уе ( М.Р.У.)
Auxiliary Relief %/ у $ (А.А.\й.)
Н агл ог11у (iое1 апд Е хсаУаог)
S1ew Cylinders 127тт. (5in.) оп1у
Cessna Shovel Лр
Cessna Shovel С1ат
ТЕ Е
kgf/ст2
1bf/in2
138
141
2000
186
152
207
190
191
155
210
193
2700
2200
3000
2750
С
System Туре
Ритр
Control Unit
Fu11y Hydrostatic
Plessey Сеаг Туре
Plessey уапе Туре
Daпfoss Orbitrol
*Мах. flow to Control Unit
—Мапиа1 Clutch machines
—/3 ЬгЛ
o т/с 131319
from т/с 131320
4 U К ga1/min.
18 litres/min.
4.8 US ga1/min.
9.6-10.2 US да1/min.
36-38 1 itres/min. 8-8.5 U К ga1/min.
16.3-19.1 litres/тгп 3.5-4.2 1) К ga1/min. 4.3-5 US ga1/min.
*Relief Va1ve Operating Pressure
о т/с по. 131319
from т/с по. 131320
СаглЬег Апде
Сазог Ang1e
Тое-in
121 Ьаг
117-124 Ьаг
5°
2°
1.6тт. (1/16in.)
9803/3200
123 kgf/ст2
120-127 kgf/ст2
1750 1bf/in2
1700-1800 1bf/in2
1
е4
TECHNICAL ОАТА
1-5
1-5
ТВАГ18М1 ЗЗi ОГ
Мапиа1 Clutch Machines
Clutch
Single Огу Р1 ае
Gear Ratios
to т/с по. 130301
from т/с по. 130302
10 Еогаг -2 Reverse
9 Еогаг -3 Reverse (Synchromesh)
330тт. (13in.) dia.
Torque Сопыегtег Machines —/З build
Gear Ratios
Direction Controt
Charging Ритр
*Е1
at 2000 еп9. rev/min.
4 Еогаг — 4 Reverse
Forward/Reverse Clutch Pack
Plessey Gear Туре
ир е гя{с 131319'
36-38 litres/min.
8-8.5 1)К ga1/min.
frotn т/с 131320
2 6 4,е /~I тп.
5 1К gai/птiп.
ОП Temperature
—Normal
— Мах. Intermittent
Converter Out Pressure
Clutch Oi1 Pressure
Sta11 Test $рее
90-100°С
120°С
0.7-1.7 Ьаг
8.2-11.0 Ьаг
1780 engine rev/min.
0.7-1.8 kgf/ст2
8.4-11.2 kgf/ст2
9.б-10.2 US ga1/min.
10-25 1bf/in2
120-160 1bf/in2
Torque Сопыегнег Machines—/5 build
TORQUECONVERTER
Diameter
Sta11 Torque Ratio
Torque Absorption а
Converter Pressure
a11
279тт. (11 п.)
2.2 : 1
210 Г\ гл (155 Ы ft) а 1700 rev/min.
kgf/ст2
Ваг
1bf/in2
in —
1000 rev/min.
2000 rev/min.
4.1-6.2
0.7-2.1
4,2-6.3
10—З0
60-90
Out —
1000 rev/min.
2000 rev/min.
0-1.3
0.7-2.1
0-1.4
0.7-2.1
0-20
10-30
9803/3200
0.7-2.1
lssue 2"
2
2
тЕснNIСАL оАтА
TRANSMISSION Continued
Н1. ТТ1Е TRANSMISSION
Direction Сопго1
Ratios
Forward/Reverse Clutch Рас
1.0 : 1 Forward
1.1 : 1
ееге
Рге55цге$
Main Line 1000 ге /глп.
2000 rev/min.
Forward Clutch 1000 rev/min.
2000 rev/min.
Рееге Clutch 1ооо rev/min.
2000 rev/min.
Е1о'г
Ваг
kgf/ст2
1bf/in2
6.9-8.9
8.6-10.7
7.0-9.1
8.8-10.9
100-130
125-155
6.2-7.9
7.6-10.0
6.3-8.1
7.7-10.1
110-145
6.9-8.9
8.3-10.3
7.0-9.1
8.4-10.5
100-130
120-150
1/min.
1) К ga1/min.
US ga1/min.
90-115
а1е$
Cooler а 50°С
800 rev/min.
4.9-6.4
1.08-1.4
1.3-1.7
1000 rev/min.
2000 rev/min.
8.6-9.1
16.3-17.0
1.9-2.0
3.6-3.75
2.3-2.4
4.3-4.5
Cooler а 100°С
800 ге /глп.
1000 rev/тгп.
2000 rev/min.
Ритр -
6.4-6.8
7.5-8.3
19.5-20.4
1.4-1.5
1.66-1.83
4.3-4.5
1.7-1.8
2.0-2.2
5.2-5.4
11.7
29.1
2.58
3.1
7.7
1 ооо rev/min.
2000 ге .'/глп.
6.4
3ЕАРВОХ
Ratios First
есопс1
Third
Fourth
5.55: 1
2.84 : 1
1.64: 1
1.00: 1
ЭРУЕ АХ1Е
Ratio -
9803/3200
18.3: 1
lssue 1
2
2
тЕснгиIСАL ОАтА
1-7
1-7
ТУ i ЕЗ
Size
20,203
Pressure
Ьаг
kgf/ст2
1bf/in 2
58
7.50 х 16 х 10
4.00
4.08
Standard геаг
14.9/13 х 28 х 8
1.79
1.82
26
Optional Front - Vredestein
- Other Makes
9.00 х 16 х 10
9.00 х 16 х 10
10.5/80 х 18 х 10
16.9/14 х 28 х 8
3.93
3.44
4.62
1.65
4.00
3.51
4.71
1.68
57
50
67
24
Ьаг
kgf/ст2
1bf/in 2
3.93
3.44
4.00
3.51
1.68
* Standard гоп
Optional геаг
3, эс, 3Сз
Standard Front - Vredestein
- Other Makes
Standard геаг
Optional гоп
Optional геаг
9.00 х 16 х 10
9.00 х 16 х 10
16.9/14 х 28 х 8
10.50 х 16 х 12
10.50/80 х 18 х 10
12.00 х 18 х 10
12.00 х 18 х 12
4.00
57
50
24
64
67
40
57
* 13.0/65 х 18 х 12
3.59
3.67
52
16.9/14 х 28 х 10
18.4/15 х 26 х 8
18.4/15 х 26 х 12
2.07
1.38
2.14
2.10
1.40
2.1.8
З0
20
З1
Ьаг
kgf/ст2
1bf/in 2
12.00 х 18 х 10
12.0/75 х 18 х 12
18.4/15 х 26 х 8
*13.0/65 х 18 х 12
2.76
2.90
1.38
3.59
2.80
2.95
1.40
3.67
40
42
20
52
16.0 х 19.5 х 10
18.4/15 х 26 х 12
2.07
2.14
2.10
2.18
31
Ьаг
kgf/ст2
1bf/in 2
12.00 х 18 х 10
12.00 х 18 х 12
18.40 х 26 х 12
2.76
3.93
2.14
2.81
4.00
2.18
40
31
13.0/65 х 18 х 12
3.59
3.67
52
1.65
4.41
4.62
2.76
3.93
4.50
4.71
2.80
30
Standard гог t
ОЕ
Standard геаг
Optional гог t
Optional геаг
30
700
Standard гопt
ОR
Standard геаг
i`Optional гог t
57
* SPECIFICTYRES FOR MACHINE OPTIONS
Machine Option
эс
.1СВ Powerbreaker
1СВ Extending Dipper
.ЗСВ 1а "
3
.зсв 1а "
2D
.ЗСВ 6 in1 Clamshovel
980313200
Туге
Front: а а~а i1аЫе ог
standard machine
Rear: 18.4/15 х 26 х 12
Front: 9.00 х 16 х 10
Rear: 16.9/14 х 28 х 8
Issue 2*
7
TECHN 1СА[ ВАТА
2-1
2-1
ТОйО1)Е SETTINGS
[]5е only where Но torque setting is specified in the text. Values аге ог гу threads ап тау Ье
within three рег сеп Ы the figures stated. Еог lubricated threads the values should Ье АЕО1СЕО
Ьу опе third.
UN F Grade '5' Во11
Во Size
in.
( тт.)
1/4
5/16
3/8
7/16
1/2
9/ 16
5/8
3/4
7/8
1
1.1/4
1.1/2
Hexagon(А/F)
in.
(6.3)
(7.9)
(9.5)
(11.1)
(12.7)
(14.3)
(15.9)
(19.0)
(22.2)
(25.4)
(31.7)
(38.1)
7/16
1/2
9/16
5/8
3/4
13/16
15/16
1.1/8
1.5/16
1.1/2
1.7/8
2.1/4
Nm.
Torque Settings
kgf т
1bf ft
14
1.4
10
2в
2.в
2о
49
78
117
170
238
407
650
970
1940
3390
5.0
8.0
12.0
17.3
24.3
41.5
66.3
99.0
198.0
345.0
36
58
87
125
175
300
480
715
1430
2500
Metric Grade 8.8 Во11
Во11 Size
in.
(тт.)
м5
М6
М8
М 10
М 12
М 16
М20
М24
М30
М36
(5)
(6)
(в)
(10)
(12)
(16)
(20)
(24)
(30)
(36)
9803/3200
Нехадоп (А/F)
in.
в
10
1з
17
19
24
30
36
46
55
N т.
7
12
2в
56
98
244
476
822
1633
2854
Torque Settings
kgf т
о.7
1.2
3.0
5.7
10
25
48
84
166
291
1bf ft
5
9
21
42
72
180
352
607
1205
2105
lssue 2
2
2
тЕснNIСАL оАТА
2-2
2-2
ТОГЮ1Е SETTINGS
Гагл
НОТЕ: Ан
огф. е figures аге 'mean' settings апд тау Ье varied Ьу 3% higher ог lower.
2О,2О ,З,ЗС,ЗС5,3О,7ОО
Sp1it Pin Retained Piston Неа
Piston Rod dia
in.
тт.
25.4
38.1
50.8
64.0
64.0
76.0
1.0
1.5
2.0
2.5
2.5
3.0
Cylinder Воге
in.
тт.
102
114
127
4.0
4.5
5.0
Piston Неад Nut
Nт
136
420
408
522
780
1051
kgf т
13.8
42.9
41.5
53.2
79.5
107.2
Cylinder End Bolts
1bf ft
Nт
kgf т
1bf ft
100
310
300
385
575
775
342
34.9
252
*1осе Retained Piston Неа
Piston Rod dia.
in.
тт.
Cylinder Воге
in.
тт.
63.5
127
2.5
5.0
гТ]
408
Piston Неад Nut
kgf т
1bf ft
41
Cylinder Еп Воб
Nт
kgf т
1bf ft
300
S1ew Actuator
Piston Неад Nuts
Cylinder ВоКб
9803/3200
42ОГ\ гл
373Nm
42.9 kgf т
38.0 kgf т
310 Ь ft
275 1bf ft
Issue 2"
3
3
ROUTINE МА1 ТЕАСЕ
Contents
Contents
Lubricants
1-1
Ноигтенег
2-1
Sегыгсе Schedule
2-2
Grease Points
Loader
Excavator
Extending Dipper
Ритр Drive апд Сго
Егоп АхIе
Ргор Shaft / 5Bui1d
Powerbreaker
Engine
СеагЬои
haft
3-1
3-2
3-3
3-4
3-5
3—б
10-1
Он
Oi1 Filter
Fue1 System—Simms Minimec (in line)
—САУ ОРА ( Аыагу)
ир to eng. по. 35216
from eng. по. 35217
Fue1 Filter
Sedimenter Во 1
Fue1 Lift Ритр
Fue1 lnjection Ритр
Fue1 песогs
Cooling уегп
Рап Ве1
Air Filter to т/с по. 129342
from т/с по. 129343
4-1
4-2
4-3
ОН 1ее1
Torque Converter
Torque Converter
Oi1 [ е~е1/5 Bui1d
Torque Converter
Torque Converter
5-1
5-2
5-3
5-4
5-5
5—б
Он Leve1
ОН Filter
Он [е~е1/5 Bui1d
Он Filter/5 Build
4-4
4-5
4—б
4-7
4-8
4-9
4-10
4-11
4-12
4-14
4-15
Drive Аиде
Oi1 1е~е1/5 Bui1d
5-7
Clutch
Adjustment
б-1
Adjustment—Foot Brake to т/с по. 129502
Adjustment—Handbrake to т/с по. 129502
Adjustment—from т/с по. 129503 (Skid ВЫс1)
Adjustment апд F1uid [ ее1 — Service Brake /5 Bui1d
Adjustment—Parkiпg Brake/5 Build
7-1
7-2
7-3
7-4
7-5
Hydraulics
F1uid [ ее1
Filter
Main Suction Strainer
Steering Ритр Strainer
8-1
8-2
8-3
8-4
Electrics
Сопго1 Вох
Battery
Неад1атр Adjustment
9-1
9-2
9-3
9-4
Grease Points апд Torque Settings
Filter
10-1
10-2
* Brakes
Precautions
Powerbreaker
9803/3200
1ззе 7"
З
11)Вй IСАГ\iТЗ
Вео ' —1 deg С
(30 deg F)
—1 to 27 deg С
(30 to 81 deg F)
Above 27 deg С
(81 deg F)
ЕГЮ1 Г\ Е
1NJECT10 П1 Р[ МР (1п line)
Mobi1 Delvac
.ЗСВ
рег Х
Universal (20W20)
ог Mobi1 Delvac 1320
Mobi1 Delvac
ТОНО[ Е CONVERTER/SHUTTLE
Mobi1 Delvac 1310
СЕААВОХ/F1NAL DRIVE10 реес
4 реес (/3 build)
9 реес (synchro)
Mobilube Н090
Mobilube Н090
СВ Super Х Universal (20W20) ог Mobi1 Delvac 1320
4
ЗЕАНВОХ
1310
реес (/5 build)
DRIVE АХ [Е (/5 build) —
То machine по. 138621/5 (Dry brakes)
From machine по. 138622/5 (Oi1-immersed
1330
.]СВ Super Х Universal (20W20) ог Mobi1 Delvac 1320
.]СВ
рег Х Universal (20W20) ог Mobi1 Delvac 1320
.ЗСВ Special аеаг Oi1
brakes)
ВААКЕ У~ТЕ1И (/5 build) —
То machine по. 138621/5 (Dry brakes)
From machine по. 138622/5 (Oi1-immersed
brakes).
Mobi1 Hydraulic Вгае F1uid 550
Be1ow —20 deg С (-4 deg F) Mobi1 ОТЕ 11
Above —20 deg С (-4 deg F) .ЗСВ 'Special' Hydraulic F1uid
CAUTION: 1 Е ОР 1NCORRECT ВРАКЕ FLU1D W1LL СА1 Е
[Е'1]1Г\К3 АСТ[АТОА
ЕА 1О1 ОАМАЗЕ.
Mobilube Н 090
НУЕЖА[[1С SYSTEM
.ЗСВ 'Special' Hydraulic F1uid
ЗАЕАЕ POINTS
.ЗСВ 'Special' МР[ Згеае ог Mobilgrease Super
Н.Р.Т.О. ЗЕААВОХ
ЮВ Super Х Universal (20W20) ог Mobi1 Delvac 1320
EXTENDING DIPPER
МоЫ! ас Е
СА1 Т1 О :
9803!3200
МоЫ1 ас Е contains 1.53% 1еад. Contaminated materials, e.g. га , contaiпers, ес., should оп1у Ье
disposed Ы in ассогдапсе wit оса' regulations covering the disposal Ы toxic 'ае.
1ббе 7
ROUTINE MAINTENANCE
2-1
2-1
НО1)ЙМЕТЕЙ
Manual апс /3 build machines.
The hourmeter is ю Ье used ю
determine the соггес service intervals.
НОШМЕТЕ
/5 build machines
РОАй'
5
980313200
Е; г
ги 4ТНАЯ
5
km4fi
2а 15 знэ~
ltsua 2
3
3
ROUTINE МА1 ТЕАСЕ
2-2
2-2
SERVICE SCHEDULE
Е егу
Еегу Еегу
Еегу Еегу Еегу
50 100 200 400 800 1600
Ноц
Ноц г
Ног$
Ног
Ног
Hours
Action
Before Starting Engine
Check/Adjust
Tightness wheel nuts
■
Туге pressures
•
Whee1 alignment
Front ах1е adjustment ( о т/с по. 68150)
Brake adjustment
■
■
п
■ и и
•п• ■ п• •
® п• ■ п• • ■
•
Clutch adjustment
п•
•
п•
•
п•
•
п•
•
п•
•
п•
п•
•
•
•
Еап Ье1 adjustment
Air с1еапег hose security
п•
•
п•
•
агег тоtоr, дупато/
alternator brush еаг
Тогяце Сопегег он соо1ег /5 build
■
п•
•
п•
•
п•
1
п•
•
п•
•
•
■
■
C1ean
Drain fuel sedimen
гар апд fuel filter
п
* Fue1 lift ритр
Injectors апд test
п
Air filter vacuator а1~е
• v
• • •
•
■
п• • п• • ■
Ваегу terminals
Change/Adjust
Fue1 filter е1еглеп
п
п•
п
п s
Air с1еапег elements
Va1ve с1еагапсе
1 п1есог ритр оН (1п line ритр оп1у)
•
*П
•
•
•
•
•
•
•
•
151 100/400 hr Dealer Service
Routine Service
9803/3200
lssue7'
3
3
ГО1)ТН\1Е MAINTENANCE
2-3
2-3
SERVICE SCHEDULE
Action
Веоге Starting Engine
Сгеае
АхIе pivot
Ритр drive
Kingpins
А11 pivot pins
Kingpost
Вгае сговв shaft
Clutch bearing
Coolant ритр
Control lever Ьа11 joints
ОН а11 linkages
Propshaft /5 build
* Front hubs (wi
геае nipple)
Check Levels апд Check for Leakage
Slewing actuator он
Engine оП
•
:п]есог ритр он (in-line ритр оп1у)
Engine coolant (Anti-freeze)
СеагЬох он manual and /3 build
Hydraulic fluid
Ваегу electrolyte
Fue
уЁегт
* СеагЬох oi1/5 build
* Drive ах1е oi1/5 build
Brake fluid/5 build
❑
1st 100/400 иг Dealer Service
Routine Service
9803/3200
lssue 5*
3
3
АОУТ1 ГЕ МА1 ТЕАСЕ
2-4
2-4
SERVICE SCHEDULE
Every
DAILY
Every
Every
Every Every Every
50 100 200 400 800 1600
Hours
Hours
Hours
Hours Hours Hours
Action
Аег Starting Engine
Check
Operation Ы electrical
equipment
lnstrument readings
Exhaust (excessive гпо1 е)
Idling speed
* Тогще converter
ОП 1еие1 /3 buiId
Main relie
а1~е pressure
Auxiliary relie
а1~е pressure
Steering relief а1~е pressure
Operation Ы а11 еМсе$
Excavator
Shovel
Transmission
Brakes
Steering
Rams ог Ieaks апд год damage
Engine роег
Мах governed engine speed
Engine ри11ед down speed
■
■
■
г—
■
■п •
п• и
п• ®
•п• ■ п•
п• •
п •
п• •
• п• • п• •
• п• • п• •
• п• • п• •
•п• • пи •
• п•
п• •
п• •
п• •
п• •
*П
•
9803/3200
•
•
•
•
•
•
•
•
•
•
•
•
•
■
■
1st 100/400 hr Dealer Service
Routine Service
Issue 4'
3
3
ROUTINE MAINTENANCE
2-5
2-5
SERVICE бСНЕЕЛ..Е
Every Every Every
Every Every Every
50 100 200 400 8С
Hours Hours Hours Нон г
Нонг5 Нон
Action
After Stopping Engine
С1апде/Асц51
Engine он
Engine он ilter element
t❑
Hydraulic fluid & clean suction strainers
Hydraulic fluid filter change
Torque converter он
Тогс 1]е coп verter он element
СеагЬох он
* АхI е он /5 build
Check
Ное апд pipework
❑■
Tightness Ы ram епд сар
( сге 'ес )
❑•
п•
Engine compression
* Torque converter оН 1е"е1
/5 build
•
*п
❑■
■
1st 100/400 иг Dealer Service
Routine Service
t Steering Ритр Strainer only
9803/3200
lssue 5°
3
АО1Т1 Е MAINTENANCE
3
3-1
3-1
LOADER
СЕЕАбЕ Ан ..
P1VOT P1NS
10 Hours
* Applies 1о bot1i L.H. and R.H.
pivots.
9803/3200
lssue 2*
3
О1Т11\ Е MAINTENANGE
3
3-2
3-2
ЕХСА!
АТОН
СЕЕА$Е А1.1
PIVOT PINS
10 Hours
СНЕСК АСТ1)АТОЕ
50 Но1г5
LEVEL
А
В
Fi11er апд dipstick.
В1 еед-off рре. [еаа9е
тау indicate а еа1 failure.
Note:Do по rease сго rails.
10
26010
9803/3200
lssue 2*
3
ROUTINE MAINTENANCE
3-3
3
3-3
EXTENDING DIPPER
GREASE SLIDING
ЕАСЕЗ
9803/3200
50 Но1]г
1 в8ие 2
3
3
ROUTINE MAINTENANCE
3-4*
#3-4
Р!ЛМР DR1VE
GREASE 1Л\П \1Е 8А1
]О11\!Т8
50 Hours
1
СВОЭЗ ЗНАГТ
GREASE Ан
Р1 VOTS
9803/3200
1е 2*
3
ROUTINE мAINTENANCE
3
3-5
3-5
FRONT АХI
Е
АДJивтмЕNт (ю т/с 68150)
*400 Hours
1
Slacken locknuts А.
2
Fu11y tighten Ьо1 в, then
slacken опе haif turn.
3
Tighten locknuts.
СЙЕА$Е
\НРР[Еб
10 Hours
[\!ОТЕ: When greasing ахiе,
eels апд
raise гоп
turn from lock to
lock to ensure f и11
penetration.
АхIе В —То т/с 68150
АхIе С —From т/с 100000
1о
ввоз1з2оо
1ssue 2''
йО1)ТПЕ MAINTENANCE
3-6
3-6
РГ 0Р8НАЕТ
СЯЕА8Е
9803/3200
50 Ноигв
3
3
RouTINE MAINTENANCE
4-1
4-1
ENGINE О11
СНЕСК LEVEL 10 Hours
ЕЖА11\ &
REFILL
А
Dipstick.
В
Filter сар.
С
Drain p1ug.
200 Hours
2604
9803/,3200
3
3
ВО1. Т1 Г']Е MAINTENANCE
4-2
4-2
ENGINE
О11 FILTER
В Е Г\i Е
ELEMENT
1
200 Hours
Unscrew bolt А, геглое
В.
Ьюду апд element
2
С1 еап а11 metal рагЁ .
3
Ае-аеглЫе with пеу'
е1 еглеп апд seal С.
8глеаг new seal with
он Ьеоге assembly.
2505
9803/3200
З
ROUTINE MAINTENANCE
З
4-3
4-3
ЕГ1С1ГЕ
FUЕL ЗУЗТЕМ
BLEEDING
1f engine fails to аг or
misfires, or if апу раг Ы the
fuel system has Ьееп
disconnected, Ь1 еед system аб
о11об..
1
Slacken screw А.
2
Орегае lift ритр
priming lever until air
гее fuel Лоб from
screw, then re-tighten.
Г\ ое:
1f the lift ритр
priming lever саппо
Ье орегае , turn
engine until lever
сап Ье то"ед.
3
Slacken screws В,
operate lift ритр lever
until air гее fuel flows
[го ггi screws then
re-tighten.
4
Slacken unions С, орел
throttle, push in engine
stop сопго1, operate
starter until air гее fuel
1о
from unions then
re-tighten.
2606
9803/3200
3
Ао1т1 N Е
мА11ТЕ 1А1ис Е
З
4-4
4-4
Е С 1 Г] Е
FUEL ЗУЗТЕМ
BLEEDIIVG
1f engine fails to start or
misfires, or if апу раг1 Ы the
fuel system Ьа Ьееп
disconnected, bleed system аз
fol lows.
1
Slacken union А.
2
Operate lift ритр
priming lever until air
free fuel flows from
screw, then re-tighten.
1Vote: 1f the lift ритр
priming lever cannot
Ье operated, turn
engine until lever
сап Ье тоiед .
3
1 асеп screws В,
operate lift ритр lever
until air free fuel flows
from сгелё then
re-tighten.
4
1 асеп unions С, ореп
throttle, push in engine
1ор control, operate
1аг1ег until air free fuel
flows from unions then
re-tighten.
3153
9803/3200
lssue 1
З
З
Аоит1N Е МА1NТЕN АN СЕ
4-5
4-5
ENGINE Я. Е1 ЗУЗТЕ1И
*From Engine
о. 35217
В [ЕЕ 01 1\ С
1f engine fails 1о 1аг or
misfires, or if апу раг Ы the
fuel уегп has Ьееп
сН 5соппесе , Ь1 еес уегп а
о11о .
1
Slacken screw А.
2
Орегае lift ритр
priming lever until air
гее fuel flows гогп
screw, then re-tighten.
Г\ ое: 1f the lift ритр
priming lever саппо
Ье орегаес , turn
engine until lever
сап Ье то\1ед .
3
Slacken screws В,
operate lift ритр lever
until air гее fuel flows
from screws then
re-tighten.
4
Slacken unions С, орел
throttle, push in engine
ор control, operate
1агег until air гее fuel
flows from unions Ъеп
re-tighten.
9803/3200
1
це 4"
з
ROUTINE МА1 ТЕАСЕ
4-6
3
4-6
ENGINE
Г1$ Е1 FILTER
DRA1N
50 hours.
Drain оН апу аег in д1аз
bowl Ьу turning [ар А.
RENEW
Е1_EMENTS
*400 Hours.
1
Support bowl R while
unscrewing bolt С.
2.
Аето~е bowl апд
element D using а
twisting motion.
З.
АеаззеглЫе using пе
element апд sealing rings.
4.
В1еед the fuel зузегл.
4273
9803/3200
1 ввие 3*
3
ROUTINE MAINTENANCE
4-7
3
4-7
ENGINE FUEL
8ЕО1МЕГ1Т BOWL
DRAIN
50 Hours
Drain off апу аег in д1аб
bowl Ьу turning ар А.
С1ЕАГ
Periodically dismantle.
1
С1атр inlet fuel line to
ргееп 1о Ы fue1.
2
Support bowl В апд
unscrew bolt С.
З
Wash element D in
с1еап fue1.
4
АеаегяЫе in гееге
огдег ensuring дабеб
аге in position апд Ьо1
is по overtightened.
5
Remove fuel line с1атр.
*6
В1еед the fuel system
9803/3200
lssue 3*
3
3
ROUTINE MAINTENANCE
4-8
4-8
ENGINE
FUEL i1i Т PUMP
* CLEAN СА1 Е 400 Hours
1
1пбсге bolt А, геглое
соег and gauze В.
2
Wash gauze with petrol
and а soft brush.
3
Ае-аббеглЫе, tightening
bolt just sufficiently ю
make а sea1.
4
В1еед the fuel system.
2608
9803/3200
lssue 4"
3
3
ROUTINE MAINTENANCE
4-9*
*4-9
ENGINE FUEL
1NJECTION PUMP
СНЕСК 0IL
[Е\/ Е[
50 Hours
DRA1N &
REFILL
200 Hours
А
Drain p1ug.
В
[ ее1 p1ug.
С
Fi11er p1ug.
9803/3200
1
ые 2*
3
ROUTINE MAINTENANCE
4-10
3
4-10
ЕГС1Г\1Е Е1)Е1. 1Г\1 ЕСТОй
CLEAN AND
ЕУ1СЕ
400 Hours
1.
Disconnectfeed pipe А
апд spi11 rail В. Note the
sealing washer С each
side о spi11 rail Ьапо.
2.
Remove the injector
securing bolts D апд the
injector.
3.
С1еап апд test injectors.
(Зее Engine Мапиа1
9803/1200).
4.
Аепе sealing аег Е
when replacing injectors.
5.
Тогое 1дт1еп securing
bolts D (see Technical Data).
9803/3200
lssue 3*
3
3
О1Т11\ Е MAINTENANCE
4-11
4-11
ENGINE
СОО111О $У$ТЕМ
СНЕСК LEVEL 10 Hours
А
Radiator filler сар.
В
Radiator drain ар.
С
Cylinder block drain ар.
D
Expansion bottle.
Warning: Оо not remove
rad iator сар when
бу$1е1т1 is overheated.
Кеер expansion
bottle half fu11.
Тор ир with
аррго рг iаIе
solution Ы
anti-freeze апд
weter.
2611А
ANT1—FREEZE
Адд 0.15 litres
('/4
pint) to соо1ап in expansion tank. А
Anti-freeze
ю radiator (бее аЬ1е).
5 аг ю freeze
25%
3.5 litres 6 1)К pints 7.2 US pints
*_12оС (10° F)
57%
8 litres 13.5 1)К pints 16.2 US pints
*-30°С (-22°F)
9803/3200
lssue 3
3
ЕО1Т1
4-12
3
Е MAINTENANCE
4-12
ENGINE
ГАГ ЕЕСТ
ADJUSTMENI"
1
50 Hours
Рог easier ассебб ю
alternator, unscrew bolts
at А ю remove ап guard
В.
2
Slacken bolts С апд О.
3
Моvе alternator аау
[гогг engine until there
is 13 тт. (0.5 in.) slack
at Е.
*4
Retighten bolts С апдО
tightening bolt С at геаг
Ы alternator 1ast.
*CAUTION: Апу leverage
required ю position alternator
must Ье applied at the drive епд
bracket опIу, using а ооеп
lever.
5
Refit ап guard апд secure.
4274
9803/3200
lssue 3*
ROUTINE MAINTENANCE
4-13
4-13
ENGINE FAN ВЕ~Т
ADJUSTMENT
* NOTE: Ensure engine is по
running.
Еог easier ассезз to alternator,
unscrew bolts а А to remove
ап guard 6.
Slacken bolts С апд D.
Мо',е alternator аау гогя
engine until there is 13тт.
(0.5in.) slack а Е.
Retighten bolts С апд D
tightening bolt С а геаг
Ы alternator 1ast.
5
Refit fan guard апд secure.
CAUTION: Апу leverage required
to position alternator
must Ье applied а he
drive епд Ьгас1 е опiу,
using а оосеп lever.
9803/3200
‚е 3'
3
АО1)Т1 Е MAINTENANCE
3
4-14
4-14
ENGINE AIR
Г i IТЕ I
То МасЫпе
о. 129342
С[ЕА 1
АС11АТОА
VALVE
50 Ноцгб
RENEW
Е1.ЕМЕГТ
800 Ноцгб
DO NOT disturb filter е1еп1еп $
Ьелееп service intervals unless
the filter warning light shows
гед.
DO 'ЮТ ар ог knock
element
ЕГ\811АЕ seal а С is smeared
with дгеабе апд is seated
соггес 1 у.
СНЕСК tightness Ы induction
hose clips а гед 1аг intervals.
1
Unscrew wing nut А апд
withdraw element.
2
Blow dirt from element
using compressed air а
по тоге than 6.9 Ьаг
(7 kgf/ст2 100 1bf/in2)
З
Check for perforation Ьу
placing а strong light
inside element. Renew if
perforated.
4
Remove апд с1еап
асаог а1~е В.
2673е
9803/3200
lssue 2
ROUTINE MAINTENANCE
4-15
4-15
ЕГЮ1 ГЕ А1R
Е11ТЕЕ
From Machine No. 129343
С1ЕАГ VACUATOR
VAkVE
ЕГ'1Е
50 Hours
МА1 Г
Е1ЕМЕГТ
800 Hours
ЕГ\1 Е" ЗДЕЕТУ
Е1ЕМЕГ\ Т
1600 Hours
DO 0Т disturb filter elements
between service intervals unless
the filter warning light shows гес .
DO NOT ар ог knock element.
NOTE: The аеу element should
оп1у Ье removed а 1600
hours ог if the main
element has been holed.
CAUTION: ВЫоге removing the
аеу element disconnect
the air с1 еапег from the
engine.
1
Unscrew nut А to remove
main element апд nut В to
remove аеу element.
2
В1 о dirt from elements
11$ Г19 compressed air to по
тоге 1 ап 6.9 Ьаг
(7 kgf/ст2; 1001bf/in 2 ).
3
Check for perforation Ьу
placing а гопд light inside
elements. Аепе if
рег{огаес .
5188
9803/3200
Issue 1
ROUTINE MAINTENANCE
5-5
5-5
ТОО1)Е CONVERTER О11 LEVEL
СНЕСК LEVEL DA1LY
DRA1N &
REFILL
800 Ноигт
А
Dipstick/Fi11er
В
Drain plug
Note: Twist dipstick to гегяое.
Check он 1е~е1 immediately
аftег stopping engine.
9803/3200
3
ROUTINE МА1 ТЕТ'АТ'СЕ
5-6
3
5-6
ТОЙОУЕ CONVERTER
О11 Ч1
ТЕЕ
RENEW
ELEMENT
400 НОцг$.
1.
1)п$сге\ bolt А, гегпое Ьоду
апд еегяеп1В.
2.
С1еап а11 гпеа1 раг 5.
З.
Re-assemЫe with пе'',
е1еглеп апд seal С.
9803/3200
lssue 1
3
ROUTINE MAINTENANCE
5-1
3
5-1
GEARBOX О11
СНЕСК LEVEL
ЕЖА1 Г\ &
ГЕЕ11_1.
50 Hours
800 Hours
А
Dipstick.
В
Fi11er p1ug.
С
Drain plug (опе each
side).
9803/3200
lssue 2
3
ROUTINE MAINTENANCE
3
5-2
5-2
TORIUE СО 1ЕйТЕй
О11 LEVEL
СНЕСК LEVEL
10 Hours
Run engine ог two minutes
then with engine idling check
он 1е iе1 (Dipstick А).
О1 А1 Г\ &
REFILL
800 Hours
Drain (Drain plug С) whilst
transmission он 'б hot.
Тор ир оr fi11 (Fi11er сар В)
with transmission fluid (бее
Lubrication Chart).
Caution: DO [\ ОТ ОУЁА —
Е ' 11
980 З/ 3200
1ввие 2
3
ROUTINE MAINTENANCE
5-3
3
5-3
TORQUE CONVERTER
011 FILTER
RENEW
ELEMENT
400 Hours
1
1]п5сге Ьо1 А, гегпое
Ьоду апд е1егпеп В.
2
С1еап а11 metal раг1.
3
Re-assemble with пе'',
element апд еа1 С.
9803/3200
ROUTINE MAINTENANCE
5-4
5-4
сЕАявоХ О11 LEVEL
'СНЕСК LEVEL
50 Hours
When checking он 1е~е1 park machine
оп 1е'е1 ground. Remove fi11/1е~е1 plug
А.
DRA1N &
REFILL
800 Hours
То drain апд refiII, park machine
оп 1е~е1 ground.
1
Remove fi11/1е~е1 plug А апд
drain plug В.
Refit drain plug В.
Refi11 а А.
9803/3200
lssue 2•
3
ROUTINE MAINTENANCE
5-7
3
5-7
НЕАН АХЕЕ О11 LEVEL
'СНЕСК LEVEL 50 Hours
When checking, park machine оп
1е~е1 ground, гегяое Fi11/[е~е1 P1ug
А. Он hould гип гогя ho1e. Тор
ир if песеагу.
ОНА1Г 1 &
REFILL
800 Hours
То drain апд refill, park machine
оп 1е~е1 ground.
1
Негяое FiIi [ее1 P1ug А
апд Drain P1ug (Magnetic) В.
Note: Wipe drain plug В с1еап
before refitting.
2
Refit drain plug В.
3
Refi11 а А.
( ее Lubrication chart)
Note: When filling the ах1е a11ow
time ог the он o drain ра the ах1 е
а1 bearings into the ах1 е агт
before rechecking the 1е~е1 otherwise
а 1о ' 1еие1 wi11 result.
9803/3200
lssue 2
3
3
ROUTINE MAINTENANCE
6-1
6-1
с1итсн
AoaUSTMЕNT
CLUTCH
СР ЕАЗЕ Р
10 Hours
(На1 urn)
Кеер clutch 9геабег filled
with 9геабе (8ее Lubrication
Chartl.
СНЕСК ЕНЕЕ
MOVEMENT 50 Hours
Adjust length Ы го Ю obtain
1'/4in (32 тт) гее то'iеment а clutch реда1.
9803/3200
1
е1
3
ЕО1Т1 Е МА1 ТЕ \]АГ'СЕ
З
7-1
7-1
*ЕООТВ!АКЕ
То МасЫпе No. 129502
СНЕСК
АОЮ3ТМЕГ']Т
50 Hours
СЕЕТ РООТ ВЕАКЕ. Screw
ир nut А to obtain 40тт.
(1'/2in.free глсеглеп оп L.H.
реда1.
1СНТ РООТ ВЕАКЕ.
Adjust until R.H. реда1 Нпе
ир with L.H. реда1 when гее
гло"еглеп is taken ир.
МасЫпе should brake in а
straight line when brake реа1
аге latched 1о9е11ег. 1f machine
pu11s to опе side slightly
increase гее movement оп
реда1 operating that side.
Рог handbrake аЩн 1глеп
ее раде 3 7-2.
2618
9803/3200
lssue 2*
3
3
ROUTINE MAINTENANCE
7-2
7-2
*HANDBRAKE
То Machine
о. 129502
СНЕСК
ADJUSTMENT
50 Ноогв
НОТЕ: The handbrake
adjustment тн в1а1' аув Ье
checked after adjusting
footbrakes.
Set handbrake 1еег оп first
notch Ы ratchet апд
adjust stop А.
Асцб1 clevis В ю remove гее
р1 ау С.
Set angle bracket ю give switch
clearance.
1-2тт
0.04 - 0.08 in.
4435
9803/3200
lssue 2"
3
РО1Т1ГЕ MAINTENANCE
7-3
7-3
В1 АКЕ5
Ггогп Nlachine Го. 129503
*(Skid виг1ав оп1у)
СНЕСК
ADJUSTMENT
50 Hours
Adjust brake linkage ю the
dimensions given Ьеюееп
the clevis pin centres.
ею handbrake stop А ю limit
огаг югае1 Ы handbrake
lever at 2пд notch Ы rack.
Jack геаг wheel off ground апд
tighten each adjusting nut В
until wheel just locks апд then
back nut о 10 flats.
Аоад 1е51 ю check brake
balance backing ОН appropriate
nut, if required, to adjust
balance.
5187
9803/3200
lssue 2•
ROUTINE MAINTENANCE
7-4
7-4
SERVICE ВЯАКЕ$
Check 1е~е1 Dai1y
Remove соуег А, опсге сар В
ап op ир if песеагу to соггесн
1е~е1 mark. DO Г'0Т a11ow fluid to
'ан below'DANGER' mark.
бее lubrication chart 'ог соггес
fluid.
WARNING
1 Е 0F INCORRECT ВАКЕ
FLU1D ‚ Л [[ САО$Е SERIOUS
ОАМАОЕ.
Check Adjustment
Югу Brakes Only)
50 Ноигs
Jack геаг wheels off 9гОопс . Tighten
each adjusting по С until шнее1
just locks ап hen slacken off 1'/х
turns. оа est to check Ьгае
balance. То adjust balance, Ьас off
appropriate по апд ге-test machine.
980313200
Issue 2•
з
7-5
ROUTINE MAINTENANCE
з
7-5
PARKING ВНАКЕ
ADJUSTMENT
Расб should цб ouch the сНбсб аб
а А. Adjust а nut В if required.
Take ир апу саЫе slack а С.
РАО RENEWAL
Renew pads when thickness D Ы
friction material is 3тт. (0.125in.).
Вас off а11 adjustment, slacken пц
Е апд withdraw pads.
lnstaIl пе pads апд adjust.
Caution: The parking brake must
NOT Ье used to б1оу the machine
from travelling speed, otherwise рад
шеаг wi11 Ье excessive. 1п the case Ы
ап егпегдепсу бОр, ие brake pads
should Ье сиеснесн апд, if necessary,
renewed.
4498
980313200
3
ROUTINE МА1 ТЕАСЕ
8-1
3
8-1
*НУОВА'11С FLU1D
LEVEL
СНЕСК[
ЕVЕ[
DRA1N &
REFILL
10 Но1г5
1600 Но1г5
FLUID [ЕУЕ[ Position machine
а hown at А with гоп1 shovel
resting оп ground, Ьоогт гагт
closed and dipper апд bucket
гагт ореп. Тне correct 1е~е1
is then 1 о thirds ир the 1е~е1
indicator tube(early machines)
ог between Ье two indicator
marks а hown at В (later
machines).
Caution: DO NOT run епдпе
with filler сар Е ( ра9е 3 8-2)
removed.
4955
9803/3200
lssue 3
3
3
ЕО1Т1 Г\] Е MAINTENANCE
8-2
8-2
* HYDRAULIC FILTER
RENEW ELEMENT
400 Hours
1
Position гпасЫпе аз а А
with а11 гагпз extended to
preуent syphoning when
filter body Гз removed.
lnstall гагп ргор В Ьеоге
atteпipting to change filter
element.
2
Remove )—Ьо! С, unscrew
through bolt D until filter
body сап Ье withdrawn
approximately 25 тт (1 in).
Г\ ОТЕ: Моге than 5 litres (1 UK
а1) wi11 flow from filter а this
1ае.
3
Remove ЬоИ D апд filter
body, discard element
апд seals.
4
азЬ а11 metal раг .з in с1еап
)СВ `Special' Hydraulic F1uid
5
АеаегпЫе using пе element
апд еа1.
6
Тор ир hydraulic уегл
а Е.
2619С
9803/3200
lssue 2'
3
ROUTINE MAINTENANCE
3
8-3*
*8-3
MA1N SUCTION STRAiNER
CLEAN
1600 Hours
Remove plug А to drain
hydraulic tank.
4.
2.
Unscrew bolts В апд
remove access plate.
З.
Remove strainer С апд
wash in petrol ог сагЬоп
tetrachloride.
NOTE: Т!пгее alternative
ппеЬоб Ы access plate
attachment аге shown а
Е, F апд G. 1f F is used, гепе
sealing washers Н.
1.
Reassemble using Пе \'(
gasket D.
NOTE: If а пе
rainer is
fitted, it should Ье similarly
washed to remove the
protective coating.
9803/3200
1ssue 2*
3
ГО1)Т1 Г'1Е МА1Г1ТЕГ1АГ1СЕ
8-4
3
8-4
9ТЕЕВ1ГЮ Р1$МР STRAINER
С1ЕАГ1
Е1ЕМЕГ1Т
1600 Но1г5.
1
Disconnect апс blank
hose А апд connection В.
2
1f hydraulic fluid is not
drained, unscrew complete
strainer assembly С апд
blank stub pipe D ю avoid
excessive fluid о .
3
1.) псге' Ьо1ю Е апд
remove element F.
4
Wash element in petrol ог
сагЬоп tetrachloride.
НОТЕ: 1f а пе
trainer is
fitted, it should Ье гт 1аг1у
washed to remove the
protective coating.
5
еаегяЫе using пе eal
апд gasket.
СА1)Т1ОГ%: Tighten bolts Е ю
а torque setting Ы 15 20 №f ft
(2.1 2.8 kgf). Overtightening
wi11 cause distortion Ы the епд
plate апд subsequent fluid
еааде.
9803/3200
2GI~4
lssue 1
З
ROUTINE MAINTENANCE
9-1
3
9-1
ELECTRICS
Control Вох
1)р to т/с No. 61767
Fuses
А
В
Flasher Unit
С
Voltage Ае9Ыаог
From т/с No. 61768
D
Fuses
Е
Flasher Unit
ОТЕ: Voltage ге9Ыаог по
required with alternator.
/5 Build
1.
Remove рапе1 F.
2.
Ри11 оП соег G
З.
Fuses аге shown а Н.
9803/3200
lssue 4
3
9-2
3
ROUTINE МА1 ТЕАСЕ
9-2
ВАТТЕВУ
СНЕСК е1 есго1 уе 1е\'е1 is
just аЬо \'е plates. АВО
DISTILLED \ АТЕА ON1_У.
Negative Earth .
Кеер terminals tight апд
с1еап, соа
ith petroleum
je11y to prevent corrosion.
Caution: Affixed lnstructions
гтш 1 Ье adhered to а а11
times.
2624А
9803/3200
i
3
ROUTINE MAINTENANCE
9-3
3
9-3
ELECTRICAL
PRECAUTIONS
NEGATIVE ЕААТН
Е1ЕСТГ !СА1ЗУЗТЕ 1
1
А1 ау соппес negative
ро1 е Ы battery to
ЕААТН.
2
Ьеп eonnecting battery
connect earth 1еад
[АТ.
3
Ьеп disconnecting
battery Disconnect
earth 1еад F 1 RST.
4
1f slaving is песеагу
епге 1Ьа1 Ъе batteries
аге wired in paralle1.
о
Do not connect or
disconnect апу plugs or
саЬ1е
hen engine is
г пп п .
5
Do not weld with
alternator connected,
remove plug and ргоес
[гогл earth. Disconnect
battery earth 1еад.
О1 АЕСААО ОЕ ТНЕЕ
1NSTRUCTIONS WILL
[ЕАО ТО
А [ТЕ А НАТО А
ДАМАС Е.
2625
9803/3200
З
3
ROUTINE MAINTENANCE
9-4
9-4
HEADLAMРЗ
With lamps оп main Ьеагл,
light pattern should а11 as
sh own.
То adjust, slacken nuts А ог В
ап reposition 1атр Ьоу as
required.
30 ins
76,2ст.)
49ft
- (14,9т.)
2626
9803/3200
lssue 1
3
3
ГО1ТП\ Е МА1 ТЕ[\ А[\ СЕ
10-1
10-1
РОУЕйВРЕАКЕй
ЗЕЕА8Е 5ТЕЕЕЗ
3 Ноцг
ЗЕЕАЗЕ АЕ1.
P1VOT P1NS
10 Ног$
СНЕСК ТОК®
8ЕТТ1ГЮ
50 Ног$
Tighten carrier bolts in sequence
Shown.
®
С1еап апд дгеае chuck апд
ее1 when changing steel.
4268
9803/3200
lssue 1
ROUTINE MAINTENANCE
10-2
З
10-2
POWERBREAKER
FILTER
With епфпе running at 1700
rev/min check position Ы
pointer. Change element when
pointer is in position shown.
1.
Drain filter Ьу removing
plug А.
2.
Remove filter Ьо 1 В, spring
С агк element О.
3.
When гe-assemЫing fit bolt Е
о new element апд fit new
seals F апд G. гяеаг new seals
with оН before assemЫing,
9803/3200
Issue 1
АТТАСНМЕГ'Т$
А
Contents
Сопеп1б
ДоиЫе Ритр (Hamworthy)
Dismantling апд AssemЫy То т/с 114049
From т/с 129804
From т/с 131516
ДоиЫе Ритр (Commercial)
Dismantling апд AssemЫy То т/с 129803
Pocke еа1 б
lnspection
2-1
2-3
2-4
F1ow Divider (Hamworthy)
Removal апд Replacement
Dismantling апд AssemЫy
3-1
3-1
F1ow Divider (Kontak)
Removal апд Replacement
3-3
Component Relief \ а1 е
Removal апд Replacement
Dismantling апд AssemЫу
Adjustment
4-1
4-1
4-2
System Relief \ ае
Removal апд Replacement
Dismantling апд AssemЫy
Adjustment
5-1
5-2
5-3
Roadbreaker
Dismantling апд AssemЫy
рее Adjustment
Fau1t Finding
6-1
7-1
7-2
Нозе Ree1
Dismantling апд AssemЫy
8-1
F1ow Divider
Removal апд Replacement
Dismantling апд AssemЫy
9-1
9-1
Control \ а1 е
Removal апд Replacement
Dismantling апд AssemЫy
10-1
10-2
Моог
Removal апд Replacement
Dismantling апд AssemЫy
11-3
ЗСВ ROADBREAKER
HYDRAULIC POWER ТАКЕ-ОЕЕ
СеагЬох
9803/3200
Removal апд Replacement
Dismantling апд AssemЫy
рее Adjustment
Sha
lssue 7
А
АТТАснiиЕNТв
А
Contents
Сол IепIб
DIPPER ATTACHMEIVTS
Control Va1ve (Hamworthy)
Removal апд Replacement
Dismantling апд AssemЫy
14-1
14-2
Control Va1ve (Рагег Hannifin)
Регпоа1 апд Replacement
Dismantling апд AssemЫy
Pressure Testing
14-4
Jaw Bucket
Dismantling апд AssemЫy
15-1
Нагп (Typical)
Dismaп tling апд AssemЫy
16-1
Extending Dipper
Регпоа1 апд Replacement
Dismantling апд Assem Ыy
17-1
17-1
Dismantling апд AssemЫy
Г\Нго9еп Filling
Fault Finding
18-1
18-3
18—ЗА
Dismantling апд AssemЫy
18-4
Dismantling апд AssemЫу
19-1
*Powerbreaker
Filter
14-5
14-7
LOADER ATTACHMEIVTS
С1ат Shovel
9803/3200
lssue 1
А
АТТАСНМ ЕNТ~
1-1
А
1-1
24
9803/3200
1$ е 1
ATTACHMENTS
1-2
1-2
DOUBLE Р1МР—НАМ'ГОЕТНУ
* То МасЫпе Г'о. 114049
Dismantling апд AssemЫy
The numerical sequence оп
the illustration is intended аб
а guide to dismantling.
For assembly the sequence
should Ье reversed.
When Dismantling
Remove агр edges апд Ыгг
гогл shafts to avoid seal сагла9е.
Mark housings апд covers to
ensure correct replacement.
Do not агладе machined
асе Ьу prising these араг1: —
use а бЫ1:4асе Наглглег.
Mark асасеп1: еаг teeth to
ensure correct replacement using
indelible ink or рап1:. Do оо1:
use а сеп1:ге рпсН or similar too1.
Remove bearings оп1у if
requiring replacement, using
service tool part по. ВТ2464.
For removal Ы bearings 9
апд 21, actuator pin 28253
апд collet 33862 wi11 also Ье
req и i red.
ОТЕ: 1п addition to
rер1асетепt дие to еаг,
bearings бНо 1 Ье гепеес
when пеу gears are 1:ес .
When AssemЫing
Renew а11 seals апд 'О' rings
lubricating а11 internal раг1:б
using JCB 'Special' hydraulic fluid.
Renew gears 15 if dimension А
is 1еб than dimension В Ьу
глоге than 0.076тт. (0.003in.)
Renew either pair Ы gears if:
а)
b)
Journal агеа Ы shaft is
pitted or огп in ехсеб Ы
0.025тт. (0.001 in.)
Кеуау, splines or gears are
Ьа 1у огп or cracked.
980313200
па11 bearings in the о11ойп9
positions:—
Item Depth below асе Ы housing
41 & 42 F1ush to 0.05тт (0.002in.)
9 & 21 0.18 to 0.23тт (0.007 to 0.009in.)
Renew еаг plates if scored or
eroded. Trim to size seals 30
апд 35 апд supports 29 апд 34,
using grease to retain them
firmly in the еаг plates.
Fit wear plates 28 апд 33
with single 1о1:б С facing the
gears оп the pressure side Ы
the ритр. Епбге that seals
апд бррог1 are not 1:гарре
between plate апд Ьоге, also
that еаг plate 33 is fu11y
Ногле in the Ьоге ап гее to тоие.
Rene
еа1 bushes 10 апд 22
if scored or сагладес , or if their
Ьогеб ехсеед 22.26тт.
(0.8765in.) diameter.
Fit еаг plates 11 апд 17 with
гесее D, 12.7 х 1,6тт
(0.5 х 0.0625in.) деер facing
the gears оп the pressure side о
the ритр. Ноже Е, 6.Зтт (0.25in.)
dia., in еаг plate 17 wi11 then Ье
оп suction side.
ТНе running clearance Ы gears
15 is 0.064 to 0.1тт (0.0025 to
0.004in.) This is achieved Ьу
addition Ы бНглб 13 апд 16
distributed equally оп each side
спе s
Ы housing 14. Те оа1
Ы shims required is found Ьу adding
the running clearance to dimension
А, then sbtracting dimension В.
A1ign еаг housings апд covers
using marks таре when dismantling.
Тогсые Settings
11:егл
1
Nm
43
kgf т
4.3
3
108
11
25
163
16.6
1 Ы11:
31
80
120
1 ое 2'
А
А
АТТАСНМЕ1\ ТЗ
1-3
1-3
-3
28
6`~i I✓'
4
~J~30
29
19
i
`~---~~
О
11
10
-9
14
15
16
17
5185
9803/3200
1ssue 1
А
АТТАСНМ ЕNТ
А
1-4
1-4
DOUBLE PUMP — НАМИОАТНУ
Егогл Machine Г\ о. 129804
Dismantling апд AssemЫy
The numerical sequence оп
the illustration is intended аз
а guide to dismantling.
Еог assembly the sequence
should Ье reversed.
When Dismantling
Remove sharp edges апд burrs
from shafts to avoid seal damage.
Маг housings апд covers to
ensure соггес replacement.
Do по damage machined асеб
Ьу prising these араг — use а
soft faced hammer.
Маг adjacen еаг teeth to
ensure соггес replacement
using indelible ink ог paint.
Do по use а centre punch ог
similar too1.
Remove bearings only if requiring
replacement, using service оо1
раг по. ВТ2464.
НОТЕ: (n addition to replacement
дие но 'еаг, bearings should Ье
renewed when new gears аге
fitted.
Bearings must fit flush with ог
ир to 0.05тт. (0.002in.)
Ьео'', the housing face.
Renew 'еаг plates if scored ог
егодед. Trim to size seals апд
supports 9, 16, 21 апд 26,
using grease to retain them
firmly in the 'еаг plate.
Fi 'еаг plates 8, 15, 20 апд
25 with single б1 о А, ог
kidney shaped cut out В,
facing the gears оп the pressure
side Ы the ритр.
ОТЕ: Either бу1 е Ы 'еаг plate
тау Ье fitted.
Ensure Ъа seals апд supports
аге по rapped between plate
апд Ьоге, also tha 'еаг plates
15 and 25 аге fu11y home in
their Ьогеб апд аге free to томе.
A1ign housings апд covers using
marks таре when dismantling.
Тогое Settings
ltem
5
18
When AssemЫ ing
Renew а11 seals апд '0' rings
lubricating а11 internal рагб
with JCB 'Special' hydraulic
fluid.
Renew either pairs Ы gears if:
а)
Journal агеа Ы shaft is
pitted ог worn in ехсебб
Ы 0.025тт.(0.001in.)
Ь)
Keyway, splines ог gears
аге Ьад I у 'огп ог cracked.
9803/3200
Nm
163
163
к9 т
16.6
16.6
[Ы ft
120
120
АТТАСН J1ЕNTs
1-5
1-5
26
5555
9803/3200
lssue 1
ATTACHMENTS
А
ОО1 В1Е Р1 МР—НАММОАТНУ
From Machine Го. 131516
Dismantling апд АвветЫу
When Dismantling
Remove bearings оп1у if requiring
replacement, using service tool
раг по. ВТ2464.
ГОТЕ: 1п addition to replacement
дие to
еаг, bearing should Ье
hen пе
гепее
ears аге fitted.
When AssemЫing
Renew either pairs Ы еаг if:
а)
Journal агеа Ы shaft is
pitted ог
огп in ехсе
Ы
0.025тт. (0.001 in.).
Ы
Кеууау, splines ог еаг аге
ЬадIу
огп ог cracked.
Bearings ггш
lush with ог ир
to 0.05тт. (0.002in.) below the
housing face.
Renew
еаг plates if scored ог eroded.
Trim to size seals 5, 9, 18 ап 22 апд
supports 4, 8, 17 апд 21 using grease
to retain them firmly in the еаг plate.
Fit wear plates 3, 7, 16 апд 20 with
single slot А, ог. kidney shaped cut
out В, facing the еаг оп the pressure
side Ы the ритр.
ГОТЕ: Either style Ы
еаг plate
тау Ье fitted.
Ensure that seals апд supports аге
пы trapped between plate апд Ьоге,
also tha
еаг plates 7 апд 20 аге
fu11y home in their Ьоге5 апд аге
free to томе,
Тогще Settings
ltem
Nm
kgf т
lbf ft
1
163
16.6
120
9803/3200
lssue 1
АТТАСНМ Е1\IТЗ
А
А
2-1
12
2-1
14
20
21
18
20
4371
9803/3200
lssue 2
А
ATTACHMENTS
А
2-2
2-2
*
DOUBLE PUMP — COMMERCIAL
То Маспе Го. 129803
Dismantling апд AssemЫy
When Assembling
Те numerical sequence боп
оп the illustration is intended
as а guide to Dismantling.
Аепе ring seals 21 and асе
seals 14 and 7, grease before
fitting. Ensure that ring seals
аге pressed fu11y into bearing
housings, with grooved асеб
towards bearings.
Рог АбеглЫу the sequence
should Ье reversed.
When Dismantling
Аепе росе seals А, ее
Section А раде 2-3
ousings and end соег
Маг
to ensure соггес assembly.
Retain деаг n pairs as
removed.
1nstall деагб tight against thrust
plates before fitting housings.
Тае саге по to distort thrust
plates 5, 9, 12 апд 17.
Tighten nuts 1 evenly in а
diagonal sequence.
Тогще Settings ( Огу threads)
Note position о1 plug 22 if
removed.
1tem Nт
kgf т
Ы ft
1 272 28 200
1)бе ехгасог М 0956 (Service
Too1s) to геглое bearings 20.
Сес а11 соглропеп
see Section А 2-4
9803/3200
or
еаг,
lssue 3*
АТТАСНМЕ1\1Т
2-3
2-3
DOUBLE PUMP—COMMERCIAL
Pocket еа1 Fitting
The following instructions
арр1у when fitting seals to а11
thrust plates.
5.5тт
(32 197.)
Cut 1 о centre seals [гогп the
seal strip to the length о[ the
seal гесебб, as shown at А.
гпеаг with grease Ье[оге
installing.
Р1асе thrust plate, seals face
downwards, оег the bearings
(as at В) апд tap lightly дошп
until сеагапсе Ьеншееп
thrust plate апд housing face
is approximately 0.8тт
(0.030in)
Cut four seals, about 13тт
(0.5 п) 1оп9 and slide them
into the radial slots in the
thrust plate (аз at С ), until
they touch the bearing.
Continue to tap down the
thrust plate until и is firmly
а9апб1 the housing. Тггп
оП the ехсезб seal length
square and 1eve1 with the thrust
plate.
6.5тт
(4 Вп.)
2957А
9803/3200
1 ввив 1
д
ATTACHMENTS
2-4
2-4
ОО1)В[Е Р1)МР—СОММЕГС1А[
1 nspection
Check housings for wear а
shown а А. If depression is
дгеаег than 0.12тт (0.005in)
the housing should Ье renewed.
Репе gears if wear (detectable
Ьу touch) is гпоге than О.О5глгл
(0.002in) оп dimensions В
ог С . Сеагб shou 1д also Ье
renewed if scoring or pitting is
evident or if the деаг teeth are
chipped.
Always гепе gears а matched
pairs. Яепе' bearings if gears
are renewed.
Thrust р1 а1е are subject to
wear оп su гасе D . N ое Ъаt
it is possiЫe for the дгеу оыиег
layer to wear through to the
bronze during the early life Ы
the thrust plate. This
condition is по detrimental,
Ьц1 wear in ехсе Ы 0.05тт
(0.002in) ‚i11 necessitate
renewal Ы the thrust plate.
Аепеа1 is also песеагу if the
р1 ае are pitted or scored.
2956А
9803/3200
А
АТТАСНМ ЕГIТ$
3-1
3-1
3483
9803/3200
1ssue 1
г
АТТАСНМ ЕNТs
3-2
3-2
НАМЛ1ОАТНУ Е [ОЛ!О1\1ОЕВ
(JCB Roadbreaker)
The numerical sequence
shown оп the illustration is
intended а а guide to removal
апд dismantling.
Рог аеглЬ1у апд replacement,
the sequence should Ье
reversed.
When Removing
B1ank hose ап pipe connections
to ргееп1 епгу Ы dirt ап loss
Ы hydraulic fluid.
When AssemЫing
Using а fine 1опе, геглое
minor nicks ап burr гогл
plunger 15 ап its housing.
1f either Ы these соглропеп1
is Ьа 1 у огп, the complete
flow divider must Ье
renewed.
ashers 6 and 13.
Аепе
connections
1
То left hand roadbreaker
2
То right hand roadbreaker
3
Feed гогл ритр
After Replacement
Adjust flow divider to
balance breaker speeds ($ее
раде А7-1).
9803/3200
АТТАСНМ ЕNТб
3-3
3-3
KONTAK Е[ОЛ! DIVIDER
(ЗСВ Roadbreaker)
Removal апд Replacement
The numerical sequence
ол'п оп the illustration is
intended а а guide но
removal.
Еог гер1 асеглеп , the sequence
should Ье reversed.
When Removing
Blank hose connections 1о
prevent entry of dirt апд о s
of hydraulic fluid.
connections
1
То left hand roadbreaker
2
То right hand roadbreaker
3
Егогл уегл relief \'а1\'е
3882
9803/3200
5ые 1
ATTACHMENTS
А
4-1
4-1
COMPONENT ЕЕ11ЕЕ VALVE
(]СВ Roadbreaker)
The numerical sequence
оп Ъе illustration is intended
а а guide to removal апд
дismantling.
Рог аеглЬ1 у апд replacement
the sequence should Ье
ге'
еге .
When Removing
Disconnect hose А Ьу removing
сге'у 1, до по remove hose
сир.
Blank hoses to ргеегт1 епгу Ы
dirt ап о Ы hydraulic fluid.
When Dismantling
сге in adjuster 10 to огсе
out spool Ьоу 6.
When AssemЫing
Аепе
Ю' rings.
ех Ч.2
Аррiу Loctit(Nut Lock )
to threads Ы capscrews 1.
After Replacement
Аее relief ‚,а1',е pressure
( ее ране А4-2).
16
завод
9803/3200
1
е1
А
А
АТТАСН1ИЕNТS
4-2
4-2
COMPONENT RELIEF VALVE
(]СВ Roadbreaker)
Adjustment
1f two breakers аге fitted, this
operation should Ье carried
out оп еасЬ relief \ а1iе А.
Оп гпасЫпе itted with the
Hamworthy flow divider,
first balance the roadbreaker
* реес (see ране А 7-1)
ОН ппасЫпе fitted with the
Kontak flow divider, first adjust
the system relie а1~е (see
ране А5-3).
Remove 1/8in. B.S.P. р1 иу В
ап соппес auge (Service
оо 1 ).
Run engine а the normal
Ьгеаег operatгng speed
according to уре Ы flow
Ёес :
divider
Hamworthy — 1800 rev/min.
Копа
— 1500 rev/min.
Орегае roadbreaker fitted with
а rammer рад а а С and сЬес
gauge reading.
Adjust а D until the gauge
reading соггеропс o the
соггес relief \,а1\,е е1Ёп9
(see Technical Оаа).
3487А
9803/3200
1
е 2"
АТТАСНМЕNТ3
А
5-1
5-1
ЗУЗТЕМ ЕЕ11ЕЕ VALVE
(ЗСВ Roadbreaker)
Removal ап
eplacement
The numerical sequence
shown оп the illustration is
intended аб а guide to
геглоа1.
Рог гер1асеглеп , the sequence
should Ье reversed.
When Removing
Blank Ное connections to
ргееп loss Ы hydraulic
fluid ап епгу Ы dirt.
А 1ег Replacement
Adjust pressure setting
(бее ране А5-3).
3883
9803/3200
АТТАСНМЕТ8
А
5-2
5-2
ЗУЗТЕМ RELIEF VALVE
( СВ Roadbreaker)
Dismantling and AssemЫy
The numerical sequence
shown оп the illustration 'б
intended аб а guide to
dismantl ing.
Еог assemЫy, the sequence
should Ье reversed.
When Dismantling
То remove plunger 13, рабб а
soft metal го through seat 15.
То remove seat, use а piloted
soft drift.
When AssemЫing
Аепе
А
а11 seals and '0' rings.
Оо not 1ар ог grind seating
асеб, Ь 1 where these аге
УОГП гепе both mating parts.
9803/3200
АТТАСНМ ЕГ\ Т5
5-3
5-3
5УЗТЕМ ГЕ[1ЕЕ VALVE
(1СВ Roadbreaker)
Ас1 згпеп
Соппес ee piece and pressure
gauge а hown (see Service
Too1s).
Disconnect self-sealing
couplings А (оп both sides
Ы machine if two roadbreakers
аге fitted).
Run engine а 2000 rev/min. and
check gauge reading.
Adjust а а В until the gauge
геасп соггеропс o the
соггес relie а1~е setting
(see Technical Оаа).
3893
980313200
ATTACHMENTS
6-1
6-1
31
17
19
~1
21 20
16
18
9-
10
5
12
11
14
15
3485 А
9803/3200
lssue 2
А
АТТАСНМЕТ8
6-2
6-2
Юн ЙОАОВЙЕАКЕЙ
Dismantling and AssemЫy
The numerical sequence оп
the illustration is intended а
лап1:Нпд. Рог
а guide to
assembly the sequence should
Ье reversed.
И1неп Dismantling
Аег removal Ы the гопt
head assembly 4, ерагае the
су1 inder assembly 5 гогл the
handle 31 а follows:
Р1 асе the roadbreaker in а
plastic container а а А апд
а11 оУ to drop оп to the studs
гогл а height Ы about 30 тт
(1.25 in.).Hydraulic fluid \'i11
drain into the container.
Ensure that the cylinder
assembly i ер vertical to
prevent о Ы ое1 7.
Turn сат 27 through 90°
before drifting out, а а1: В.
САУТ1 О[\: Оо not dismantle
handle 31, as it
contains а nitrogen
ассити 1аног
requiring specialised
inflation equipment.
9803/3200
#When Assembling
1 прес1: the lower thin edge
Ы ,а1iе 9, if апу пс аге
ргееп1: in addition to the
calibration notch С the
should Ье renewed.
Г' ОТЕ: Va1ve 9 is а гла1:си
fit to the cylinder 12 апд
is identified Ьу опе, two or
three punch глаг , in the
lower асе D, which must
correspond to опе, two or
three punch marks оп the
side Ы the cylinder.
Аепеу, а11 '0 rings апд
еа1.
Lubricate а11 глоЛпд parts
апд '0' rings with hydraulic
fluid before assembly.
Арр! у [ ос11е 242 to сарсге '
1: пгеа Е when refitting hose
Connection 1апде.
Tighten nuts 3 progressively
in а diagonal sequence.
Ае1:огще nuts 3 after first
ау use.
Torque Settings
1:егл
Nm
д1 г
1bf ft
3
127
13
94
lssue 2*
ATTACHMENTS
7-1
7-1
СВ ROADBREAKER
То Ва1апсе Breaker 8реес
ОТЕ: This operation is оп1у
applicable to machines fitted
with the На i огпу flow
divider А' The Копа1 flow
divider fitted to 1аег machines
is non-adjustable.
Ensure that the hydraulic
fluid is а
orking temperature
Ьу the operation Ы services.
Соппес flow meter as а В агв
check that ритр output is
correct at 2000 rev/min.
(5ее Technical Оаа).
Соппес flow meter as а С
апд adjust flow divider as а D
until the flow гае is equal to
half the actual ритр output.
( сге' оы to increase flow).
Operate both roadbreakers
simultaneously апд adjust flow
divider until the right пап unit
орегаеб slightly Габег than the
left hand.
Adjust согпропеп relief а1~е
pressures (бее ране А4-2).
Operate roadbreakers both
together апд separately to
ensure that а satisfactory result
аб Ьееп achieved.
NOTE: 1t тау Ье necessary to
гпа1 е further adjustment to the
flow divider until individual
ЬгеаГег performance is ассераЫе.
9803/3200
lssue 1
А
АТТАСНМЕ N ТS
7-2
7-2
ЕАЦ1Т E11VD11VG —]СВ Roadbreaker
А
1f breaker fails to operate with pressure available,
В.
1f breaker i 1о
С.
1f there are он leaks, check 9.
o operate,
аг а check 1.
аг а check 4.
Check
Action
1.
Are Ье couplings secure?
YES:
NO:
Check 2
Secure couplings
2.
1s the distributor а1~е stuck?
YES:
NO:
Raise breaker ЗООтт. (12in.), hold сопго1
handle down and drop оп chuck.
Check 3.
З.
Are Ье tie rod nuts loose?
YES:
NO:
Retorque
Overhaul breaker
4.
1s the hydraulic он со1д?
YES:
NO:
А11о
ime to
Check 5
5.
1s the р11 п9ег sticking?
YES:
NO:
Overhaul breaker.
Check 6.
6.
1
YES:
NO:
Remove restriction ог гепе
Check 7.
7.
Are Ье tie rods loose?
YES:
NO:
Retorque.
СЬес 8.
8.
1s the muffling соНаг displaced оп
steel?
YES:
NO:
С 1ап9е to пе ' steel.
Check [1о and pressure Ы system.
9.
Л1Ьеге are Ье leaks showing?
In Handle:
Оп Stee1:
Ьеге а restriction in hose?
9803/3200
аггп.
hose.
Аепед seals.
Overhaul breaker and гепе
gland sea1.
А
8-1
9803/3200
АТТАСНМЕТ3
А
8-1
lssue 1
А
АТТАСНМЕNТS
8-2
8-2
ЯОдОВЯЕдКЕЯ НОЗЕ REEL
Dismantling апд AssemЫy
When AssemЫing
АррI у Anti-seize рае to inner and
outer
гасе Ы bearing 17.
АррIу hydraulic он o spindle,
'О' rings and Ыock,items 13, 14
and 15.
9803/3200
lssue 1
А
АТТАСНМЕТ5
А
9-1
9-1
15
14
3899
9803/3200
АТТАСНМЕТ
FLOW О1\11 ОЕГ
(Hydraulic Power Тае-ОН)
ТЬе numerical sequence
shown оп the illustration is
intended а а guide to гегпоа1
апд dismantling.
Рог assem Ыy апд replacement,
the sequence should Ье reversed.
When Removing
B1ank Ьое апд pipe connections
to рге 'еп еггу Ы dirt апд
1 о Ы hydraulic fluid.
When Assem Ыing
Using а Лпе опе, гегпо 'е
minor nicks апд Ьгг rom
plunger 15 апд its housing.
1f either о these согпропеп
is badly 'огп, the complete
flow divider must Ье renewed.
Аепе \' washers 6 апд 13.
connections
1
Feed гогп loader circuit
2
То motor
3
То сопго1
а1'е
After Replacement
Adjust Ло divider to асЫе 'е
соггес haft speed ( ее ране
А 12-1).
9803/3200
А
АТТАСНМЕNТS
10-1
д
10-1
СОГЗТО1 \/ДIЛ/Е
(Hydraulic Power Take-Off)
Removal and Replacemeni
The numerical sequence
shown оп the illustration is
intended а а guide to
removal.
Рог replacement, the
sequence should Ье гееге .
When Removing
Blank hose connections to
prevent 1о of hydraulic
fluid ап д епгу Ы dirt.
9803/3200
lssue 1
А
АТТАСНМ ЕNТS
А
10-2
10-2
21
31
4033
9803/3200
АТТАСНМ ENTS
А
10-3
А
10-3
CONTROLVALVE
(Hydraulic Power Take-off)
Dismantling and А $еп1Ь1у
The numerical sequence shown
оп the illustration is intended а
а guide to dismantling.
Рог аеглЬ1 у the sequence
should Ье геегес .
1Nhen Dismantling
1f геглое , 1abe1 spools 11 and
21 1о ensure replacement in
their original Ьогеб.
1Nhen Assembling
Аепе
а11 ' О' rings апд seals.
Adjust screw 4 so that spool
11 саппо Ье то~е
опагсб
from the neutral position..
9803/3200
lssue 1
_
) Г
А
9803/3200
АТТАСНМЕП1Т5
А
lssue 1
А
А
АТТАСНМЕNТЗ
11-2
11-2
ЕАЕВОХ А[ЮN1OTOR
(Hydraulic Power Take-Off)
Removal and Replacement
ТЬе numerical sequence
Ьоп оп the illustration is
intended а а guide to
removal.
Рог гер1асегпеп , the sequence
should Ье reversed.
When Remoцing
Blank hose connections Ю
ргееп loss Ы hydraulic fluid
ап епгу Ы dirt.
А 1ег Replacement
Refi11 деагЬох via 1е~е1 plug А,
44,
`
1.
ч
1f the гпоог has Ьееп
overhauled ог renewed, check
shaft speed ( ее раде А 12-1)
9803/3200
lssue 1
/
А
11-3
АТТАСНМ ЕNТЗ
11-3
l
9803/3200
1ввие 2"
АТТАСНМ ЕN Т
А
11-4
11-4
МОТОЕ
(Hydraulic Power Take-off)
Dismantling апд Assem Ыy
ТЬе numerical sequence shown
оп the illustration is intended
а а guide to dismantling.
Renew gears in pairs if:
а)
Journal агеа Ы shaft is
pitted, ог worn in ехсе
Ы 0.001 in. (0.025тт).
b)
Сеаг аге badly ,огп ог
cracked.
с)
Сеаг width В is 1е
han
housing width С Ьу
0.003in. (0.076тт) ог гпоге.
Еог assembly, the sequence
should Ье reversed.
When Dismantling
Remove Ьагр есе and Ьггз
from shaft to avoid seal damage.
Маг end covers 2 and 22 and
housing 11 to ensure соггес
replacement. Do по1 damage
machined асе Ьу prisin Ьее
араг — use а soft-faced hammer.
1 е service tool А, раг1 Но.
ВТ2464, to remove bearings 5
and 17.
Маг adjacent teeth Ы gears 10
ю ensure соггес replacement,
using indelible ink.
Do по use а сепге рпсп ог
similar too1.
Renew ,еаг р1 ае 7 and 13 if
scored ог eroded. Ensure 1Ьа
гесее D аге diagonally оррое
and facing the gears.
Running clearance between gears
and wear р1 ае5 is 0.0045 tc
0.006in. (0.11 to 0.15тт'.`This С
is achieved Ьу addition Ы shims
9 and 12, 0.0015in. (О.А~8тт)
thick, д istributëdёacn side Ы
housing 11. ТЬе total Ыспе s
Ы shims required is found Ьу adding
the running clearance to dimension
В, then subtracting dimension С.
~r . Д
b • Сб &- 0'/
When Assem Ыing
Renew а1 еа1 and '0' rings,
lubricating а11 internal раг
with ]СВ 5ресiа hydraulic
fluid.
Renew seal ЬЫпе 6 and 18 if
sealing асе аге damaged ог
if Ьоге аге scored ог worn аг9ег
Ьап а diameter о[ 1.2515in.
(31 .788гтi гтi).
Ensure Ьа drain adapter Х,
in end cover 2, i гее from
obstruction.
A1ign gears, housings and соег using
marks таре оп dismantling.
Топе Settings
ltem
1
Ы ft
100
kgf т
13.8
з5 •6 .
Using servic;e tool раг Но.
892/00065, install bearings 5
and 17 to а depth Ы 0.007 tc
0.009in. (0.18 to 0.23тт)
below machined surface Ы ежи
cover. Г\ е bearings should Ье
fitted if gears аге renewed.
9803/3200
lssue 1
А
АТТАСНМ ЕNТS
11-5
11-5
СЕААВОХ
(Hydraulic Power Take-off)
Dismantling апд AssemЫy
The numerical sequence о 'п
оп the illustration is intended
а а guide to dismantling.
Еог assembly, the sequence
should Ье reversed.
Wben Dismantling
Аето,е casing 4 complete
with еаг 7 and bearing 8.
Wben AssemЫing
Аепе ' оН seals 9 ап 15.
Use геае to retain rollers in
bearings 10, 11 ап 16.
6
3919 А
9803/3200
А
АТТАСНМЕТ5
12-1
12-1
HYDRAULIC POWER ТАКЕ-ОДЕ
Output Shaft Speed
F1ui гогл the ритр enters
the flow divider а port А.
А constant quantity, controlled
Ьу adjustment В, is fed to the
attachmen роо1 Ла port С.
Ритр output in ехсе of this
quantity is fed to the power
take-off motor via port D.
The power take-off is designed
to орегае а а shaft рее of
530-550 rev/min а ап епфпе
рее of 1800 rev/min. This
requires а flow to the motor of
22 UK ga1/min (100 litres/min).
With а ритр outpŭt of 29 UK
ga1/min (132 litres/min.), the
resul ant flow to the attachment
spool wi11 Ье 7 1!К ga1/min.
(32 1 itres/тin.)
Adjustment
Connect flow meter Е, а
shown, апс ас1 ы
he flow
divider to фе the specified
motor flow ( сгеу in to
псгеае).
Г\ ОТЕ: 1f the ритр output
andard, then the
is Ье1о
геыиге flow to the motor
тау Ье achieved оп1у а the
ехрепе of flow to the
attachment spool.
3901
9803/3200
7
А
АТТАС Н М ЕП1Т5
14-1
14-1
# CONTROL VALVE — НАМИОАТНУ
Removal and Replacement
Тпе ппегса equence
оп the illustration is intended
а а guide ю removal.
Рог replacement the sequence
should Ье reversed.
When Removing
Prior to disconnecting hoses,
орегаюе control levers to veпt
pressure апд аЬеI hoses to
ensure соггес replacement.
Blank а11 hoses and pipes to
ргееп1 entry Ы сг and о s
Ы hydraulic fluid.
When Replacing
Adjust 1еп91 Ы link А
о 1 а1 реда1 рас аге 1е\Iе1
еп spool is in the neutral
position.
Connections
В То Excavator Va1ve
С То Tank
D From Shovel Va1ve
Е Jaw агт', ос Епд.
F Jaw Ram , Неад Епд.
3907
980313200
lssue 2
А
А
АТТАСНМЕГ\]Тб
14-2
14-2
‚
19
- 20
21
22
е~2
5
27
--28
32
23
31
15
Х33
30
14
25
29
26
13
12
11
10
3902
9803/3200
1ssue 1
А
14-3
АТТАСНМЕNТS
А
14-3
*CONTROLVALVE—HAMWORTHY
Dismanting and AssemЫy
The numerical есепсе
shown оп the illustration is
intended а а guide to
dismantling.
Еог assembly, the есепсе
should Ье reversed.
When Dismantling
То prevent spool rotating
when removing items 8 and 19
use barrel с1атр раг Но.
992/02100 with the spool
protruding from the block.
Alternatively items 8 to 23
тау Ье removed а ап
assembly and mounted in а
vice ог dismantling. 1 е
sof а'А if the barrel с1 атр is
по available.
If removed, IаЬеI spool 23 ю
ensure гер1асегпеп he
соггес
ay ир.
When Assemhing
1 епе ' а11 '0' rings and seals,
lubricating а11 internal раг1
with JCB 'Special hydraulic
fluid.
9803/3200
lssue 2*
А
ATTACHMENTS
А
14-4
14-4
CONTROL '/А['/Е — РАЙКЕЙ HANIFIN
Removal апд Replacement
The numerical sequence оп
the illustration is intended а
а guide to removal.
Еог replacement the sequence
should Ье reversed.
When Removing
With the engine off, орегае
а11 controls to vent residual
pressure Ьеоге disconnecting
hoses.
B1ank а11 hoses апд pipes to
ргееп епгу Ы dirt апд loss
о{ hydraulic fluid.
When Replacing
Adjust length Ы link А зо that
реда1 pads аге 1е~е1 when
spool is in the neutral position.
Connections
В
С
D
Е
F
То Roadbreaker F1ow
О i',iсiег.
То Tank via ЕхсааЮг
\/ а1 е Exhaust Line.
То Attachment, (Jaw Ram
Неад Side/Extending
Dipper Ram Неад Side1.
То Attachment (Jaw Ram
Rod Side/Extending
Dipper Ram Rod Side)
From Ритр .
NOTE: Нобе В is оп1у fitted
when а roadbreaker is used
with dipper mounted
а11ас 'гпеп1.
9803/3200
lssue 1
ATTACHMENTS
¥
ю
1
у
§
\
@
ГА
АТТАСНМЕNТ8
14-6
14-6
СОТЕО[ \/А[\/ Е —РА1 КЕЕ НА 1 Р1 Г\]
Dismantling and AssemЫy
Г
ТЬе numerical sequence
Ьо\\'П оп Ье illustration is
intended а а guide to
dismantling.
Рог аегпЫу, Ье sequence
should Ье reversed.
When Dismantling
Г
То remove plunger 25 ра а
soft гпеа1 гос through еа 26
То remove еа 26 use а
рг1 онед soft drift.
When Assembling
Аегло"е minor nicks апд Ыгг .
Excessive wear оп роо1 or Ьоге
must Ье remedied Ьу renewal of
согпр1 ее ',аКе.
Во по ар or 9гГп eating
faces, Ы where these аге worn
гепе\\' ЬоЬ mating раг .
Аепе\\' а1
t
еа1 апд 'О' гГп
.
Аег АзегпЬ1у
Аее relief '‚а1"е pressure
8ее раде А 14-7.
Г
0803/3200
lssue 1
АТТАСНМЕNТS
14-7
14-7
CONTROL '/АЕ"/ Е — РАГКЕ HANIFIN
Relief \ а1 е
Ргеыге Testing
1f а powerbreaker is fitted
disconnect both pipes С and
fit plugs 816/00197 (Service
Too1s).
Соппес а pressure gauge to
test adapter А, usin пар
соппесог В 892/00099
(Service Too1s).
Run the engine а 2000 rev/min.
and depress сопго1 \'аК'е реда1
.to obtain maximum gauge
reading.
When ап а1 асгпеп is fitted,
оЪег Ъап а powerbreaker,
the service wi11 have to reach
fu11 travel Ьеоге the maximum
reading is attained.
1f the reading does по
correspond to that given in
the Technical Оаа section
adjust а
own D.
9803/3200
1
е 1
А
АТТАСНМЕ NТS
А
15-1
15-1
3922
9803/3200
1ssue 1
А
АТТАСНМЕNТ
15-2
15-2
]Д
А
В1)СКЕТ
Dismantling and Assem Ыy
The numerical ещепсе оп
the ilIustration is intended
аб а guide to dismantling.
Еог assembly, the sequence
should Ье reversed.
UVhen Dismantling
Епбге that bucket jaw is
adequately брроге ЬеТоге
removal оТ гагп 14 ог pivot
pins 16 апд 18.
UVhen AssemЫing
Е shims 2 in sufficient
quantity to ае ир сеагапсе
Ье \'ееп tooth апд оер1 ае.
Torque Setting
1 егп
1
9803/3200
ЬТ ft
300
kgf т
41.5
lssue 1
А
16-1
9803/3200
АТТАСН1V1 ЕNТS
А
16-1
lssue 3
А
АТТАСНМЕГТ8
16-2
16-2
RAM — Опе Piece Piston Неад
(Тур i са
Dismantling апд АssетЫу
The numerical ещепсе оп the
illustration is intended а а guide
to Dismantling а typical ram.
Components Ы specific гагп5 тау
vary in shape and quantity, ог
details геег to Раг1 Catalogue.
1f replacing еуе еп bushes,
position the splits Х а hown.
Renew ел сар lockwire and
secure to ее pipe.
Piston Неад Torque Settings
Note: Protection Ьаг D is fitted
to .]СВ .]ал' on1y.
Рог assembly the ещепсе should
Ье ге"егес .
VЧhen Dismantling
1t тау Ье песеагу to use
hydraulic pressure or согпргее
air to drive out the piston assembly.
Piston Аос
D iameter
тт
38
51
64
in.
1,5
2,0
2,5
тт
70
92
102
Тог i е
Setting
in.
Соде
2,75
Е
3,625 F
4,0
G
Тогще Setting Соде:—
Nm
WARNING: Ensure that the еп
сар 1 is securely in position
during this operation а evere
injury сап Ье caused Ьу а suddenly
released piston rod.
Cylinder
Воге
kgf т
Е — 420 42.9
F - 408
41.5
G — 522 53
Ы ft.
310
300
385
VVhen AssemЫing
Аепе а1 еа1 and '0' rings,
lubricate а11 internal раг1 with
]СВ 'Special' hydraulic fluid.
* 1) е sleeve А part Но. 892/00024
to fit seal 12 onto 64 тт (2,5 in.)
dia rod.
3640А
lnstall опе piece еа1 С centrally оп
the piston head using expander
sleeve В part пов:892/00012 — 92 тт (3,625 in.)
892/00013 — 102 тт (4 in.)
Position опе split seal and опе
еаг ring оп each side Ы еа1 С.
* End сар, item 1, is to Ье 1 ююе
to cylinder with 4 drops Ы
Loctite 242 (Service Тоо1) оп
Ьоогп 3 or 4 threads.
9803/3200
lssue 3"
А
17-1
А
АТТАСНМЕNТЗ
17-1
4414
9803/3200
А
17-2
АТТАСНМЕГ'1 Т
А
17-2
EXTENDING О1РРЕ1
Removal and Replacement
Prior to disconnecting hoses
fit locking pin 1, stop engine
апд орегае control 1еег to
еп pressure.
Labe1 hoses to ensure соггес
replacement.
Blank а11 hoses апд pipes to
prevent entry Ы dirt апд loss
Ы hydraulic fluid.
Dismantling апд Assembly
The numerical sequence оп
the illustration is intended аб
а guide to Dismantling.
Рог Assembly the sequence
should Ье reversed.
Рог Вагп Dismantling see
рауе А 16-1.
9803/3200
lssue 1
А
А
АТТАСНМЕNтв
18-1
18-1
23
2-~~.
8
9
10
11
12
16
‚15
19 ао
17
1
35
34\
22
21
20
27
5556
9803!3200
lssue 1
А
АТТАСН МЕNТЗ
18-2
18-2
РО'ГЕВЕАКЕ
Dismantling апд AssemЫy
When Dismantling
The accumulator, items 2 to 7,
contains pressurised Nitrogen.
Dismantle оп1 у if requiring
attention.
Веглое сге 4 1оч1 у ю ге1 еае
Nitrogen pressure.
Веглое item 6 using tool
825/99836.
Ensure еа! аге fitted а hown.
Вепе
uds 24 if the rubber
buffers аге loose ог damaged.
Ри
eal 35 using tool 992/07500.
Replace chuck 27 if Ьоге diameter
ог tool exceeds б7тт(2.637in).
Соа diaphragm Лап9е with
petroleum je11y апд fit into body 2
ensuring it is соггес 1 у seated.
Usiпg tool 825/99836 fu11y tighten
item 6 Ьу hand. Scribe а line асго
items 6 апд 2, hammer tight until
lines аге 6 ю 8тт. (0.236 to 0.314in.)
араг .
Рог Nitrogen filling ее раде 18-3
Тогсще Settings
Иегл
1
26
Ггл
170
650
980313200
дг
15
66
1bf ft
110
480
4400
1
ые 3'
А
АТТАСНМЕГIТ3
18-3
А
18-3
РОУЕйВйЕАКЕН
Nitrogen Filling
Nitrogen filling kit 992/06600
Comprising
А
Nitrogen bottle adapter апд
уа1уе.
В
С
Соппесюг hose.
Accumulator adapter апд
pressure даыуе.
Fit adapter апд pressure аое С to
accumulator апд lock into position
with 1 пог1ес гпд О. Соппес to
nitrogen bottle using hose В апд
adapter А.
C1ose adapter а1~е а nob Е.
Release accumulator сгел' (item 4 оп
ране 18-1) 1'о complete югп$ using
handle F.
Ореп nitrogen bottle а1~е А.
Ореп ае Е апд a11ow pressure to
build ир to 50 Ьаг (51 kgf/ст2;
725 1 bf/in 2).
С1ое а1~е Е, nitrogen bottle а1~е А
апд tighten accumulator screw а
handle F.
9803/3200
lssue 1
АттАснмЕNтв
А
18-ЗА
18-ЗА
рОЁ'!ЕйВйЕАКЕ
Fau1t Finding
аг а check 1.
А
1 brake ails to орегае,
В.
If Ыош рошег is гедисед, заг а check 7.
С
1f there аге он leaks, заг а check 11.
NOTE: Oi1 leaks тау оссиг immediately after fitting пе
seals. These should cease after а few hours operation.
1.
Аге the pressure апд return lines геегзесР
YES:
NO:
lnterchange hose connections.
Check 2
2.
Аге the зсге
YES:
NO:
Check 3
Secure couplings
З.
1s the striker piston jammed?
YES:
NO:
Check 4
Check 6
4.
Is there оо miich дгеае оп the зее1?
YES:
NO:
Реглое excess геазе
Check 5
5.
1s the оП оо hot?
YES:
NO:
Егее piston апд а11 о оН to соо1
Dismantle breaker апд с1 еап
6.
1s there а fault in the hydraulic зуегп?
YES:
NO:
Ресу fault
Overhaul breaker
7.
1s the уегл pressure соггес ?
YES:
NO:
Check 8
Ас 11] pressure
8.
1s the return line back pressure higher than
8 Ьаг (116 1bf/in 2 )
YES:
N0:
Check filter апд hose connections
Check 9
9.
Is the steel jammed?
YES:
NO:
Check that breaker is being орегаес а right
angle to material.
Check 10
YES:
NO:
Репе accumulator
Overhaul breaker
couplings secure?
10.
Воез the hose vibrate?
11.
1s он leaking гогл зсге
breakerbody?
9803/3200
couplings ог frот
COUPLINGS:
ВОВУ:
Tighten couplings
Dismantle breaker апс гепеш seals.
lssue 1
А
А
АТТАСНМЕГ1ТЗ
18-4
18-4
ТЕ ~1. ТАLЕ Е11ТЕЕ
Dismantling апд AssemЫy
1.
2.
Filter components.
Details Ы collar 11 components.
VVhen Dismantling
А11 numbered items in the following instructions геег to the аЬое photographs which show the dismantling
sequence.
Dismantle ир to item 4 then ргосее
З.
а ollows,
Extend line А down оп to filter housing to
show
аг Ы Ьу-раз section.
4.
Remove items 5 to 7. Ёхеп line А towards
сегнте Ы indicator spindle. Slacken indicator
locking зсге . Spring 9 wi11 turn indicator ю
пе " position В; mark position with а 1ine.
Remove indicator 8. ОеЫгг spindle 12 to
ао?
amage to seals then гегпое а11
components ир ю item 17. Removal Ы collar
11 тау require the use Ы а оо1 similar to
that illustrated а Е.
9803/3200
lssue 2
АТТАСН1ЛЕNТ8
18-5
18-5
TELL TALE FILTER
ип B.S.P.
То dismantle the Ьу-равв, items 19 to 21, tool
F must Ье таде а illustrated. Minimum length
о centre bolt is 55тт. (2.17in.).
5.
Screw tool F into the inlet port to relieve spring
pressure оп circlip 19 which сап then Ье
геое through outlet port. Аегпое tool F
ап withdraw piston апд spring.
YVhen AssemЫing
6.
Вееге dismantling ргоседиге ир to item 9.
Using tool F push piston in until both piston
rings аге just visiЫe гогп inside filter housing а$
а
. Fit indicator onto spindle with pointer in
line with В апд 1оса1е оп епд Ы spring 9.
Тигп against spring tension until pointer is in
line with А; make sure the indicator spindle
lever is held in соггес position against the епд
Ы piston а а Н, then Iock indicator to spindle.
Remove tool F апд assem Ыe items 7 to 1.
9803/3200
Н. View through outlet port.
Issue 1
А
19-1
9803/3200
ATTACHIVIENTS
19-1
lssue 1
А
19-2
АТТАСНМЕГ'1Т8
А
19-2
СЕАМ SHOVEL
Dismantling and АегпЫу
ТЬе numericaI sequence оп
the iIlustration is intended аз а
guide ю dismantling.
Рог аззегпЫу, the sequence
should Ье reversed.
When Dismantling
В1ап а11 Ьозез апд pipes ю
prevent епюгу Ы dirt.
Ensure юЬаю Ысею с1ат апд
back Ь1 аде аге adequately
supported Ьеоге removing
гагпз 8 ог pivot pinsl0.
Рог гагп dismantling зее раде
А 16-1
Torque Settings
[\] гп
kgf т 1bf ft
Item
1 407 41.5 300
9803/3200
1
е1
ВООУ AND FRAMEWORK
В
Contents
1еу' Асыаог
В
Contents
Веглоа and Replacement
Dismantling and АббеглЫу
2-1
2-3
Воот and Dipper
Веглоа1 and Replacement
3-1
Kingpost
Веглоа1 and Replacement
4-1
Kingpost Carriage
Веглоа1 and Replacement
4-1
СаЬ
9803/3200
Glazing
* Rear Window
6-1
6-3
1 ввие 2*
В
2-1
9803/3200
ВООУ AND ЕГАМЕОК
В
2-1
lssue 1
ВООУ АО РВАМ ЕЧIОВК
В
2-2
2-2
SLEW ACTUATOR
Removal and Replacement
The numerical sequence shown
оп the illustration is intended
as а guide to геглоа1.
Рог гер1 асеглеп he sequence
should Ье reversed.
When Removing
Position апд support Ьоогл and
dipper as shown.
Drain он ia both plugs а 3.
[аЬе and blank hoses 5 to
ensure соггес гер1 асеглеп
апд ргееп епгу Ы dirt.
When Replacing
Вепе thrust washer 8 with the
chamfer facing оагсб Ъе
kingpost.
Take саге to а1 ign master
spline А.
Refi11 а В with Mobilube
Н 090 он .
Тогце Settings
1 егл
6
9803/3200
В
1bf ft
600
kgf т
83
*) у"
ВООУ А \!О Е1 АМЕР4ОК
В
В
2-3
2-3
22
Э921
9803/3200
1ssue 1
ВООУ AND FRAMEWORK
В
2-4
2-4
51Е
В
дСТ1 дТОЕ
Dismantling ап AssemЫy
The numerical sequence
shown оп the illustration is
intended а а guide to
дismantling.
Ео аеглЬ1 у, the есрепсе
should Ье reversed.
When Dismantling
То гегпое items 19, 20 апд 21,
enter ре -1оо through hole
for plug 17.
NOTE: Items 11а но 16а аге
fitted оп later machines in
р1 асе Ы items 11 to 16.
When AssemSing
Position глаег spline А
directly аЬое сепге tooth В
Ы гас 22.
A1ign hole С in bush 19 with
геае nipple D (if Л11е ). ОН
ае machines, align hole С
with hole Е in асыаог Ьоу.
* То
. е Settings
ltem [\ гл
kgf т
Ы ft
1
372
38
275
5
10
17
420
95
95
42.8
9.7
9.7
310
70
70
[\ ОТЕ: ltem 5 тау Ье torqued
higher to а 1о holes for
split pin 4 to line ир.
1
9803/3200
1ввие 2*
в
в
ВООУ дГ]О ЕйАМЕЛОЕ{ К
3-1
3-1
о
и
3894
9803/3200
В
3-2
ВОВУ AND FRAMEWORK
В
3-2
ВООМ АО DIPPER
Аетоiа1 and Replacement
ТЬе numerical sequence
shown оп Ье illustration is
intended а а guide to
гегл о"а 1.
Рог replacement, Ье sequence
should Ье ге"егес .
V11hen Removing
After positioning support,
ор engine апд орегае Ьоогл
and dipper controls to vent
residual pressurг.
Labe1 and Ь1 ап Ьое 1о ensure
соггес replacement апд
prevent entry Ы dirt.
9803/3200
lssue 1
В
4-1
9803/3200
ВООУ АГ\Ю ЕЯАМЕЛ]ОI К
В
4-1
lssue 1
В
воду AND FRAMEWORK
В
4-2
4-2
К1 Г']СРОТ/ К1 Г']СРОТ CARRIAGE
Torque Settiпgs
Removal and Replacement
The numerical sequence
shown оп the illustration is
intended аз а guide Ю
removal.
1 егп
1bf ft
kgf т
10
600
83
л) 1
з3
Еог replacement, the sequence
should Ье ге"еге .
А — .1СВ 20, 3 апд ЗС.
В — .1СВ 30
When Removing
First remove boom and dipper
(нее ране В 3-1).
Labe1 and Ь1 ап1 hoses to ensure
соггес repIacemerlt and prevent
entry Ы dirt.
То remove pivot pin 13, use а
1in. 1Л\ Е Ьо1 in the 1арре
hole provided.
[\ ОТЕ: Оп .]СВ 2D, 3 and ЗС
machines, before swinging Ъе
kingpost rearwards, lower the
hoist зо Ъа he ор pivot
Ьо clears housing С.
When Replacing
Ensure that when hydraclamps
аге ргез
гi е , с[еагапсе D
is 1/8 to 3/16 in (3 to 5 тт).
епе'л thrust washers 12 and
15 with Ыиаптегз facing towards
the kingpost.
1f а пе kingpost is fitted,
арр1 у а liberal coating Ы геазе
around the actuator splines Ю
рге"еп machining particles
from entering the actuator.
Take саге to align master
spline.
980313200
- с'4 /'
.
. ‚Л.----
'9 ТС
--‚7. 4' 5iго7 д
lssue 1
в
6-3
ГЕАГ WINDOW
Setting
With the door in the side stow
position асыб1 пы1б А апд В
to give minimum clearance а
С.
Tighten self locking пы1 В to
a11ow door to гоае with
minimum Ы vertical гло"еглеп .
9803/3200
ВООУ & FRAMEWORK
в
6-3
В
6-1
ВООУ AND FRAMEWORK
В
6-1
Glazing
When fitting glazing rubber 1о
рапе1 еде, a11ow ог sma11
оег1 ар Ьеоге cutting.
Рге both ешЁ о9е11ег, then
push back оп to the рапе1
ensuring соггес location.
Commencing а ower согпег,
carefully fit the д1 а . The use
Ы glazing suction cups wi11
simplify this operation,
particularly when handling
агдег size windows.
9803/3200
lssue 1
В
6-2
ВОДУ A'1D FRAMEWORK
В
6-2
Complete 91аз installation
using а glazing tool ($егусе
оо1з).
DO 0Т 1) Е Е0 СЕ.
Аегпо' е the оо! rom the
glazing tool and fit the соггес1
size еуе ёг the filler strip
which is then threaded through
еуе and handle.
$ аг а1 а point away from the
glazing гпЬЬег joint. Insert
tool еуе in the filler strip
channel and hold the end Ы
the filler strip in расе.
Commence drawing the tool
еуе round the channel.
When cutting filler strip, a11ow
sufficient оег1 ар to р1асе
joint under ргезпге.
Use зрпг tool to ргез home
the joint and апу гла11 sections
Ы filler strip not соггес1 у
locating.
9803/3200
lssue 1
С
Е1ЕСТА1св
С
Contents
Сопеп
Battery
агег Моог
* А1 егпаог
General Maintenance
Testing—Specific Gravity
—High Рае Discharge
Dry-Charged Ваегу Preparation
Testing апд Реглоа
Dismantling апд AssemЫy
2-1
2-2
General Description
Charging Circuit Check
Теп -18АСР ,САУ АС5Р апд АС5 НЕР
3-1
3-2
3-4
—DN460
Undercharged Ваегу
Dismantling апд AssemЫy-18ACR
-DN460
3-6
3-7
3-8
3-10
—АС5НЕР
3-12
Dynamo
Теп
Регоо 'а1 апд Аер1 асеглеп
Dismantling апд АеглЫу
4-1
4-2
4-3
Сопго1 Вои (Dynamo оп1у)
Согоропеп Кеу
Теп апд А
5-1
5-2
5-4
леп —Е1есгiса1 Settings
—Mechanical Settings
Fau1t Finding
Starting System
Charging уегл
Lighting уЁегл
6-1
6-1
6-2
Wiring Diagram
То т/с по. 61767— апсаг
—Austrian
—бегглап
7-1
7-3
7-5
7-7
7-9
7-11
7-13
7-15
7-17
т/с по. 61768 to 68150 (А11 markets)
т/с по. 100000 оп —Standard апд American
А`
_Austrian
—СЗегглап
—Swedish
* /5
9803/3200
Bui1d
Issue 5*
С
Е[ЕстА1сS
1-1
С
1-1
ВАТТЕ R 1 ЕS
General Maintenance
ТЬе primary ыпс1 оп Ы the
battery is to provide the 400800 аглреге required to start
the engine. А we11 maintained
battery Ьа5 ап adequate power
гееге ЫгЁ this wi11 diminish
rapidly if the battery is allowed
to deteriorate.
Attention to the following
points wi11 appreciably extend
the useful life Ы the battery.
Кеер the battery and terminals
clean and dry. Spilled аег
ог electrolyte саызеб corrosion
Ы metal раг and also
епсоыгаде 'tracking'of current
Ье1 ееп the terminals. ТЫб
сап partially discharge the
battery оег а prolonged period.
Use only distilled water ог
'topping ир'.
'Л( еп charging а battery
'in situ', the еагЁЫпд саЫе
should Ье disconnected to
avoid possible alternator
damage.
1f removing the battery from
the machine, disconnect the
earthed terminal first (and
reconnect last). ТЫ5 wi11
ргеепЁ '1абЬ over'if the
раппег оысЬе5 the machine
bodywork.
Terminal connections should
Ьае bright metal to metal
сопас and should Ье kept
tight. глеаг the terminals with
рего1 еыгл je11y to reduce the
possibility Ы corrosion.
Maintain the battery in а
'charged' condition. Stored
batteries (except 'dry charged')
should Ье given а trickle
сЬагде еегу three to four
weeks. Check eiectrolyte
1 е~е1 and specific gravity ап
hour after the charging period.
9803/3200
lssue 1
С
ELECTRICS
1-2
1-2
ВАТТЕR1ЕS
Testing—Specific Gravity
The specific gravity Ы the
electrolyte gives ап indication
Ы the бае Ы charge Ы the
battery. Readings should Ье
taken using а hydrometer,
when the electrolyte
temperature is 15°С (60°F).
1f the battery has recently
Ьееп оп charge, wait
approximately опе hour
(ог slightly discharge the
battery)to dissipate the
'surface charge Ьеоге testing.
Readings should Ье аб
tabulated ап should по ary
between ce11s Ьу глоге than
0.04. А геаег variation
indicates ап internal fault оп
that particular се11.
1f the electrolyte temperature
is other than 15°С (60°F) а
'correction асог' ГП1б Ье
applied to the reading obtained.
Адд 0.007 рег 10°С (18°F) if
the temperature is higher than
15°С (60°F) ап subtract the
same if the temperature is
lower. Г'ое that batteries ог
use in high агтЫеп
temperature агеа have а lower
specific gravity electrolyte
( ее аЬ1 е).
Specific Gravity а 15°С (60°F)
АгтЫеп Temperature ир to 27°С (80°F)
АгтЫеп Temperature аЬое 27°С (80°F)
9803/3200
Fu11y Charged
На 1 Discharged Fu11y Discharged
1.270-1.290
1.240-1.260
1.190-1.210
1.170-1.190
1.110-1.130
1.090-1.110
1ввие 2
С
ELECTRICS
С
1-3
1-3
ВАТТЕ 1 ЕS
High Еае Discharge Те
The test is used to determine
the electrical condition Ы the
battery and to 9 У ап псса1 оп
Ы the remaining useful 'life'.
Веоге testing ensure that the
battery is а east 75%
charged (зее Specific Gravity
testing).
Adjust the discharge евег
(Service tools W1 L/18) to 3 к
Атр hour rating Ы the
battery (арргох паеу 380
агпрегез) and соппес опе сир
о еась battery terminal,
observing polarity.
ое the оглеег геасп .
ТЬе battery should Ье сараЫе
Ы maintaining а1 least 9 volts
ог 10 зесопс . А rapidly
falling voltage indicates а
fault in опе ог гпоге ce11s.
4102
Оо по leave the discharge
1ез1ег in circuit for longer Ьап
is песеагу to complete the
test.
9803/3200
Issue 2
С
С
Е[ЕСТЕ{1С
1-4
1-4
ВАТТЕ i1Е
Огу Charged—Preparation ог Service
*Obtain electrolyte о specific
gravity 1.26 (Arctic апд
temperate climates) or 1.23
(tropical climates) or mix опе
раг (Ьу о1 ите) Ы Sulphuric
Acid 1.840 to the quantity Ы
д istilled water shown in the
tab 1е.
WARNING: Always ас Acid
to Water. If water is poured into
Concentrated acid ап explosion
тау ге511.
A11ow the mixture to соо1 to
ambient temperature Ьеоге
checking specific gravity.
Ас а 'correction асог' о
0.007 рег 10°С (18°F) if
electrolyte temperature is
аЬое 15°С (60°F). Similarly,
subtract the same if the
electrolyte temperature is
below 15°С (60°F).
1)пеа1 the battery ап i11
with electrolyte to the юор Ы
the plates. Check the
electrolyte 1е~е1 ап pecific
gravity Ы each се11 а [ег
approximately fifteen minutes.
Charge the battery а
approximately 8-10 Аглр
until а11 се11 аге gassin гее1 у
ап have uniform specific
gravity.
Electrolyte Mixture ТаЫе (Parts Ьу Vo)ume)
Sulphuric Acid
Ambient temperature ир to 27°С (80°F)
Ambient temperatures аЬое 27°С (80°F)
эвозlз2оо
1
1
Distilled Water
Fina1 Specific
Gravity а 15°С (60°F)
3.1
3.7
1.260
1.230
lssue 2r
С
2-1
Е IЕстА1 сS
С
2-1
ЗТАЕТЕЕ МОТОЕ
Testing
Check that а11 battery апд
starter connections are с1 еап,
tight ап making доо metal
ю metal contact. A1so ensure
that the battery is we11
charged ап that Neutral деаг
is engaged.
1f the starter fails ю urn the
engine connect а voltmeter
асго
e battery terminals
апд operate the 1аг
itch.
А falling voltage reading ( о
approximately half у 1егл
voltage) indicates that the
starter is drawing current but
is ргоЬаЫу mechanically
faulty. 1f the voltmeter reading
remain 1еау at у 1егл
voltage, reconnect it (а hown)
Ье1 ееп the starter main input
terminal апд а доо 'earth' ап
again operate the 1аг1 switch.
Should the meter по' how а
1 еау reading at у 1 егл voltage,
the solenoid апд 1аг1 switch
are in good огег Ы the starter
motor has ап internal 'орел
circuit'. 1f the meter reading is
его the 1аг
itch, solenoid
ап interconnecting саЬ1 е
should Ье checked for continuity.
Removal
Веоге removing the starter
motor, disconnect the battery
negative terminal апд then
follow the numerical sequence
shown оп the illustration.
9803/3200
lssue 2
С
С
Е[ЕстАiсв
2-2
2-2
2
1
10
16
20
2043 В
9803/3200
1ввие 2
С
Е[ЕСТА1 СЗ
С
2-3
2-3
ЭТАРТЕВ МОТОР — [1)САЗ М50
Dismantling
Fo11ow the numerical sequence
shown оп the illustration.
NOTE: Dismantle only to item
34 unless the field windings 38
are to Ье renewed. Test the
windings electrically before
removing them гогп the motor
yoke 15.
1 зе а slotted з1 ее ube to
displace ring 23 to а11о
withdrawal Ы ring 22.
А11 о brake shoes 28 to remain
in the endplate (11) unless the
shoes require гепеа1.
short circuit between the coils
and the yoke. Renew the coils
as necessary, use Роме Shoe
screwdriver С50 (Service tools)
to гегпое зсгез 36.
Check bronze bushes 32 and 34
ог еаг. оа пе bushes in
clean, warm engine он or
2 hours before fitting.
A1ign crosspin С with the notches
in the brake shoes (28) before
assembling brush саггег and
Ьас р1 ае to motor yoke. Мае
sure that brushes 14А are
installed in the insulated brush
Ьохез.
Servicing and АбзеглЫу
Renew brushes 14 and 14А if
their 1егщЪ is less than 8тт.
(0.3in.).
C1ean the commutator (А) with
petrol or сагЬоп tetrachloride
(зее Саге and Safety section ог
precautions). If individual соррег
Ьагз are burnt or eroded the
armature has Ьгоеп windings and
гшз1 Ье renewed. Otherwise
polish with fine grade glass
рарег ( Нот егпегу). Renew
armature if the commutator
diameter is 38тт (1.5in.) or
1ess.
Set the movement Ы drive
pinion 24 as о11оз:
Соппес а 6v battery and
switch as shown. Орегае
switch and check dimension D.
Adjust to 0.38-0.63тт.
(0.015-0.025in.) Ьу slackening
locknut 17, rotating eccentric
pin 18 as necessary and
retightening locknut.
Check thefield winding for
орел circuits Ьу connecting ап
Ohmmeter (0 to 100 ohms)
between the stud terminal В
and each positive brush (14А)
in turn. А high ог
reading indicates ап ореп circuit.
Similarly, соппес the гпеег
between brushes 14А and the
motor yoke 15. Апу reading
other than infinity indicates а
9803/3200
lssue 2
С
Е[
ЕстА1 С8
С
3-1
3-1
А[
ТЕНАТОН8
General Description
The alternator is а three phase generator having
atic power
а rotating field winding ап
windings
When the аг1 switch isturned оп, current
from the battery Лоз Ьу ау о he [\ о
Charge warning lights, to the field winding.
This сгеае а magnetic field which
supplements the residual magnetism in the
rotor ро1 е . А he engine is заге , the ап
belt drives the rotor ап alternating current
is депегае in the power windings а hey
are' cut' Ьу the rotating magnetic field. А
built-in diode bank rectifies the current for
supply to the battery. А sma11 proportion о
the rectified current is fed back to the rotor
to maintain the magnetic field.
Output is controlled Ьу а solid зае regulator
which varies the field current in ассогапсе
with electrical demand.
Servicing is ге гiсе o periodic inspection
Ы slip ring brushes. Bearings are зеа1 е ] ог
life' ba11 гасе .
Service Precautions
1) е оп Negative Earth systems оп у.
2.
Ensure that battery Negative terminal is
соппесе o the earthing саЫе.
З.
[\ е 'ег make or break connections to the
battery or alternator or апу раг Ы the
charging circuit whilst the engine is
running. Disregarding this instruction
'i11 result in damage to the regulator or
rectifying diodes.
N1ain output саЬ1 е are 'live' even
еп
engine is по running. Take саге по o
еагЪ соппесог in тои1 дед plug 1f
remove гогл alternator.
9803/3200
5.
During агс welding оп а machine, ргоес
the alternator Ьу removing the тои1 дед
р 1 II 9.
6.
1f 1ае starting is песеагу, соппес he
есопс1 battery in раrа11 е1 without
disconnecting the vehicle battery гогл
the charging circuit. The 1а \'е battery
тау иеп Ье ае1 у геое after а агt
иа Ьееп obtained. Take саге to соппес
batteries positive to positive, negative
to negative. ее а1 о [\ ое З.
7
ELECTRICS
3-2
3-2
*CHARGII\1G CIRCUIT СНЕСК
Ensure that а11 battery апд
alternator connections аге in
р1 асе, secure апд making good
metal to metal сопас , especially
'earth' connections to chassis
апд engine.
Adjust alternator drive Ье11
tension if necessary апд make
sure that the battery is we11
charged.
1f the No charge warning bulb
is in good order, withdraw
the triple plug from the back Ы
the alternator. Make а temporary
Connection ЬеЁ"ееп the ЗМА[[
terminal in the plug апд earth а
Ьо'л'п. 1[ the No charge warning
bulb б111 fails to light check the
В го'л'п/В1 асi cable ог continuity.
1f the bulb по'м lights check the
alternator ог defective regulator
(Зее Alternator Testing).
Turn аг switch to the оп
position.
pressure' апд 'No charge'
warning lights should g1ow.
1f апу lights fai1, proceed to
Check 1.
5 аг engine, а11 warning lights
should extinguish rapidly
1f No charge warning remains
ON proceed to Check 2.
1f оН pressure warning remains
оп ЭТОР ENGINE
1 ММЕВ1 АТЕ[У and investigate
engine lubrication system.
Check 1
With аг switch 'ON' гу
1пеаег motor апд бсгееп wiper.
1f items орегае normally,
check warning light bulb(б) ог
Ыошп filament.
Simultaneous failure Ы а11
items indicates а fault а the
start switch. Check for cable
disconnection Ьеоге
condemning the switch itself.
9803/3200
1 ввие 2'
С
ЕLЕСТА1св
3-3
С
3-3
СНАЕС1 Г 1С С1 ЕС1)1Т СНЕС1С
Cfieck 2
5 ор engine and turn start
switch 0 F F.
* Withdraw the alternator plug
and, using the voltmeter
section Ы а suitable test meter
(Service Too1s) сес or
battery voltage between the
1аге terminals and 'earth'. 1f
the reading i его, check the
Ьгоп саЫе or continuity,
particularly at the [агег
terminals.
1f the ammeter reading is 1ow
check 1'па а11 charging саЬ1е
and соппесог are соо1. А 'пот
connection is 'resistive' and
should Ье cut back and remade.
1f the meter reading is 1ow Ы1
everything else is satisfactory,
ор the engine and саггу out
further [е [ а indicated under
Alternator Testing.
If the voltage is соггес , check
the alternator output а ollows:
*Using а дитту connector Х,
connect the ammeter section Ы
the test meter between the
alternator and the alternator
plug а hown (positive meter
1еад Ю alternator). Note
that connections are similar ог
both Ыса and АС De1co
alternators.
connect the voltmeter section
Ы the е 1 meter асго he
battery (оЬер'е polarity).
Start the engine and run at
2000 rev/min.
А the engine 1аг , the
voltmeter reading should rise
rapidly to charging voltage
(14 to 15 volts).
Switch оп af1 lights and
auxiliaries and check the
ammeter reading. This should
Ье approximately 40 агпреге .
9803/3200
lssue 3*
С
3-4
9803/3200
ELECTR ICS
С
3-4
1ввие 4
Е IЕстА IСв
С
3-5
С
3-5
А1ТЕАГ'АТОА 18ACR
Testing
Веоге ебёп9 alternator, саггу
out charging circuit checks
1 and 2.
Аегпа! е alternator ехегпа1
connection ( Феге necessary)
and start engine.
Failure Ы the alternator to
сЬагде the Ьа1 егу тау Ье
саивед Ьу оме Ы the following
conditions. These аге listed in
approximate огдег Ы
probability.
Соппес est глеег (Service
Too1s) in circuit, using а дитту
alternator соппесог as shown
in charging circuit Check 2.
1.
Defective regulator.
2.
Dirty slip rings ог worn
slip ring brushes.
3.
Defective Rectifier.
4.
Defective surge protection
diode.
5.
Орем ог бЬог circuited
field (гООг) winding.
6.
Орест ог short circuited
роег (баог) windings.
Regulator Снеск
Run the engine а 2000 ге /гпёп,
switch оп а11 lights and auxiliaries
and check the ammeter reading.
1f the ammeter по indicates а
high гае Ы charge, (approximately
40 аглрб) the alternator is in доо
огдег Ы he regulator is defective.
18АСА оп1 у
1f the ammeter continues to
бЬо а 1ow reading, disconnect
the surge protection diode А
and гереа he test.
1f the ammeter reading is по
satisfactory, the diode is
defective. Otherwise, геглое
the alternator ог further testing.
Емсаб 18ACR
Remove alternator end со' ег
апд temporarily соппес he
regulator field to еагЬ as а Х
ог У, according to the туре Ы
alternator fitted:
14TR Regulator (Х) —
Regulator case to alternator
frame.
ВТА Regulator (У) —
бгееп wire to alternator гагле.
САУ АС5А апд АС5НЕА
(Lower illustration)
'F' terminal оп the brush
Ьох to negative (—) terminal.
9803/3200
1ввие 4
С
ЕIЕСТА1 С$
З-6
С
З-6
ALTERNATOR—DN460
Testing
ОеесЁб in the charging system
wi11 manifest ав опе ог тоге Ы
the following three conditions.
1.
2.
1f 1атр does по light, check
the brushes, slip-rings апд rotor
windings ог орел circuit.
1f 1атр lights, гепе the
regulator ап check the rotor
windings.
Faulty indicator 1атр
operation.
Undercharged battery.
3. Overcharged battery.
ЕА11ТУ 1NDICATOR LАМР
СРЕ i АТ 10
ТебЁ [атр ог Nогта1 Operation.
Start
Switch [атр Engine
Off
Off
Stopped
ОН
Оп
Stopped
Оп
ОП
Виппгпу
Sw► itch Оп, Iатр ОН and
Engine Running а Charging
Speed. Check for
undercharged battery condition
(Зее Раде С 3-7),ог
defective а1 егпаог.
1f 1атр оеб not орегаЁе
погта11 у check as о11об:
Switch Off апд Iатр Оп.
(This condition wi11 сливе ап
undercharged ЬаЁЁегу). 1f
switch functions соггес1 у,
гепе the rectifier bridge.
Sи►itch Оп, Iатр Off апд
Engine Stopped. (This condition
‚‚,i11 cause ап undercharged
battery).
With the Switch Оп,
дisconnect 1еа гогт 1Г\ О
terminal апд earth it. 1f
1атр а 1б to light, check 1атр,
switch апд leads.
Маке Earhing tool А to the
dimensions shown. 1f the 1атр
lights, гер1асе IND terminal
1еад ап insert the tool into
the ЁебЁ hole to earth the field
windings as shown.
9803/3200
л
1 i п(25IIIiТI
Ч
lssue 4
С
Е [ЕстА1св
С
3-7
3-7
ОЕГСНАГЮЕО ВАТТЕ 'ЧУ
OVERCHARGEDBATTERY
(lnchcator [атр operating normally)
(Ваегу in оо condition Ьш
using excessive water).
Check that the condition has not
Ьееп caused Ьу:-
Check for Ьог circuit in the
field winding, defective or
missing insulation 1еее from
the brush 1еад сир, or defective
regulator.
1.
Accessories 1е оп ог ап
ехепе period.
2.
Slipping drive Ье11.
З.
Faulty wiring or connections.
Withdraw the alternator plug and
check for system voltage at the
large terminals, а hown at В.
1f ЁЬеге is Но reading ап ореп
circuit exists between the
connector and battery.
1f the оЁаде is correct check
the alternator output а ollows:—
Using а дитту connector, а
shown at С, connect the ammeter
between the alternator and the
alternator plug (positive meter
1еад to alternator).
connect the о11тле1ег асго
the battery observing polarity.
5 аг the engine and run at
maximum ге .
А the engine starts the
voltmeter reading should rise
rapidly to а charging о11а9е
Ы 14 to 14.5 volts.
Switch оп lights and auxiliaries
and check the ammeter reading
is арргох. 40 аглр5.
1f the reading is 1о check for
alternator faults.
9803/3200
lssue 4
С
С
Е[ЕСТГ 1С$
3-8
3-8
27
30
28
22
31
20
21
звавд
9803/3200
lssue 3"
С
3-9
ELECTRICS
С
3-9
А[ТЕй[\ АТОГ 18АСГ
Dismantling and Assembly
Use the numerical sequence as
а guide to dismantling.
Еог assembly, геегзе the
seq uen се.
When Dismantling
[еас А and В must Ье
unsoldered when separating
items 16 and 20 and items
22 and 31.
Use Service Тоо1 892/00044
to drive out гоЮг 31 and its
bearings from the end brackets.
CAUTION: When unsoIdering
ог soldering саЫез to rectifier
16, it is essential to avoid
overheating the diodes ог
Ьепспд the diode pins. Саггу
out soldering as q uickly as
possible whilst gripping the
pins with long nosed pliers to
conduct а 'ау ехсезз heat.
Ensure that leads аге soldered
to the соггес positions:
С, D and Е.
С1 еап асез Ы slip ring 22 with
petrol moistened cloth, ог егу
Лпе glass рарег if burning is
evident. Во not use етегу cloth.
Аепе brushes 9 if their length
is less than 8тт. (0.3in.) ог if
the spring pressure is less than
198 to 283g (7 to 10о ) with
brush pressed flush with the
housing.
То ensure гее глоеглеп Ы
brushes, lightly polish side
faces.
*Regulators Х (14TR) and
У (8ТА ) аге alternatives. 1f
interchanged follow instructions
supplied with пе unit.
980313200
це 3*
С
ELECTRICS
З-10
З-10
22
19
20
21
24
23
`С~РГ
~С6Г~'Ги'
9803/3200
С
С
Е[ЕстА1СS
3-11
3-77
А[ТЕВГ\ АТОВ—О 46О
Dismantling апд ЧвветЫу
When AssemЫing
The numerical sequence оп
the illustration is intended as
а 91йе to dismantling.
Ensure that shaft ап bearing
17 are perfectly сеап after
removal Ы protective аре.
Рог assembly reverse the
sequence.
То retain the brushes in р1 асе
Ьеп entering the rotor into
position, insert а screwdriver
ог го a Ьоп а А.
When Dismantling
Mark а11 раг as they are
removed to ensure соггес
ге-аепп Ь Iу.
Torque Settings
Item Nт
19
68
Кдпп
7.0
1bf ft
50
5ерагае the drive епд bracket
апд rotor assembly 2 from the
• аогап
апд housing 3.
Remove nuts 4 to release the
1еас Ьеоге separating the
• аог winding from the slip
ring еп bracket 18.
Таре over bearing 17 ап he
slip ring еп Ы the shaft to
ensure cleanliness. 11 е
pressure sensitive аре, as
sticky аре would leave а
deposit оп the shaft.
When removing the ри11еу,
secure rotor 24 in а vice to
slacken пШ 19. Оо по
overtighten vice as the rotor
is easily distorted.
9803/3200
1
е1
С
3-12
9803/3200
Е 1ЕСТR 1сs
С
3-12
lssue 1
С
Е [ЕСТА1С
3-13
3-13
А[ТЕГН\ АТОЕ АС5НЕЕ
Dismantling апд AssemЫy
Те numerical sequence
оп оп the illustration is
intended а а guide to
Dismantling.
Рог АеглЬ1 у the sequence
should Ье reversed.
When Dismantling
оЁе positions Ы regulator
connections (11) Ьеоге
removal.
Withdraw drive-end shield (17)
and rotor (20) complete, the
rotor тау Ье drifted out Ы
drive еп bearing аЁег removal
of еу 19.
Во поЁ dismantle the rectifier
рас 33, renew only аз а
complete unit.
When Assembling
Сес bearings for
renew if песеагу.
еаг and
Spin the rotor ЬеЁееп сепЁге
and polish the Нр ГП9 to
obtain true concentricity within
о.о5тт. (о.оо2гп.)
lnspect brushes (А), if length
is 1е гЛап 8тт. (0.312in.)
renew brush and holder аеглЬ1 у
6 complete.
9803/3200
С
С
С
Е1ЕстА1 св
4-1
4-1
ОУГ\!АМО
Testing
Disconnect саЫеб гогл
дупато terminals and
bridge the terminals with ап
auxiliary саЫе.
Run engine at idling speed and
соппес1 о11гле1ег V ЬеЁ'уееп
terminals апд earth аб shown.
Gradually increase engine
speed and оЬбеге voltmeter
reading which should rise in
proportion to engine speed
and without fluctuation.
СА1ТОГ : Во not a11ow
reading to ехсеед 15 о11б, ог
serious сагяаде to the дупато
тау Ье caused.
1f reading соеб not reach
12 volts, the dynamo is
defective.
1330
9803/3200
С
Е1ЕСТR1СS
С
4-2
4-2
DYNAMO
Removal and Еер1 асегпеп
The numerical sequence
shown оп the illustration is
intended as а guide to гегпоа1.
Рог replacement, reverse the
sequence.
When Removing
Disconnec Ьа 7 Ьу removing
Ьо1 6, only if drive Ье1 8
requires renewal.
When Replacing
Adjust position Ы упагло to
give 0.5in. ( 13тт) deflection
Ы the drive bёlt as а1 А.
1f а replacemen упагпо is
being fitted, polarise as
follows to suit the гпасЫпе
electrical 5у 1егл:
1.
Fit the упагпо to the
machine, bиt до по
соппессаЬ1 е5 1.
2.
Соппес а length Ы cable
to the positive battery
terminal and hold the other
епс to dynamo terminal В
ог а е',' seconds.
З.
Аето 'е cable гогп
battery and соппес
саЫе5 1.
ОТЕ: Ргогп machine Но.
55500, а negative еаги уегп
is used.
9803/3200
lssue 1
С
С
ELECTR ICS
4-3
4-3
9
9803/3200
С
С
Е [ЕСТВС
4-4
4-4
DYRIAMO
Dismantling and АегпЬ1у
The numerical sequence оп
the illustration is intended а
а guide to dismantling.
Рог аеглЬ1 у, гееге the
sequence.
When Dismantling
Вето~е оп1 у items 1 to 23
inclusive, unless renewing
field coils.
lnspection and Вераг
Renew brushes 12 if chipped
огп to а
or cracked, or i
1 ег19 Ъ Ы1е
an 0.5in.
(12.7тт).
1345
Renew springs 14 if tension,
an
measured а а А, is 1е
(51Og).
18
Check commutator е9глеп1 В
ог burning, which тау indicate
ап ореп circuited winding.
Unless the commutator is
heavily Ыгге or pitted, с1 еап
with а petrol moistened cloth
or fine 91а рарег. Otherwise
skim the commutator оп а lathe
о а minimum diameter Ы
1.45in. (3
тт). Polish with
veryine g`lass рарег. Оо по
use еглегу cloth.
С1еап ou 1о1 between
е9глеп1 Ы до по undercut.
9803/3200
1337
lssue 1
С
5-1
Е[
ЕСТА 1С
С
5-1
CONTROL60Х
Component Кеу
1 'D' Terminal
2 'Е' Terminal
3 'А' Terminal
4 'F' Terminal
5 Cut-out соге and winding.
6 Voltage Regulator соге
and winding.
7 Voltage Regulator
armature.
8 Voltage Regulator
adjustable contact.
9 Adjustable contact arm
securing screws.
10 Cut-out stop arm.
11 Cut-out armature
12 Cut-out fixed contact.
13 Cut-out adjusting сгеw
14 Voltage Regulator
adjusting сге .
9803/3200
lssue 1
С
5-2
ЕI
ЕстА1С8
С
5-2
СОNТRОi В0Х
Testing апд Adjustment
САИТ10N: Check апд adjust
а uickly а possible to avoid
inaccuracies дие to heating
Ы the unit. Епнге that
оо1 етр1 оуед до по cause
а short circuit between
апд control
adjusting сге
Ьох соег.
Electrical Settings
/о1 ае Regulator
Disconnect cable гогп 'А'
terminal, гегпое linked plugs
and соппес oltmeter V
between the cut-out adjusting
screw В апд а good earth.
With engine running а
approximately 1800 rev/min.
the voltmeter геасПп9 should
Ье between the following
limits.
Ambient
Voltmeter
Temperature Reading
10°С (50°F) 16.1 to 16.7
20°С (68°F) 16.0 to 16.6
30°С (86°F) 15.9 to 16.5
40°С (104° F) 15.8 to 16.4
Adjust а песеагу Ьу
turning the ге911аог adjusting
screw С clockwise to increase
ог anti-clockwise to decrease
the voltage.
81ор engine and гесоппес1
cable to 'А' terminal.
9803/3200
lssue 1
С
5-3
Е[ЕСТЕ 1 С5
С
5-3
СОNТRО[
В0Х
Electrical Settings-Cut-ou[
Cut-in \ о1 аде
Connect о1 гпеег between
the 'D' terminal and а good
earth.
Switch ог] working lights,
аг engine and increase speed
slowly. ОН reaching 12.7 to
13.3 volts, the о1 гпеег needle
should drop slightly, indicating
closure Ы contacts (cut-in
voltage).
1f reading is incorrect, reduce
engine реес and adjust Ьу
turning the с -оШ adjusting
screw В clockwise to increase
or anti-clockwise to decrease
the cut-in voltage.
S1ow1y орел the throttle to
recheck setting а аЬое.
Огор-ОП \ о1 аде
Disconnect саЫе from the'А'
terminal and connect
о1 гпеег between this terminal
and а good earth.
Run engine а approximately
1000 rev/min. 1 еп slowly
deccelerate. Voltmeter needle
should fa11 to его оп reaching
11.0 to 8.5 volts, indicating
opening Ы contacts (drop-off
voltage).
NOTE: Огор-оЛ voltage
cannot Ье ас} iе i externally.
1[ the voltage reading is
incorrect, either adjust а
described under "Mechanical
Settings ( Раде С 5-4) or Ш а
replacement control Ьох.
9803/3200
lssue 1
Е1ЕСТЕ 1 С
5-4
С
5-4
СОNТЕО1 В0Х
Mechanical Settings—Voltage
ReguIator
АеаеппЬ1 е control Ьох onto
machine and сНес electrical
setting (see ране С 5-3).
Disconnect battery earth cable,
remove control Ьох from
machine and carefully prise ир
ад D to remove cover.
Е and
1 асеп securing сге
insert 0.021 in. (0.53тт)
ее1 ег gauge Ье1 ееп armature
F and соге асе а hown.
With armature ргее
uarely
gauge,
retighten
against 1 е
сге .
With gauge sti11 in position
slacken locknut G, adjust
fixed contact until it touches
moving contact and retighten
locknut.
Reassemble control Ьох onto
machine and сНес electrical
setting (see раде С 5-2).
Mechanical Settings — Cut-out
Disconnect battery earth cable
remove control Ьох from
machine and carefully prise ир
ад D to remove cover.
Рге armature Н onto соге
асе; gap Ье1 ееп armature
tongue an
Ёор arm J should
Ье 0.025 Ёо 0.О4Оi п. iО.63 to
1.02тт). А ]1 gap Ьу
carefully bending ор arm.
Ае1 еае armature and
carefully bend Лхе contact
blade К to give а gap Ы 0.010
to 0.020
0 (03,5 to 0.51тт)
а L. снес that blade еЛес s
slightly а armature is ргее
against соге асе.
NOTE: 1псгеае ог есгеае
gap L to raise ог lower drop-off
о1 аде respectively.
9803/3200
1 з5 е 1
С
ЕЕЕстА1 св
С
6-1
6-1
FAULT FINDING —
ТАГТ1 Г\
У~ТЕМ
Diagnosis
Fau1t
1.
агег inoperative
а. Battery discharged.
Ь. Роог саЫе connections.
с. Defective саЫез.
д. Brushes
огп or sticking.
е. Commutator worn or dirty.
f. Pinion jammed.
g. Faulty switch, о1 епо or relay.
Ь. Faulty windings.
2.
агег орегае
but оеб по
crank engine.
а. СЬес 1 а, b, с, д, е.
Ь. Faulty drive assem Ыy.
с. Engine fault.
3.
агег cranks
engine slowly
а. Check 1 а, b, с, д, е.
Ь. Faulty switch.
FAULT FINDING—CHARGIN
Fau1t
4.
У~ТЕМ
Diagnosis
n
Ваегу 1о
сЬагде (1оу
Hydrometer
а. Check 1 а, b, с.
Ь. Dynamo or alternator drive Ье1 б broken or slipping.
reading).
с. Faulty Ьаегу.
д. Dynamo or alternator output insufficient.
е. Сопго1 Ьох or о1 аде сопго1 incorrectly set or faulty.
980313200
1 ззе 1
Е1ЕСТй1С
С
6-2
6-2
FAULT FINDING — С,ARGING У~ТЕМ (Continued)
Fau1t
5.
Diagnosis
Го output or 1ow
intermittent output
from дупато or
а1[егпаог.
а. Check 1 Ь, с, апд 4 Ь.
Ь. Brushe
огп or sticking.
с. А1 егпаог slip rings worn or dirty.
е. Faulty windings.
6.
Excessively high
output гогл
дупато or
а. Check 4 е.
а1 Ёегпаог
FAULT EINDING— LIGHTING У~ТЕМ
Diagnosis
Еаы1
7.
А11 lights
inoperative.
а. Check 1 а,Ь,с.
Ь. Fuse Ь1оп
с. Faulty ammeter (if fitted).
8.
1 ndividual lights
inoperative.
а. Check 1 Ь,с.
Ь. Ви1Ь burned out.
9803/3200
lssue 1
С
С
Е1ЕСТ 1 СЗ
7-1
7-1
Component Кеу
1 Alternator
6 Battery
7 Flasher Unit
8 Heater
9 Ногп
10 Ногп Button
11 Рапе1 Light
12 Starter Motor
13 Voltage Stabiliser
14 Terminal Connector
15 Temperature Gauge—
Engjne
116 Temperature Gauge—
Transmission
17 Temperature Transmitter—
Engjne
t 18 Temperature Transmitter—
Transmission
19 Wiper Motor
20 ЕедЫа1ог
23 Fuse Вох
24 Dynamo
25 Battery lndicator
26 Роег Point (3D оп1 у)
27 Lamp Socket
28 Fue1 Tank Unit
29 Fue1 Gauge
30 Cigarette Lighter—
(3D оп1у)
1_а пi р
38 Веасоп
39 Dipper
40
Lamps—Right Наяд
62 Working—Front
63 Working—Rear
65 Неад
67 Flasher—Front
68 Flasher—Rear
70 Number P1ate
71 Stop/TaiI
72 Side
Warning Lights
81 Alternator/Dynamo
82 Flasher
84 Main Веат
85 Oi 1 Pressure
86 Working Light—Front
87 Working Light—Rear
88 Air Cleaner
89 Веасоп Light
Switches
101
Starter
102
103
104
105
107
108
110
111
113
114
115
Working Lamp—Front
Working Lamp—Rear
Неад1 атр
Stop Lamp
Flasher
ОН Pressure
Heater
Dip
Air Cleaner
Neutral Start
Веасоп Light
Interior (ЭС & 30 Оп Iу)
Wire Со1ог Соде
Lamps—Left Наяд
42 Working—Front
43 Working—Rear
45 Неад
47 Flasher—Front
48 Flasher—Rear
51 Stop/Та i 1
52 Side
В
Black
G reen
G
1_ с; Light СЭгееп
Вгоып
N
Огапде
О
Р Purple
R Red
U
В1 ие
W White
У
Ye11ow
t Torque Converter machines оп1 у
9803/3200
1
уе 2
С
С
ELECTRICS
7-2
7-2
72
12
~В
71
к
70
105
бе
у1
-113 -в
17
114
88
си
i1
f1
27
28
св
51
в
39
в
52
13
•
25
101
о
4-В
ИУ
11
01
r,
о
-В 16 84
ГN
ик
65
В
45
В
uw
30
ск
82о
9
В
Ф
1•г
в
ск
ии
47
оси
и
1с
23
Pw
1
Р
8
бу,
6а
1
с
68
1)У
и
102 86 87
S
В
ив
В
иУ
i1
103
iii
а
14
42
иУ
24
110
е 20
UY
В
NY
12
81е
6г
38
Му
к ~г
43
г --- в
си
г
сУ
8
1
89
МУ
с 115
4.в
с
19
В-
В
19
81
85
w-
108
ши
1
о
22 В
9803/3200
1 ввие 2
С
Е I ЕстА СЗ
7-3
7-3
Lamps—Right Наяд
Component Кеу
1
6
7
8
9
11
12
13
14
15
t 16
17
t 18
19
20
23
24
25
26
27
28
29
30
33
34
35
Alternator
Battery
Flasher Unit
Неаег
Ногп
Рапе1 Light
аг1 егМооr
'о11 аде Stabilizer
Terminal Соппесог
Temperature Gauge—
Engine
Temperature Gauge—
Transmission
Temperature Transmitter—
Engine
Temperature Transmitter—
Transmission
Wiper Моог
Regulator
Fuse Вох
Оупагпо
Battery lndicator
Power Point (3D оп1 у)
Lamp Socket
Fue1 Tank Unit
Fue1 Gauge
Cigarette Lighter (3D оп1 у)
Diode
Lighting Re1ay
Ногп Re1ay
62
63
67
73
74
Working—Front
Working—Rear
Flasher—Front
Stop/Tai1/Flasher
Неад/Side
Warning Lights
81
82
84
85
86
87
88
89
Switches
101
102
103
105
108
110
113
114
115
116
117
Lamps
38
Веасоп
39 0 ррег
40
!пегог (ЭС & 30 only)
Lamps—Left Наяд
42 Working—Front
43 Working—Rear
47 Flasher—Front
53 Stop/Tei1/Flasher
54 Неад/Side
Alternator/Dynamo
Flasher
N1ain Веат
Oi1 Pressure
Working Light—Front
Working Light—Rear
Air Cleaner
Веасоп Light
агег
Working [аглр— Егоп
Working Lamp—Rear
ор Lamp
ОП Pressure
Неаег
Air Cleaner
Neutral Start
Веасоп Light
Mu1ti-Purpose
Неад/Sidelight
Wire Colour Соде
В
G
LG
N
О
Р
B1ack
Green
Light Green
Brown
Огапде
Purple
R
Ае
U
В1 ие
W White
У
Ye11ow
t Torque Converter machines only
9803/3200
1 ввие2
С
С
ELECTRICS
7-4
7-4
74
12
27
В.
г
54
26
wR
81
27
С
в
131
°114 113.WY
28
105
13
25
611
г
88
39
в1
27
г
Ii
с
1~г п
53
в1
ср
73
Ас
в1
611
47
84
иА
В1
7
115
82
1 О5е~ ьIЦ
----' 5 L 491
611—у 116
LcN
в1
67
П)
1
'
У-
в138
в,
30%51
`
р
86 87
85
РВ
в
101
С
9
40
в1
110
8
в1
19
в1
19
81
30
в1
43
в
63
8.1
42
81
62
в1
85
шип
си
9803/3200
+ 108
18
В
1
си --1---в
1 ввие 2
С
С
ЕIЕстА1СЗ
7-5
7-5
Lamps—Right Наяд
Component Кеу
1
6
7
8
9
10
11
12
13
14
15
t 16
17
t 18
19
20
23
24
25
26
27
28
29
30
Alternator
6attery
Flasher Unit
Heater
Ногп
Ногп 6utton
Pane1 Light
Starter Motor
Voltage Stabilizer
Terminal Соппесог
Temperature Gauge—
Engine
Temperature Gauge—
Transmission
Temperature Transmitter—
Engine
Temperature Тгап5гтйЁ[ег—
ТгапбгтН55 оп
Wiper Motor
Regulator
Fuse Вох
Вупагло
Battery Indicator
Power Point (30 only)
Lamp Socket
Fue1 Тап Unit
Еце! Gauge
Cigarette Lighter (30 only)
Lamps
38
39
Веасоп
Dipper
40
lnterior (ЭС & 30 оп1у)
1ап1р5-1е
42
43
47
53
54
Working—Front
Working—Rear
Flasher—Front
Stop/Tai1/Flasher
Неад/Side
Warning Lights
81
82
84
85
86
87
88
89
А11егпа1ог/0упагто
Flasher
Main Веат
Oi 1 Pressure
Working Light—Front
Working Light—Rear
Air Cleaner
Веасоп Light
Switches
101
102
103
105
107
108
110
113
114
115
117
118
1агег
Working [агтр— Егоп1
Working [агтр— еаг
Stop Lamp
Flasher
Oi1 Pressure
Heater
Air Cleaner
Neutral Start
Веасоп Light
1-I еад /Sidelight
Hazard Warning
Wire Colour Соде
Наяд
Working—Front
Working—Rear
Flasher—Front
Stop/Tai1/Flasher
Неад/Side
t Тогцуе Сопег1ег machines оп1у
9803/3200
62
63
67
73
74
В
G
В1 ас
Green
1-с Light Green
Вго' л
N
О
Огапде
Р
Purple
R
ес
и В I не
W
White
У
Уе11ош
lssue 3*
С
С
ЕLECTRICS
7-6
7-6
'7
1
1
1
17
В
си
18
св
Х19
1
1
2О
си
ср
34
сР
2
R
1
37
QХ16
4
а 31
г-
38
55
г
39
О40
53
и
L
а
‚
1
22
оо
2546
9803/3200
1ббе 3*
С
ELECTRICS
С
7-7
7-7
Согяропеп Кеу
1
2
ВаЁЁегу
Ёагег МоЁог
3 Alternator
4 Fuses (8 атр)
5 Ногп
6 Ро 'ег Point (Optional)
7 Wiper МоЁог
8 Heater
t 9 Temperature Gauge—
Transmission
10 ВаЁегу lndicator
11 Fue1 Gauge
12 Тегпрега1 ге Gauge—Engine
13 \'о1 Ёа9е Stabilizer
14 Flasher Unit
16 [атр Socket
17 Cigarette Lighter (Optional)
t 18 Temperature Тгап5глгЁЁег—
Тга пзгл iз iоп
19 Еие1 Tank Unit
20 Temperature Transmitter—
Engine
Lamps
21
Alternator Warning
22
23
24
25
26
27
28
29
30
1 nterior
Веасоп (Optional)
Веасоп Warning
Air Filter Warning
Oi1 Pressure Warning
Рапе1 Lights
[Н Flasher lndicator
АН Flasher lndicator
Number P1ate
31
Dipper
32
33
34
35
36
37
38
39
40
41
42
43
44
Front Working Light Warning
Rear Working Light Warning
[Н Rear Cluster
[Н Front Cluster
АН Front Cluster
АН Rear Cluster
[Н Неад1атр
АН Неад1атр
1Иаiп Веат Warning
[Н Front Working
АН Front Working
[Н Rear Working
АН Rear Working
Switches
45
46
47
48
49
50
Неаег
Air Filter Warning
Neutral агt
агег
Engine ОН Pressure
Brake Light
51
lndicator
52 Side/Неад1атр
53 Ногп
54 Веасоп [агпрз (Optional)
55 Headlamps—Dip
56 Front Working [атр
57 Rear Working [атр
Wire Colour Соде
1ас1
G reen
1-с Light Згееп
N
Вго 'п
Огап9е
О
Р
Purple
Вес
В
G
и
В 1 це
У
White
Ye11ow
t Тоге Converter machines оп1у
9803/3200
1ssue 3'
С
С
Е1ЕСТГ 1 СЗ
7-8
7-8
1
45
•
~8
в
си
10
wR
13
47
Ф
wv
48
О2 5
вес
св ---_1
1~ i
~4
12
6
20
си
с _926
27
сР
СР
СР
5а
ив
с
и
30 1
L
37
31
w
=16
4
и
и
25д6
9803/3200
lssue 3•
С
4+
ELECTRICS
7-9
7-9
Component Кеу
1 Ва1 Ёегу
Ёагег Motor
2
3 Alternator
4 Еиве — 8 атр
4а Fuse — 16 атр ( ог Соее МаГег).
5 Ногп
6 Wiper Motor—Front
6а Wiper Motor—Rear
7 Thermostart
8 Неаег Моог
9 Неаег Resister
10 ]оЁае Stabilizer
11 ВаЁЁегу Condition Gauge
12 Ее Gauge
13 Temperature Gauge—Engine
114 Temperature Gauge—Transmission
15 Fue1 Tank Unit
16 Temperature Transmitter—Engine
t 17 Temperature Transmitter—Transmission
18 Cigar Lighter
19 Flasher Unit
20 Наагс Flasher Unit
21 KettIe осГеt
Lamps
22 [Н Rear Flasher
23 [Н Front Flasher
24 АН Front Flasher
25 АН Rear Flasher
26 [Н and АН ор
27 Оррес Веат
28 Main Веат
29 Number Р1 ае
30 Оррег
31 [Н Tai1
32 [Н Side
33 R Н Side
34 АН Таг1
35 Front Working Option U.S.A.
36 Rear Working
37 Веасоп
38 1 nterior
39 Instrument
40 Torque Converter Instrument
t Тогсре Converter machines оп1 у
9803/3200
Warning Lights
41 Left Turn
42 Right Turn
43 Наагс
44 Oi1 Pressure
45 Alternator Rear
46 Alternator Front
47 Main Веат
48 Rear Working
49 Front Working
50 Веасоп
51 Air Filter
Switches
агег
52
53 Neutral агt
54 Air Filter
55 Неаег
56 Наагс
57 Indicator
ор атр
58
59 ОН Pressure
60 Horn
61 Неад1 атр Flasher
62 Dip
63 Аоас Light
64 Rear Working
65 Front Working
66 Веасоп
Note 1: 'Апеп hazard warning is fitted, the
ire between the 1абпег unit and the
[С
indicator switch is omitted.
Note 2: Тпе 16 атр fuse 4а is used onIy
when а coffee maker is to Ье ес from the
cigar lighter. Тпе G wire feeding the cigar
lighter is then disconnected.
Wire Со1 ол Соде
6lack
В
Green
G
Pink
К
[С Light Green
N
Вгоп
О
Р
R
S
U
W
У
Огапде
Purple
Аед
1 ае
В1 ие
White
Ye11ow
1
е1
r-r
С
Е1ЕстАiсв
7-10
7-10
7
52
Wуе53
wR
с
11
1
10
св
13
51
с
4а
в iс
4\-414
с-
си
17
с5
сУ
4
9
8
св
с5
.- ▪ --____ СG И--
4
-Ф -- - Р - f° °-i-1С К--
го
И
59
L
вв
26
и
с ---~58
4
-:Х
►И
26
5
Р
ЕХ
L
Г
4
Г
aN
4
Р
Г
50
wo
с
.в
~~4
р
О65
ur
35
35
И
4
р
64
ов
О48
36
36
зп7д
9803/3200
1ssue 1
С
С
Е1ЕстА1 С
7-11
7-11
Component Кеу
1 Battery
2 Starter Моог
3 Alternator
4 Fuse
5 Ногп
6 Wiper МоЮг— ЕгопЁ
6 а Wiper Моог— Аеаг
7 Thermostart
8 Неаег МоЁог
9 Неаег Resistor
\1о1 а9е Stabiliser
10
11 Ваегу Condition Gauge
12 Fue1 Gauge
13 Temperature Gauge—Engine
114 Temperature Gauge—Transmission
15 Fue1 Tank Unit
16 Temperature Transmitter—Engine
117 Теппрегаыге Transmitter—Transmission
18
Cigar Lighter
19
20
21
Flasher Unit
Наагс Flasher Unit
Ке 1е Socket
Lamps
22 L. Н. Side Repeater
23 L.H. Реаг Flasher
24 L.H. Егог Flasher
25 R.H. Егог Flasher
26 R.H. Реаг Flasher
27 R. Н. Side Repeater
28 L. Н. апд R. Н. Stop
29 Dip Веат
30 Number Рае
31 Dipper
32 L. Н. Та i 1
33 L. Н. Side
34 R. Н. Side
35 R.H. TaiI
36 Егоп Working
37 Реаг Working
38 Веасоп
39 lnterior
40 1 nstrument
41 Тогще Сопуегег lnstrument
t Тогще Сопегег machines оп1 у
9803/3200
Warning Lights
42
Left Тыгп
43 Right Turn
44 Hazard
45 Oi1 Pressure
46 Alternator—Rear
47 Alternator—Front
48 Dip Веат
Rear Working
49
50 Front Working
51 Веасоп
52 Air Filter
Switches
53 Starter
54 Геыга1 5 аг
55 Air Filter
56 Неаег
57 Наагс
58 Direction 1псНсаог
59 Stop [атр
60 Oi1 Pressure
61
62
63
64
Ногп
Dip Веат F1ash
Dip Switch
Аоас [атр
65
66
67
Rear Working
ЕгОп Working
Веасоп
Гое: When hazard warning fs fitted, the
[СГ wire Ьеншееп the flasher unit апд the
indicator switch is omitted.
Wire Со1 оиг Соде
В
8lack
G Green
Р!П
К
LG Light Green
N
Вгоп
О
Огап е
Р
Purple
R
Вес
S
S1ate
и В Iiiе
W White
У
Уе11 ош
lssue 1
С
С
ELECTRICS
7-12
7-12
ч
7
м
1
ч
о
1
1
bYR
12
10
и~ д
BLG
_G
18
11
55 --
Ь -:-17 -z
г
56
~
--ои ----
1чцье
GS
Г~
LGн
r-r -т- ; --,5
57
и
4
г
ог -иск -
р
45
—=
Уди
cw
®б0
®42
Q 43
', 3
1
ОР
Рв
4
21
4
62
Х48
24
Т 255
2 р27
28
28 t
5
1129
4
R
39
33
,.51
34
35
С
4
wo
Р
66
иУ
4
Р
65
ив
49
36
36
0о1
_и
38
37
37
36456
9803/3200
С
С
ЕIЕСТА1С$
7-13
Component Кеу
1 Ва1 егу
2 Starter Моог
З Alternator
4 Fuse
5 Ногп
6 Wiper Motor—Front
6А Wiper 1Иotor—Rear
7 Thermostart
8 Неаег Motor
9 Heater Resistor
10 Voltage Stabiliser
11 Battery Condition Gauge
12 Fue1 Gauge
1З Temperature Gauge—Engine
t 14 Temperature Gauge—Transmission
15 Fue1 Tank Unit
16 Temperature Transmitter—Engine
t 17 Temperature Transmitter—Transmission
18 Cigar Lighter
19 Flasher Unit
20 Kettle Socket
Lamps
21
L.H. Side Repeater
22 L.H. Rear Flasher
2З L.H. Front Flasher
24 R.H. Егоп Flasher
25 R.H. Rear Flasher
26 R.H. Side Repeater
27 L. Н. апд R.Н. Stop
28 Dipped Веат
29 Number Р1 ае
ЗО Dipper
З1
L. Н. Tai1
З2 L.H. Side
33 R.H. Side
З4 А.Н. Tai1
З5 Егоп orking
З6 Rear Working
З7 Веасоп
З8 lnterior
З9 lnstrument
40 Torque Converter lnstrument
7-13
Warning Lights
41
Left Turn
42 Right Turn
4З Hazard
44 Oi1 Pressure
45 Alternator—Rear
46 Alternator—Front
47 Dip Веат
48 Rear Working
49 Front Working
50 Веасоп
51 Air Filter
52 Flasher Failure Warning
Switches
5З Starter
54 Neutral 5 аг1
55 Air Filter
56 Heater
57 Hazard
58 Direction Indicator
59 Stop [атр
60 Oi1 Pressure
61 Ногп
62 Dip Веат F1ash
6З Dip Switch
64 Аоас 1_атр
65 Rear Working
66 Егоп Working
67 Веасоп
Wire Colour Соде
В
6lack
G
Green
К
Pink
LG Light Green
Вгоп
N
Огапде
О
Р
Ригр1 е
Аес
R
S 51ае
В1 ие
U
W
White
У
Ye11ow
t Torque Converter machines оп1у
9803/3200
lssue 1
С
С
Е[ЕСТЕ 1С3
7-14
7-14
7
WY~54
53
с
шв
11
l
I•-°С )~6а
12 I
66JJ
~1о
~
13
си
16 1
с
вi
L —с
4
1
с
с
~I О52
ся
С
9
58
св
Г. 8
г J22, D21
сА
сш
®41
Q42
Э23
24
325
Е 26
27 1
59
27
1
и
~
Ф
64
.4.
4
—и
т
4Ф
т
Р~~8
1
---
Р
Т
;
Ь;'67
0 -
--------5---
40z
--1
П37
4
ю
Р
®66
ии
35
49
4
Р
65
ив
048 1
35
2з6
36
3644 А
9803/3200
С
С
Е IЕСТА1СЗ
7-15
7-15
Componenfi Кеу
1 Ва1 егу
агег Моог
2
3 Alternator
4 F иses — 8 атр
5 Fuse — 16 атр ( ог Coffee Maker)
6 Ногп— Егоп
7 Ногп— Аеаг
8 Wiper Моог— Егоп
8а Wiper МоЮг— Аеаг
9 Thermostart
10 Rear Window ОеггНбег
11 Неаег Моог
12 Неаег Resistor
13 Уо1 а9е Stabiliser
14 Ва1 егу Condition Gauge
15 Fue1 Gauge
16 Temperature Gauge—Engine
17 Temperature Gauge—Transmission
18 Fue1 Tank Unit
19 Temperature Transmitter—Engine
20 Temperature Transmitter—Transmission
21 Cigar Lighter
22 Flasher Unit
23 На2аг Flasher Unit
Lamps
24 L.H. Rear Flasher
25 L.Н. F ront Flasher
26 R.H. Front Flasher
27 R.H. Rear Flasher
28 L.H. and R.H. ор
29 Main Веат
30 Dipped Веат
31 Number Р1 ае
32 Dipper
33 L.H. Tai1
34 L.Н. Side
35 R.H. Side
36 R.Н. TaiI
37 Front Working
38 Rear Working
39 Веасог
40 1 nterior
Engine Compartment
41
42 1 nstrument
43 Тогцце Converter lnstrument
51
52
53
54
Front Working
Rear Working
Веасоп
Air Filter
Swifiches
55 1агег
56 Neutral агt
57 Air Filter
58 Неаег
59 Нааг
60 lndicator
61
ор атр
62 Оi 1 Р ressure
63 Horn—Front
64 Ногп— Аеаг
65 Неад1 атр Flasher
66 Dip
67 Аоа Light
68 Егоп Working
69 Rear Working
70 Веасог
Note 1. 'А/ еп hazard warning is fitted, the
LGN wire Ье1'уееп the 1азпег unit апд the
indicator switch is omitted.
Note 2. Тпе 16 атр fuse 5 is used only
«4 ег а coffee maker is to Ье fed from the
cigar lighter. Тпе G wire feeding the cigar
lighter is then disconnected.
Wire Colour Соде
6lack
Згееп
Pink
Light G reen
В rown
Orange
Purple
Rе
1 ае
В1 ие
White
Ye11ow
Warning Lighfis
44 [ е Ти rn
45 Right Turn
46 На2аг
47 Oi1 Рressure
48 Alternator Rear
49 Alternator Front
50 Main Веат
9803/3200
1ssue 1
Е1ЕСТ~1СЗ
7-16
С
9
7-16
с
14
О15
13
16
Си
19
Си
с
58
GS
GV•— .---GS
19
L
12
22
LCN
г
±
23
и -о›
а
+о
1
4
59
-
о+--- иск —J
_4Сд_--
L_ --
О62
47
28
бР
28
31
32
з
34
43
Ч
1
43
4
ФФ
UY
68
О 51
69
О52
4
и —- ю-----
®64
N
4
1
70 '
9803/3200
ив
L
]38
Рв
3в
4О
р
41
L
r
wo- ~
iз9
L
1ssue 1
с
ELECTRICS
7-17
7-17
C1RCUIT DIAGRAM
Main Components
Warning Lights
1
Ваегу
2
SoIenoid
3
50
агег Моог
Water Тегярегаюге
51
Transmission Oi1 Pressure
4
Thermostart
52
Transmission О11 Temperature
5
Егоп
iper апд Switch
Rear ‚Л1 рег апд Switch
53
Engine Oi1 Pressure
54
Air Filter
Fue1 СЗаыде Вагдее-
55
Direction 1псПсаог
8
Fue1 Саиуе Sепдег
56
Наагс Warning
9
Diode Вап
57
НапЬгае
10
Виггег
58
Alternator—Rear
11
Fuses
59
А1 егг'аог— Ргоп
12
Неаег Моог
60
Main Веат
13
Flasher Unit
61
Егоп
14
Наагс Unit
62
Rear Working
15
А1 егпаог
63
Rear Fog
16
Ногп
6
7
Lights
Switches
25
Neutrai
26
агег
orking
агt
27
Water Temperature
28
Transmission ОН Pressure
29
Transmission ОН Temperature
30
Engine Oi1 Pressure
31
Air Filter
32
НеаегМоюг
33
Hazard Warning
34
Direction lndicator
35
Brake Light
36
Handbrake
37
lnterior Light
38
Веасоп
39
Ногп Push
40
Headlight Flasher
41
Dipswitch
42
Road Lights
43
Ргогт Working Light
44
Rear Working Light
45
Rear Fog Light
70
L.H. Ргоп Flasher
71
L.H. Rear Flasher
72
R.H. Rear Flasher
73
R.H. Ргог' Flasher
74
Brake
75
lnterior
76
Веасоп
77
Main Веат
78
Dip Веат
79
Number PIate
80
Dipper
81
L.H. Tai1
82
L.H. Side
83
R.Н. Side
84
R.Н. Tai1
85
lnstrumentation
86
Ргоп
87
Rear Working
88
Rear Fog
orking
СаЫе Colour Соде
Fuse ldentification
В
Вас
Г\ о.
Rating
Circuit
G
Green
1
8атр
Direction Indicators,Horn,Head [атр,
[С
Light Green
N
Brown
Р
Ригр1е
F1ash.
2
8 атр
Fue1 Gauge,Handbrake 'л1/[,
3
8 атр
Dipped Веат Неад [атр.
4
8 атр
ор Lights.
Магп Веат Неад1атр апд W/L.
5
8 атр
Неаег, Screen Wipers.
6
8 атр
Веасоп, Нагагд Warning Lamps, lnterior
Lamps.
7
1 батр
R.H. Side апд Tai1 Lamps, Front Working
Light, Number Р1ае Light.
8
16 атр
L.H. Side апд Tai1 Lamps. Rear Working
Light.
9803/3200
R
Рес
U
S1ate
В1 ие
W
White
У
Уе11 о
lssue 1
с
Е[
ЕСТй 1С
7-18
7-18
i'
25
б
WY
нв
у
4
26
~7
50
Q,
51
52
9
си ~~
ши
27
28
си -~
х.28
ши -0
53
G
св -~8
`q 30
в _ э -%
в—~
31
12
Gs
71
зл
Gw
(!55
55
cw1--~~;72
GW
1
73
6, 56
11
—с
з5
ОР
35
св~
36 _ ОР ,Q,57
уа
== 74
58~
w rдПi-в
W--
✓✓
9
37
38
76
15
75
В~
гв
GЗ39
1_n 40
16
uW—~~i"г
uw
11
uw 1
иА
иа
—О-Ю
11
so
;77
а у
ав
7
у
а—.
83
-К04
R1 q 5
р
43
—
61
иУ; в
[иУ-
Нб
44
б2
45
гз
9803/3 200
RY
88
е-1
О
CONTROLS
О
Сопеп
Сопеп
СаЬ Layout
1-1
1-2
* /5 Bui1d МасЫпе$
Driving Controls
Мапиа1 Clutch Machines to т/с по. 130301
2-1
Тогсе Converter Machines
2-2
Мапиа1 Clutch Machine
2—З
гогл т/с по. 130302
* /5 Bui1d Machines
lnstrument Рапе1
То Machine No. 68150
З-1
Егогп Machine No. 100000
З-2
* /5 Bui1d Machines
/
2-4
3-3
lnstrument Рапе1
Removal апд Replacement
4-1
lnstrument С1п 1ег
Dismantling апд АssетЫу
5-1
Сго haft
9803/3200
Removal апд Replacement
6-1
Dismantling апд AssemЫy Handbrake
7-1
Dismantling апд А 5еглЬ1у Реа1$
8-1
lssue 4*
D
соГитАои`s
D
1-1
1-1
САВ IАУОИТ
1
Throttle [еуег.
2
еа А i гтiеп (Reach).
3
еа Rotation Lock
4
Windscreen Wiper.
5
6епегаог Warning Light
(Red).
6
Oi1 Pressure Warning
Light (бгееп).
7
Реаг Window
о 'а9е
Pins апд tubes.
8
Shovel Controls
9
Ехсаа1ог Controls
9803/3200
lssue 2
СОТЕЮ1$
1-2
1-2
САВ LAYOUT
1
НапЬга1 е
2
3
Brake Pedals
Dump Реда1
4
5
Accelerator Реда1
Gеаг Lever
6
Еогуаг / Яеег$е
7
Selector
Brake F1uid R eservoir
Instrument Рапе1
8
9 Demist/Heater
Control
10
Сод баг КпоЬ
Engine $ ор Control
11
Shovel Control
12
Washer Bottle
13
14
Windscreen Washer
КпоЬ
Ехсааюг Controls
15
Stabiliser
Controls
16
17 Hydraclamp
18
Throttle Lever
Реаг Window
19
20
21
Stowage Pins
Зепегаог Warning
Light ( Ае )
Oi1 Pressure Warning
Light (Огапде)
9803/3200
Issue 1
D
CONTROLS
2-1
2-1
саглNG CONTROL$
MANUALGEARBOX
1
Clutch Реда1.
2
Сеаг Lever.
3
High/Low Ratio Lever.
4
L.H. Brake Реда1.
5
R.Н. Brake Реда1.
6
Harкibrake Lever.
7
Throttle Реда1,
Brake реса15 1ИUST Ье latched
о9еЪег when travelling оп
public гоас .
Do по change еаг when
machine is moving.
Do по use clutch реда1 а а
ооге 1.
2568
9803/3200
CONTROLS
2-2
О
2-2
onivING CONTROiS
ТОРО1)Е СО \'ЕРТЕР
1
сеаг Lever.
2 Forward/Reverse
$е1 есог.
3
Handbrake Lever.
4
L.Н. Brake Реда1.
5
R.H. Brake Реда1 .
6
Throttle Реда1.
111
Brake реса15 ггш Ье latched
together when travelling оп
public гоас .
Во по change еаг when the
machine is moving.
2569
9803/3200
D
CONTROLS
2-3
D
2-3
DRIVING CONTROLS
From Machine No. 130302
МА 1 А1 СЕАЙВОХ
1
Clutch Реда1
2
3еаг Lever
3 High/Medium/Low
Ratio Lever.
4
L.H. Brake Реда1.
5
R. Н. Brake Реда1.
6
Handbrake Lever.
7
Throttle Реда1.
Brake реса15 М1 Т Ье latched
together when travel ling оп
public гоас .
Оо поЁ ле clutch реда1 а а
ооЁге5Ё.
9803/3200
CONTROis
2-4
2-4
DRIVING CONTROLS
Оеаг 1еег
Forward/Reverse
Selector.
Handbrake
L.H. Brake Реда1
R. Н. Вгае Реда1
Throttle Реда1
Dump Реда1
980313200
lssue 1
CONTROLS
D
О
1NSTRUMENT
PАNEL
1
2
3
4
Battery Condition
Indicator.
Proof Meter.
'1аег Тегпрегаыге .
Рые'.
5
Indicator Warning Light.
6
7
8
Air Cleaner Warning Light.
Headlight Warning Light.
Direction Indicator
SW1tch.
Oi1 Pressure.
Тогсые Converter Он
9
10
Pressure.
Тогсые Converter Он
Тегпрегаы ге .
12 Engine 81ор Control.
1З Working Light Indicator.
14 Cigarette Lighter.
15 8 агег Switch.
16 Heater Switch (Т',о
реес ).
17 Rear Working Light
SW1tch.
18 Side/Headlight Switch.
19 Dipswitch.
20 Front Working Light
SW1tch.
21 Horn.
22 Сод Start Plunger.
2З Сод Start Reservoir.
24 Ро''ег Point.
25 Hazard Warning Light.
11
25
9803/3200
2565А
D
D
соп1тАоLв
3-2
3-2
1NSTFiUMENT
Рь ГЕ1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
*25
Battery Condition
lndicator.
Ргоо meter.
Water Temperature.
Fue1
lndicator Warning Light.
Air Cleaner Warning Light.
Headlight Warning Light.
Direction lndicator,
Неад1 атр Flasher, Ногп.
Engine Oi1 Pressure.
Ро'"ег Point.
Нааг Warning Light.
[\ о Charge Warning Light.
Windscreen Washer.
Engine ор Control
Сод Start Plunger.
Сод Start Reservoir.
Torque Converter ОН
Temperature.
Torque Converter Он
Pressure.
51аг[ег Switch.,
Аеаг Working Light
SW1tch.
Side/Headlight Switch.
Heater Switch
(Т 'о speeds)
Front Working Light
SW1tch.
Cigarette Lighter
(аег Reservoir
18 19
9803/3200
20 21 22 23
24
lssue 2*
3-3
3-3
1NSTRUMENT РАГЕ1
Fue1 gauge
Тгасюг meter
Ногп
Direction Indicator
Dip stalk
WARNING LIGHTS
6 Main Ьеат
7
Air filter
8
Transmission он
pressure
9
Engine.oil pressure
10
lgnition light
11
12
13
14
15
16
17
18
19
Indicator
Transmission он
temp.
Hazard warning
‚Г'аег temperature
Handbrake
$ агег switch
Неаег
Аоа Lights
Нагак warning
5W1tch
20
21
йеаг working lights
Егоп working lights
980313200
Issue 1
CONTROLS
О
5-1
5-1
INSTRUMENT CLUSTER
Dismantling and AssemЫy
When AssemЫing
The numerical sequence
shown оп the illustration is
intended а а guide 1о
Dismantling.
Аепе bulbs 5, voltage
stabiliser 6 ог other егп а
required.
Еог АегпЬ1 у the sequence
should Ье reversed.
АеабегпЬ1 е рапе1 within 20
minutes о1 removing
dessicators from heat source.
When Dismantling
Take саге по o damage the
instrument pointers and
avoid 1оп9 '0' rings 9, 16
and 19.
Remove dessicators 20, heat
for 1 hour а1 арргох. 230°С
(450°F) to drive out moisture.
1689А
16
9803(3200
1ssue 1
г
CONTROLS
6-1
6-1
СВО
О
ЗНАЕТ
Вето',а1 апд Replacement
The numericai sequence
shown оп the i llustration is
intended а а guide to
Ае пп о\'а 1.
Рог Аер1 асеглеп he
sequence should Ье reversed.
When Replacing
1 ооЬгае links А аге
дismantled ог replaced they
should Ье гее1 with а
distance between clevis pin
сепЁе Ы 238тт. (9.375in.).
8ее section 3 рае 7-1 апд
2 for ооЬгае ап
апЬгае
adjustment.
9803/3200
lssue 1
CONTROLS
О
7-1
О
7-1
НАГ\1 ОВ ААКЕ
Dismantling and АеглЫу
The numerical sequence
shown оп the illustration is
intended а а guide to
Dismantling.
Рог аегпЬ1 у the sequence
should Ье гееге .
11
9803/3200
lssue 1
D
CONTROLS
8-1
8-1
ВЕАКЕ АГ'Ю С1.1)ТСН PEDALS
Dismantling and АбегпЬ1у
The numerical sequence
shown оп the i1lustration is
intended а а guide Ю
Dismantling.
Еог аеглЬ1у the есрепсе
shou 1д Ье reversed.
А
В
D
Магша1 Clutch Machines
Torque Converter МасЫпе5
9803/3200
Е
НУОДШЛСЗ
Сопег
Е
Сопеп
Transmission/Steering Ритр
5ее Section Н
Ритр
Removal and Replacement
2-1
Ритр-1С8 2D and 3
(То т/с 100611)
(From т/с Г\1о. 100612)
Dismantling апд Assembly
Dismantling and Assembly
3-1
3-5
Ритр-1С8 ЗС,З0 and 700
(То т/с Но. 56670)
(From т/с по. 56671)
Dismantling and Assembly
Dismantling and Assembly
3-3
3-5
Loader Va1ve—Hamworthy
Removal and Replacement
4-1
Loader Va1ve—Hamworthy
—ЗрООI5
Dismantling and Assembly
4-3
Main Relief Va1ve (V1107)
Main Relief Va1ves (V61107)
Main Relief Va1ve
Dismantling апд Assembly
Dismantling and Assembly
Pressure Testing
4-5
4-7
Dismantling and Assembly
Pressure Testing
4-9
6-7
Removal апд Replacement
Removal апд Replacement
Dismantling and Assembly
Pressure Testing (МЯ.У.)
5-1
5-5
5-9
Removal апд Replacement
6-1
Spools
Dismantling апд Assembly
6-3
Auxiliary Relief Va1ve
Dismantling апд Assembly
Pressure Testing
6-5
6-7
Auxiliary Relief Va1ve
(3 Spooi Va1ve оп Iу)
Loader Va1ve—Cessna
(То т/с по. 104066)
(From т/с по. 104067)
Excavator Va1ve
4-10
5-16
Excavator Va1ve—
*Нугас1ап1р 8е1есог Va1ve
Removal and Replacement ир to т/с Но. 129624 6-8
Dismantling апд Assembly ир Ёо т/с по. 129624 6-9
Removal and Replacement from т/с Но. 129625 6-10
Dismantling and Assembly from т/с Но. 129625 6-11
Rams — Тургса1
— Stabiliser
— Тургса1
Removal and Replacement
Removal and Replacement
Dismantling апд Assembly
7-1
7-2
7-4
8е11 Sealing Coupling
Dismantling апд Assembly
8-1
9-1
а 11 Finding
Circuit Diagram
9803/3200
]СВ 2D, 3 and ЭС
асв 3D
10-1
10-2
1ббе 4*
Е
НУОВА1)11С
Е
2-1
Removal апд Replacement
(Тур iса 1)
The numerical sequence оп
the illustration is intended а
а guide Ю removal.
Еог replacement, thesequence
should Ье reversed.
When Removing
Raise lift аггп o gain ассе .
1f hydraulic pressure is по
available, select'lift аггп raise'
оп сопго1 1е 'ег whilst lifting
arms with а suitable hoist.
‚УАВГ'!1Г'!С: Веоге working
beneath shovel, fit гагп ргор 2,
раг по:
102/11600 — 2D.
106/08100 — 3,3С,З0,700.
То prevent excessive fluid 1о ,
either lift the гоп Ы the
machine so ЁЪаЁ the ритр is
higher than the fluid 1е 'е1,
ог drain the hydraulic system.
If the уегп is по drained,
quickly fit plug 7 (раг по.
892/00052) to retain the fluid.
NOTE: 8расег 11 is fitted to
certain machines only — ее
Раг1 Catalogue.
When Replacing
Веоге fitting guard 3, check
fluid 1е 'е1 and M.R.V.operating
pressure. Check for leaks
whilst operating а service.
9803/3200
1 ввие 2*
Е
Е
НУЕЖА1ЛЛС
3-1
3-1
18
16
14
3875
9803/3200
lssue 1
Е
НУОйА1)[1С
3-2
3-2
Р1.] МР
20, 3 То т/с N о. 100611
Dismantling and AssemЫy
ТЬе numerical sequence оп
the illustration is intended as
а guide to dismantling.
Ensure Ъа dimension Н is
0.003 to 0.007in. (0.076 to
0.178тт) less than dimension J.
Рог assembly, the sequence
should Ье reversed.
When AssemЫing
When Dismantling
Remove бЬагр edges and
Ыггб from shaft to avoid
seal damage.
ГЛаг covers 9 and 11 and
housing 18 to ensure соггес
replacement. Оо по damage
machined асе Ьу prising
Ьебе араг
use а soft-faced
hammer.
Еепе а11 seals and 'О' rings
using 1СВ 'Special' hydraulic
fluid as а lubricant.
Fit bearing Ь1 осб 12 and 14
with recesses К positioned оп
the inlet side Ы the ритр and
facing the gears.
A1ign housings and covers
using the глаг таре оп
dismantling.
Torque Settings
lnspection
СЬес housing Ьоге dimensions
А and В. 1f деаг гас А is
огп дгеаег than В Ьу more
than 0.004in. (0.1тт) or
heavy scoring is present,the
соглр1ее ритр ГП151 Ье
renewed. Light scoring тау Ье
removed with very fine emery
cloth.
Ensure that bearing Ь1 ос аге
free гогп scoring or damage,
especially in Ьоге5 С and оп
асеб D. Use fine emery cloth
to remove scoring and to
ensure гее movement in the
ритр body.
Renew gears if widths Е vary
Ьу more than 0.0002in.
(0.0а5 тт) or journal
diameters F vary Ьу more
than 0.00051г(0.013тт).
Polish out light scoring оп
side асеб using very fine
emery cloth and а сгар
bearing Ыоск as О\ П а G.
9803/3200
Item
8
1bf ft
(
ГП
$О -%— 124-4В 1
Е
Е
HYDRAULIcs
3-3
3-3
2
5
4
3
9803/3200
''
3
1 зое 1
HYDRAULICS
Е
Р1)МР
ЭС, 3D, 700 То т/с
Е
о. 56670
Dismantling and AssemЫy
ТИе numerical sequence оп
the illustration is intended as
а guide to dismantling.
Еог assembly, the sequence
should Ье reversed.
1 пба11 bearings 5 and 19
0.18 to о.гзтт. (0.007 to
0.009in.) below end соег
machined surface. Use service
оо11 892/00065.
Renew gears in pairs if :
When Dismantling
а)
Journal агеа Ы бНа is
pitted or огп in ехсе
Ы 0.025тт. (0.001 in.)
b)
Кеу''ау or gears are badly
', огп or cracked.
с)
Зеаг width В is less than
housing width С Ьу 0.076тт.
(0.003in.)
Remove бНагр edges апд burrs
from shaft to avoid seal
damage.
Mark end covers 2 and 24 and
housing 13 to ensure соггес
replacement. Do по damage
machined асеб Ьу prising
these араг — use а soft-faced
На гтiгтiег.
Mark асасеп деаг ееЬ to
ensure соггес replacement
using indelible ink or paint.
Do not use а сепге punch or
similar too1.
* Remove bearings 5 апд 19 if
requiring replacement, or to
сгШ out bearing 23. Use Service
Тоо1 раг Но. ВТ2464 as а А.
Г\]ОТЁ: 1п addition to
replacement дие to еаг,
bearings should Ье renewed
when пе gears are fitted.
When AssemЫing
Renew а11 seals and '0' rings.
lubricating а11 internal рагб
with СВ 'Special hydraulic
fluid. еа1б 22 and 22а are
alternatives.
Renew seal bushes 6 and 20
if sealing асе are damaged
or if Ьоге are scored or огп
to а дгеаег diameter than
31.788тт. (1.2515in)
9803/3200
Rene
еаг plates 7 and 15 if
scored or eroded. Ensure that
recesses D,12.7mm. diameter х
1.6тт. деер (0.5 х 0.06251п.)
асе the gears оп the discharge
side Ы the ритр. Ho1es Е,
6.3тт. (0.25in.)diameter wi11
then align with drain holes in
end covers.
Running clearance Ье1 ееп gears
and wear plates is 0.11 to
0.15тт. (0.0045 to 0.006 п.)
This is achieved Ьу addition
Ы shims 9 and 14, 0.038тт.
(0.0015in.) thick, distributed
еасЬ side Ы the housing 13. ТИе
total thickness Ы shims
required is found Ьу adding the
running clearance to dimension
В, then subtracting dimension С.
A1ign gears, housings and covers
using marks таре оп dismantling.
*Тоге Settings
ltem Nm
kgf т 1bf ft
1 136 13.8 100
1 в5ие 2*
Е
3-5
9803/3200
HYDRAULICS
Е
3-5
lssue 1
HYDRAULICS
Е
Е
3 —6
3-6
р1;Мр
2D, 3 From т/с Г\ о. 100612
ЭС, 3D, 700 From т/с о. 56671
Dismantling and AssemЫy
The numerical ещепсе оп
the illustration is intended а
а guide to dismantling.
Рог assem Ыy, the ещепсе
should Ье reversed.
When Dismantling
Remove пагр edges and Ыгг
гогл shaft to avoid seal damage.
Маг cover 4 and housing 15
to ensure соггес replacement.
Do not damage machined асеs
Ьу prising 1:пее араг1: — use а
soft-faced hammer.
Маг асасеп1: деаг ее1:и to
ensure соггес1: replacement
using indelible ink or paint.
Do not use а сеп1:ге punch or
similar too1.
Remove bearings 14 only if
requiring replacement. 1) е
service tool раг Но. ВТ2464
а а А.
lnstall bearings 14 пю housing
and end со
Лi ЬЮ 0.002in.
(0.05тт) тахi тит Ье1 о ace
Ы bearing Ьоге.
Renew wear р!а1:е 6 and 11 if
scored or eroded. Trim to size
еа1 8 апд 13 and supports 7
апд 12, using дгеае to retain
them firmly in the wear plates.
Fit wear р1 а1:е
ith single
slots В facing the деаг оп the
ргеыге side Ы the ритр.
Ensure 1:па1: seals and
ррог1: are not trapped
between plate and Ьоге, also
that wear plate 11 is fu11y
home in the Ьоге and гее to
томе.
A1ign 9еаг , housings and
covers using marks таре
dismantling.
пеп
Torque Settings
11:епп 1ЬПt (9 ПП
3
120
16.6
, :z
NOTE: 1n addition to
replacement дие to wear,
bearings shou{д Ье renewed
when new деаг are fitted.
When AssemЫing
Renew а11 еа1, lubricating а11
гегпа1 раг using JCB
'Special' hydraulic fluid.
Renew еаг in pairs if:
а)
Journal агеа Ы shaft is
pitted or worn in ехсез
Ы 0.001 in. (0.025тт).
b)
Keyway or еаг are
badly огп or cracked,
9803/3200
lssue 1
Е
4-1
HYDRAULICS
Е
4-1
3809
9803/3200
уе 1
HYDRAU L1CS
Е
Е
LOADER \/АЕЛ/ Е (Hamworthy)
Removal апд Replacemeпt
The numerical sequence оп
the illustration is intended а
а guide ю removal.
Еог replacement, reverse the
sequence.
When Removing
Prior to disconnecting hoses
and pipes, operate control
levers ю
ent pressure and
1abe1 hoses ю ensure соггес
replacement.
Blank а11 hoses апд pipes ю
prevent епгу of dirt and 1о
of hydraulic fluid.
Connections
Shovef Ram, Неад End.
Shovef Ram, Rod Епд
Lift Ram, Rod End.
Lift Ram, Неад Епд.
Excavator Va1ve, High
Pressure Саггуо\'ег.
F Exhaust.
А
В
С
D
Е
G
Реес'
After Replacemeпt
Adjust main relief valve
( ее ране Е4-10).
9803/3200
lssue 1
HYDRAULICS
Е
Е
4-3
4-3
257
8
9
26
6
22
21 -20
2о
Г
1312
10
9803/3200
3859
lssue 1
HYDRAULICS
Е
Е
4-4
4-4
[ОАОЕ \ А1ЛЕ (Hamworthy)
Dismantling апд AssemЫy—Spools
The numerical sequence оп
the illustration is intended а
а guide 1о dismantling.
Рог assembly, гееге the
sequence.
When Dismantling
То prevent роо1 rotating
when removing items 12 апд
22 use barrel с1 атр part по.
992/02100 with the spool
protruding from the block.
Alternatively items 12 ю 26
тау Ье removed а ап assembly
апд mounted in а vice [ог
dismantling. 1 е soft ]а\ if
the barrel с1атр is пою
available.
Labe1 апу роо1 removed to
ensure replacement the right
ау round in the соггес1 Ьоге.
When AssemЫing
Аепе
а11 'О` rings апд еа1.
Lubricate а1 г'Ёегпа раг1
with аСВ 'Special' Hydraulic
f1u id.
9803/3200
3867
1ssue 1
f
&
оо 2
НУЕЖА1)11С
~~.
\
и
ш
\
е
Е
нУДААиL1С
4-6
4-6
[ОАОЕГ \ А[']Е (нamworthy)
DismantIing and AssemЫy
—Main Relief Va1ve (1V1.R.V.)
The numerical sequence оп
the illustration
пеп1е 1аб
а guide to dismantling.
Рог assembly, reverse the
sequence.
(\ ОТЕ: The M,R.V. туре
shown is ПЁе only to а1~е
blocks with the serial number
prefixed "V 1107".
4Nhen Dismantling
Drive ou а1~е cartridge 12 in
ап upward direction, using а
Ьгабб ог Ьгопге drift.
VVhen AssemЫing
Вепе
а11 '0' rings and seals.
If апу wearing раг requires
renewal, the mating раг
should also Ье renewed.
Lubricate а11 internal раг
with ]СВ 'Special' hydraulic
fluid.
Drive in the cartridge until
the пар ring А 1осае in the
housing гесе .
Lightly дгеабе items 8 and 9
о retain in position.
Тогсе Settings
ltem
6
(\
1 Ь ft
30
kgf т
4.1
К/61
~G•G
ТЕ : After assembly the
pressure setting must Ье adjusted
ее раде Е 4-10
9803/3200
Е
Е
НУОА1)11С5
4-7
4-7
VВ 1107
14
V 6 1107
9803/3200
Е
HYDRAULICS
Е
4-8
4-8
1
ОАОЕЕ VALVE (Hamworthy)
Dismaпtling апд AssemЫy
—Main Relief Va1ve (M.R.V.)
When AssemЫing
Renew а11 'О' rings апд seals.
The numerical sequence оп
the illustration is intended а
а guide to dismantling.
Рог assembly, reverse the
sequence.
NОТЕ: The M.R.V. type
shown is fitted оп1у to ',а1',е
blocks with the serial пглЬег
prefixed "VB1107".
Оо not grind or 1ар р1 п9ег 15
to its seat а the components
have а гопс finish.
1f апу wearing part requires
renewal, the mating part
should also Ье renewed.
Lubricate а11 internal parts
with JCB 'Special' hydraulic
fluid.
VVhen Dismantling
Тар out items 12 to 16 using
а mild steel rod .25in.
(6тт) iа., passed through
~а1~е seat 17.
11$е а Ьга$$ or Ьгопе гос ,
0.625in. (15.8тт) dia., to
drive out the ',а1',е seat in the
opposite сПгес1оп.
9803/3200
Lightly дгеае items 8 апд 9
to retain in position.
Тогще Settings
Item
6
1bf ft
30
kgf т
4.1
ОТЕ: Аег assemЫy the pressure
setting must Ье adjusted, see
раде Е 4-10
Е
Е
НУОГА111Сб
4-9
4-9
1ОАОЕГ VALVE
(Hamworthy 3 Spoo1)
Dismantling and AssemЫy
—Auxiliary Relief Va1ve (А
.\1)
ТИе numerical sequence оп
the illustration is intended аб
а guide to dismantling.
Еог assemby the sequence
should Ье reversed.
When Dismantling
Ноiд cartridge body 4 in а
barrel с1атр раг Но. 892/00039.
When AssemЫing
* 1f seating асе А Ы а1~е is огп,
гепе Ьо1Ь а1~е and seat 1.
Аепеу '0' rings.
Thoroughly clean а11 components
and lubricate with JCB 'Special'
hydraulic fluid.
1f dismantled beyond item 5,
it is essential to reset the А.R.V.
pilot setting (бее раде Е 6-7).
3865А
9803)3200
lssue 2*
Е
Е
HYDRAULICS
4-10
4-10
11
3813 А
9803/3200
1ввие 2
HYDRАULICS
Е
Е
4-11
4-11
[ОА1ЭЕ VАLVE — Hamworthy
Main Relief Va1ve ( М.ЕЛ/.)
Pressure Testing
1.
With shovel апд Ьсе1: ог' the ground апд
engine 1орре , орегае а11 сопго1 1еег
еп1 residual pressure.
t
2.
connect а 0-6000 1bf/in 2 (420 kgf/ст2 ) 4)3
pressure gauge fitted with а snubber
(5ее Service Too1s Catalogue) to test
adapter А, using service оо1 В part Но.
892/00099. 1f adapter А is по Л11е ,
remove plug or connection С апд connect
gauge into excavator а1\,е.
ОТЕ: Оп loading shovel machines,
begin the test at operation 6.
З.
With engine running at maximum rev/min,
fu11y retract а stabiliser ram апд note
maximum gauge reading, which should
equal the pressure specified in Technical
Оаюа.
4.
Аереа the check Ьу operating other
excavator services, when а similar gauge
reading should Ье obtained in each case.
А 1о reading оп апу опе service would
indicate а fault within that service, e.g.
fluid 1еаае, defective ram seals or
defective auxiliary relief \'а1~е ( А. А.У.).
1f adapter А is поЁ fitted, connect а
tee-piece into the lift ram feed as at Е.
Роп the engine at maximum rev/min,
extend the lift rams to fu11 travel апд
note the maximum gauge reading.
1f the shovel circuit рге5[ ге5 are
consistently higher 1 ап 1'ое recorded
оп the excavator services,the fault is
likely to Ье а еа at the high pressure
саггу-о \ ег юоЬе.
7.
If а11 gauge readings are approximately
equal, Ьо1 differ гогп the specified
M.R.V. setting, adjust the M.R.V. as
shown at D. Веоге setting the pressure,
опсге the adjusting сге
o or three
огп to release апу гарре dirt.
NOTE: Тпеге are по А. А.\' in the
stabiliser services.
5.
1f а consistently high reading is obtained
оп а11 excavator services, adjust the
N1. R.V. setting as shown at D. 1f а
consistently 1о reading is obtained,
proceed to the ое1 circuit as follows:
6.
With gauge соппес1е at А, run engine
at maximum rev/min, fu11y extend the
lift rams апд note the maximum gauge
reading. Аереа1 the check with the
shovel rams.
9803/3200
lssue 1
Е
5-1
9803/3200
НYDRAULICS
Е
5-1
1ввие 2
Е
HYDRAUL 1С6
Е
[ОАОЕЙ VALVE (Сепа)
То М/с No. 104066
йегпоа1 and Replacement
б1ае 1
The numerical sequence оп
the illustration is intended а
а guide 1о removal.
Рог replacement, reverse the
sequence.
When Removing
Ргог to disconnecting hoses
and pipes, орегае сопго1
1 е1ег5 to еп pressure and
1abe1 hoses 4 to 9 to ensure
соггес replacement.
Blank а11 hoses and pipes to
ргееп епгу Ы dirt апд
loss Ы hydraulic fluid.
СоппесIiоп5
3 — Excavator Va1ve, High
Pressure Саггу-оег.
4 — С1 ат Ram, Неад End.
5 — Shovel Ram, Код Епд.
6 — Lift Ram, Неад Епд.
7 — С1 ат Ram, Код End.
8 — Shovel Ram, Неад End.
9 — Ы Ram, Ао End.
10 — Feed.
11 — Exhaust.
9803/3200
lssue 1
Е
5-3
9803/3200
HYDRAULICS
Е
5-3
Е
1.ОАОЕЕ VALVE (Се55па)
То М/с No. 104066
Аетоиа1 and Replacement
Stage 2
Т1- е numerical sequence оп
the illustration is intended а а
guide to removal.
Рог replacement, reverse the
sеq иепсе.
When Replacing
Аепе а11 'О' rings апд
Ьопдед washers.
980313200
нУЕЖАи11СS
Е
Е
5-5
9803/3200
HYDRAULICS
Е
5-5
Е
5-6
HYDRAULICS
Е
5-6
[ОАОЕЕ '/д['/ (Сепа)
Егогп М/с Nо. 104067
йегяоэа1 and Replacement
Stage 1
The numerical sequence оп
the illustration is intended а
а guide to гегпоа1.
Рог replacement, гееге
the sequence.
When Removing
Prior to disconnecting hoses
and pipes, орегае control
levers to vent ргеоге and
1abe1 hoses to ensure соггес
replacement.
Blank а11 hoses and pipes to
prevent entry Ы dirt and
loss of hydraulic fluid.
Connections
3— Ехсааог \/а1 е, High
Pressure Саггу-оег.
4— Exhaust.
5 — С1ат Ram, Неад Епд.
6 — Shovel Ram, Rod End.
7 — Lift Ram, Неад End,
8 — С1ат Ram, Rod End.
9 — Shovel Ram, Неад Епд.
10 — Lift Ram, Rod Епд.
11 — Feed,
9803/3200
lssue 1
Е
Е
HYDRAULICS
5-7
5-7
3161А
9803/3200
Е
НУОЕА1[1С5
5-8
Е
5-8
1.ОАОЕЕ \/А1.\/ Е (Себбпа)
Егогл М/с Г\ о. 104067
Removal and Replacement
5 ауе 2
The numerical sequence оп
the iilustraton is intended а а
guide to геглоа1.
Рог replacement, гееге Ъе
sequence.
‚
Г'! еп Replacing
Аепе
а11 'О rings.
9803!3200
lssue 1
Е
HYDRAULICS
5-9
5-9
LOADER ']А1.']Е (Сепа)
Dismantling апд AssemЫy
When AssemЫing
The control а1~е comprises
three control sections, as
listed below, plus 1,о end
со'ег . These are held
together Ьу tie bolts and the
interconnecting galleries are
еа1е Ьу '0' rings.
Renew '0' rings апд lubricate
with Mobilplex 47 or similar
mineral-base геае.
Ensure соггес alignment о1
sections as То11о :
1.
lnstall Ьо1
hrough
епд plate 4.
2.
[ау end plate оп bench,
Ьо1 pointing лрагз.
The sections тау Ье
ерага1е Ьу removing the
through bolts or dismantled
in situ as described оп their
respective ра9е .
З.
Stack control есопапд
епд plate 5 оп to the
Ьо1, ensuring that
0' rings are correctly
positioned.
When Dismantling
4.
Tighten Ьо1 evenly to
25-40 Ы ft (3.5-5.5
kgf т).
1.
2.
З.
Lift Ram Section (УВ)
Shovel Ti1t Section ('Д1)
Shovel С1ат or Attachment
Service Section (СС).
Mark each Section to еплге
соггес re-assemЫy.
5
2
301ВА
9803/3200
3г
Е
Е
НУОРА1Л 1С
5-10
5-10
17
9803/3200
Е
HYDRAULICS
5-11
Е
5-11
1.ОАОЕЕ VALVE (Себбпа) — В Section
Dismantling and AssemЫy
В-NON RETURN VALVE
ТЬе numerical sequence оп
the illustration is intended а а
guide to Dismantling.
When Assembling
Аепеу 'О' ri ng 19.
Еог Assembly the sequence
shou 1д Ье ге 'егес .
С-MAIN RELIEF VALVE
When Dismantling
А-LIFT RAM 8РООП
When Dismantling
Do по remove сге 11 unless
spring 13 is Ьгоеп.
Components remaining inside
item 20 cannot Ье гепее
ерага1е1 у апд should по Ье
disturbed unless it is песеагу
о remove dir гарреd
beneath еа D.
When Assembling
VUhen Assembling
Аегпо"е minor nicks апд burrs.
Excessive еаг оп spool 15 ог
in its Ьоге, must Ье remedied
Ьу гепеа1 Ы the complete
control section.
Ensure that the orifice in the
сепге Ы plate 29 is с!еаг.
Do по1 ргоЬе with wire.
Аепе
asher 21 апд 'О' rings
22, 23 апд 28.
1f сгеу 11 Ьа Ьееп removed,
re-assemble using Loctite 241.
Аепе 'О' rings 8 апд 9.
Тогые Settings
Item
5
11
9803/3200
kgf т
1bf ft
1.8- 4З z у,д.=-1-8 ь -7
24-1 -а
lssue 1
Е
Е
НУОА111С5
5-12
5-12
26
25
32
33
3019
9803/3200
Е
Е
НУОАА111С
5-13
5-13
1ОАОЕГ VALVE (Сепа) —WW Section
Dismantling апд Assembly
О-А1Х 11АГУ RELIEF VALVE
The numerical sequence оп the
illustration is intended а а
guide 1о Dismantling.
When Dismantling
Соглропеп remaining inside
item 28 саппо Ье renewed
ерагае1 у апд should по Ье
disturbed.
Рог Assembly Ъе sequence
should Ье reversed.
When AssemЫing
А- НО\,'Е1 T1LT RAM
РОО1
Аепе Ьаск-ир washer 29 апд
'О' rings 30 апд 31.
When Dismantling
Во по remove сге 11 unless
spring 13 is Ьгоеп.
Е-SHUTTLE VALVE
When Assembing
When Assem Ыing
Remove minor nicks or Ыгг .
Excessive еаг оп spool 16 or
in its Ьоге, must Ье геглесПе
Ьу гепеа1 Ы Ъе complete
control section.
Ensure that piston 36 slides
гее1 у in Г Ьоге.
Аепе
1 сге 11 has Ьееп removed,
ге-аеплЫе using Loctite 241.
Аепе
rings 8 апд 9
Torque Settings
1 егл
5
11
(д т
1Ь
1А--У3 iг 1-.4--8
о.7--Э-:'1 i- с
В & С-NON RETURN \'А1\'Е
When AssemЫing
Аепе
rings 21,23 апд
27, а1 о Ьаск-ир аег 20
апд 22.
9803/3200
9
ring 37.
Е
Е
НYDRAULICS
5-14
5-14
4
8
19
16
22
9------10
715---~
14-
Ос)-------23
25
26
о
с 24
13
21
12---
3020
9803/3200
Е
нYDRAUL1cS
5-15
Е
5-15
1ОАОЕ VALVE (Се55па) —СС Section
Dismaпtling апд AssemЫy
В-NON RETURN \'А[\'Е
The numerical sequence оп the
illustration is intended а а
guide 1о Dismantling.
When AssemЫing
Рог Assembly the ещепсе
should Ье reversed.
C—AUxi IARY RELIEE \'А[\'Е
Аепе 'О' ring 20.
When Dismantling
А- НО\'Е[ С[АМ OR ATTACHIVIENT
SERVICE РОО1.
When Dismantling
Components remaining inside
item 21 саппо Ье гепее
ерагаеу ап should по Ье
disturbed.
Оо not remove сге 11 unless
spring 13 is broken.
When AssemЫing
When AssemЫing
Аепе Ьаск-ир washer 22
апд 'О' rings 23 ап 24.
Remove minor nicks or Ь1 гг5.
Excessive еаг оп spool 16 or
in itsbore, must Ье remedied
Ьу renewal Ы the complete
сопго1 section.
1[ сге 11 has Ьееп removed,
re-assemble using Loctite 241.
Аепе 'О' rings 8 апд 9.
Тоще Settings
Item
5
11
9803/3200
1bf ft
7
kgf т
14-8
Оу 1
и
9-~
11е 1
Е
5-16
Е
HYDRAULICS
5-16
3814 А
9803/3200
1ввие 2
HYDRAU L1CS
Е
Е
5-17
5-17
[ОАОЕВ i/ALi/ Е — CESSNA
Main Relief i/а1' е (М.В \'.)
Ре 'де Testing
1.
With shovel and Ысе оп the ground апд
1f the зое1 circuit pressures are
consistently higher Ьап Ьо5е гесогес
оп the excavator services, the fault is
гогп Ье1\'ееп the
likely ю Ье а lea
sections Ы the shovel а1~е.
engine 1оррес , орегае а11 control 1еег
о ег residual pressure.
2.
Соппес а 0-6000 1bf/in 2 (420
/с 2 ) Д
pressure gauge fitted with а snubber
(нее Service Too1s Catalogue) to test
adapter А, using service tool В part Но.
892/00099. If adapter А is по fitted,
remove plug or connection С and соппес
gauge into excavator а1~е.
NOTE: ОН loading shovel machines,
begin the test at operation 6.
З.
With engine running at maximum rev/min.
fu11y гегас а stabiliser ram and note
maximum gauge reading, which should
equal the pressure specified in Technical
Data.
4.
Аереа the check Ьу operating other
excavator services, when а similar gauge
reading should Ье obtained in еасЬ сане.
А 1ow reading оп апу опе service лоыи
indicate а fault within that service, e.g.
fluid leakage, еесе ram seals or
defective auxiliary relie а1~е (АА.У.).
NOTE: ТЬеге are Но А. АУ' in the
stabiliser services.
5.
If ап incorrect reading is obtained оп а11
excavator services, ргосее o the
shovel circuit as follows:
6.
With gauge соппесе at А, run engine
at maximum rev/min. fu11y ех1еп the
lift rams ап note the maximum gauge
reading. Аереа he check with the
shovel rams.
1f adapter А is not fitted, соппес а
tee-piece into the lift ram feed as at D.
Run the engine at maximum rev/min,
extend the lift rams to fu11 гае1 ап
note the maximum gauge reading.
9803/3200
7.
1f а11 gauge readings are approximately
equal, Ы differ гогп the specified
M.R.V. setting, the M.R.V. Е, which is
поп-adjustable, must Ье геое ап
either cleaned or renewed.
Е
6-1
9803/3200
HYDRAULICS
Е
6-1
Е
НУОГА1)11С3
6-2
6-2
EXCAVATOR \'А[УЕ
RemovaI and Replacement
After Replacement
The numerical sequence
оп the illustration is intended
аб а guide to removal.
1f slew override is excessive, this
тау Ье дие to air гарре in the
A.R.V. cavity. 81асеп plug R
and 9еп 1 у operate the slew
service until air is ехре11 ед.
Re-tighten p1ug.
Рог replacement, reverse the
sequence.
When Removing
Prior to disconnecting hoses
and pipes, operate сопго1
1еегб to еп pressure and
IаЬе1 hoses to ensure соггес
replacement.
Blank а11 hoses and pipes to
ргееп епгу Ы dirt and loss
Ы hydraulic fluid.
Connections
А
В
С
D
Е
F
G
Н
J
К
L
М
N
Р
Е
L.H. S1ew Cylinder.
R.H. S1ew Cylinder.
Воот Ram, Неад End.
Воот Ram, Ао End.
R.H. Stabiliser Ram,
Неад End.
R.H. Stabiliser Ram,
Ао End.
L.H. Stabiliser Ram,
Аос' End.
L.H. Stabiliser Ram,
Неад End.
Bucket Ram, Ао End.
Bucket Ram, Неад End.
Dipper Ram, Неад End.
Dipper Ram, Ао End.
Exhaust to Тап .
Feed from Shovel Va1ve.
НОТЕ: '[.Н.' and'А.Н.'
indicate left hand and right
hand when viewe гогл the
геаг Ы the machine.
9803/3200
Е
Е
НУОЕА1]11С8
6-3
6-3
21
20
23
24
25
7
13-----®
------ 9
10
3858
980313200
Е
Е
нvDRAUL1Cs
6-4
6-4
EXCAVATOR '/А1.'/ Е
Dismantling and AssemЫy—бpools
ТИе numerical sequence оп
the illustration is intended as
а guide ю dismantling.
Еог assemЫy, reverse the
sequence.
When Uismantling
То prevent spool rotating
when removing items 12 and
22 use barrel с1атр рагю Но.
992/02100 with the spool
protruding from the block.
Alternatively items 12 ю 26
тау Ье removed as ап
assembly ап mounted in а
vice [ог dismantling. 1]бе 6О[1
аб if the barrel с1атр is not
available.
Labe1 апу spool removed ю
ensure replacement the right
ау round in the correct Ьоге.
When AssemЫing
Renew а11 'О' rings апд seals.
Lubricate а11 internal рагюб
with ]СВ 'Special' Hydraulic
fluid.
9803/3200
3867
Е
Е
НУОГА111Сб
6-5
6-5
3
2
3810
9803/3200
Е
HYDRAULICS
Е
6-6
6-6
ЕХСА\ АТОВ VALVE
Dismantling and AssemЫy
A—Auxiliary Relief Va1ve (А.А.\'.)
(То т/с No. 58449 оп Iу)
В—Auxiliary Relief \1а1 е (А. R.V.)
(А11 Machines)
С—Anti-cavitation Va1ve
(From т/с No. 58450 оп1у).
The numerical есепсе оп
the illustration аге intended as
а guide to dismantling.
Рог assemЫy the есепсеs
should Ье reversed.
Г\ ОТЕ: То remove relief
valves В from а1~е block,
use extractor D, part Но.
992/02800.
When Dismantling
НоIд Cartridge Ьоду Ы уа1уе А
ог В in а barrel с1атр part
по. 892/00039.
1f it is песеагу to remove seat
Е, use extractor F, part по.
992/02900. 1 nsert 1ареге р1 и g
G into end Ы spigot and push
spigot through а1~е seat until
plug сопЁасЁ gallery wa11 as
shown. Strike end Ы extractor
to expand spigot and then
ехЁгасЁ seat Ьу tightening nut.
When AssemЫing
1f seating часе Ы а1~е is огп,
гепе' both а1~е and seat.
Renew'О' rings.
G
3891
Thoroughly clean а11 components
and lubricate with ]СВ 'Special'
hydraulic fluid.
1f А.Я.'/.' А ог В have Ьееп
dismantled beyond item 4, it
is essеntial to reset the pilot
setting (бее ране Е 6-7).
9803/3200
1
е1
HYDRAULICS
Е
Е
6-7
6-7
А1)Х111АЕУ RELIEF \1А1.\1Е
(Hamworthy Pi1ot Operated)
Pressure testing
Соппес а 6000 1bf/in2
(420 kgf/ст2) gauge, раг по.
892/00001 to test fixture
992/01000 апд 1пап ритр
Р365 ( ее Service оо1s
cataIogue).
Сд11Т1О : До по соппес
the fixture to а глоог driven
ритр.
Ву геегепсе to the аЬ1е Ье!о ,
check that the correct соде is
епгае оп the cartridge а А
(8ее TechnicaI Оаа).
lnsert the cartridge 1 (сопе епд
first) into the fixture апд fit
Ьопдед еа1 апд plug 2.
Орегае папс ритр апд оЬеге
gauge reading which wi11 rise
until the pilot а1~е operates апд
он есаре а З. The highest
obtainaЫe reading should equal
the appropriate piIot setting as
shown in the наЫе.
То adjust the pilot setting, grip
the cartridge in barrel с1 атр
part по. 892/00039, slacken
locknut 4 апд 1игп сге' 5 as
required. Recheck setting after
tightening locknut.
2339
Соде
01д
New
Operating Pressure
Ьаг
kgf/ст2 1bf/in2
С1
21/197 145
С2
С3
22/197 152 155
23/197 156 162
24/197 166 169
25/197 172 176
26/197 179 183
27/197 186 190
28/197 193 197
29/197 200 204
30/197 207 211
С4
С5
С6
С7
С8
С9
00
9803/3200
148
2100
2200
2300
2400
2500
2600
2700
2800
2900
3000
Pi1ot Setting
Ьаг kgf/cm2 lbf/in
121
128
134
140
146
152
159
164
170
177
124
131
136
143
149
155
161
167
173
180
1760
1860
1940
2030
2120
2210
2300
2380
2470
2560
lssue 2'
L
НУОРА1) 11Сб
G
6-8
6-8
HYDRACLAMP SELECTOR VALVE
АГЮ СНЕСК VALVE
* То МасЫпе Го. 129624
Rемо~а1 апд Replaceмent
The numerical sequence оп
the illustration is intended as
а guide to removal.
Рог гер1асегпеп he sequence
should Ье reversed.
When Removing
Position the machine as б 1О\ П
with stabilisers апс bucket оп
the ground.
With the engine о , operate
а11 сопго1б to vent residual
pressure Ьеоге disconnecting
hoses.
[ lank а11 hoses ап pipes to
prevent the епгу Ы dirt апд
loss о1 hydraulic fluid.
И1hen Replacing
Еп$11ге that hexagonal епс Ы
check iа1iе 9 is соппесе o
the pipe leading to the selector
',а1',е.
4418
9803/3200
lssue 2'
Е
Е
нУОРАиI1сs
6-9
HYDRACLAMP 8Е1ЕСТО VALVE
А1\Ю СНЕСК VALVE
*То Machine о. 129264
6-9
е
Dismantling апд AssemЫy
The numerical sequence оп
the illustration is intended а
а guide to dismantling.
Рог assembly the sequence
should Ье reversed.
Вепе а11 '0' rings апд
bonded washers.
selector Va1ve
* Check spool 2 апс Ьосу ог
scoring ог wear. 1f either аге
unserviceable the ',а1',е
assemЫy must Ье renewed.
Check Va1ve
1f either the ba11 17 ог еа 18
show signs Ы pitting ог wear
both must Ье renewed.
9803/3200
lssue 3`
Е
Е
HYDRAULICS
6-10
6-10
ЕСТОЕ VALVE
HYDRACLAMP 3Е 1
AND СНЕСК VALVE
Егогл МасЫпе о. 129625
Removal and Replacement
The numerical sequence оп
the i11ustration is п1епсес as
а guide to removal.
Еог гер1асеглеп the sequence
shou 1д Ье reversed.
When Removing
Position the machine as
shown with stabilisers апд
Ьсе оп the ground.
With the engine stopped
орегае а11 сопго1 б Ю vent
residual pressure before
disconnecting hoses.
Blank а11 hoses апд pipes to
prevent the епгу Ы dirt апд
loss Ы hydrauIic fluid.
д967
9803/3200
Е
Е
HYDRAULICS
6-11
6-11
HYDRACLAMP 5Е1.ЕСТО VALVE
AND СНЕСК VALVE
Ргогл Machine о. 129625
Dismantling and AssemЫy
The numerical sequence оп
the illustration is intended as
а guide to dismantling.
Рог assembly the sequence
should Ье reversed.
Аепе а11 'О' rings апд
Ьопдед washers.
Check spool 2, Ьоду апд
~а1~е seat for scoring ог еаг.
1f апу item is unserviceable the
~а1~е assembly must Ье гепеес .
Соглр1ее assembly to Ье checked
as follows:
With lever in 'О ' position
pressurise рог В to 138 Ьаг
(140.6 kgf/ст2 ; 2000 1bf/in2)
leakage гогл рогб А and С
should по ехсеед Зсс/min.
11
4993
9803/3200
Е
НУОА1Л.1С5
Е
7-1
Removal and Replacement
(Тур iса 1)
The numerical sequence
shown оп the illustration is
intended а а guide to removal
Ы а11 гагл ехер1 the stabiliser
гагл .
Еог replacement, the sequence
should Ье reversed.
When Removing
Ве[оге removing pin 2, ensure
that Ьоогп, dipper, loader аггп
ог bucket аге adequately
supported ю prevent collapse.
Аег retracting piston гос 3,
51ор engine апд vent residual
ргеоге Ьу operating
control levers.
Labe1 апд blank hoses ю ensure
correct replacement апд prevent
епюгу Ы dirt.
3892
9803/3200
lssue 1
Е
7-2
HYDRAULICS
Е
7-2
3856
9803/3200
Е
7-3
ТАВ1113ЕГ ГАМ
Removal and Replacement
ТИе numerical sequence оп
the illustration is intended а
а guide to гегяоа1.
Рог replacement the sequence
should Ье reversed.
When Removing
Р1асе а large Ь1 ос Ы 'люо
under the stabiliser to limit
the ram travel.
Епге that расег 4 до not
drop inside the stabiliser 1eg
when pin 3 is removed.
With both pins removed,
operate the stabiliser service
to ех1епс the ram until the
юор pin сап Ье replaced а at 6.
Геюгасю the ram а at 7 to
reduce both the сопюепю Ы fluid
апд the lifting height required.
B1ank апд 1abe1 hoses 8 to
prevent епюгу Ы dirt апд to
ensure соггесю replacement.
9803/3200
HYDRAULICS
Е
7-3
OOl£/£086
bL
Э
вЭi1пдааАн
Э
Е
НУОйА 11С8
Е
7-5
7-5
ААМ—Опе Piece Piston Неад
(Тур iса )
Dismantling and AssemЫy
The numerical sequence shown
оп the illustration is intended
а а guide to dismantling а
typical гагп. Соглропеп 5 Ы
specific rams тау агу in
shape and quantity, ог details
еег to раг1 catalogue.
1f replacing еуе еп Ь151Пе5,
position the splits У а shown.
*Еп сар, item 1 is to Ье Ше to
cylinder with 4 гор5 Ы Loctite
242 (Service Too1s) оп bottom
3 ог 4 threads.
[оаег аггп апд shovel rams
to Ье overhauled in pairs.
Аепе еп сар lockwire and
secure to ее pipe.
Г\]ОТЕ: ltems 7 to 10 аге
fitted to dipper and Ысе rams
оп у.
Piston Неад Torque Settings
Рог assembly, the sequence
should Ье reversed.
When Dismantling
Piston Ао
D iameter
тт.
51
64
64
64
in.
2.0
2.5
2.5
2.5
тт.
—
102
114
127
1t тау Ье песеагу to use
hydraulic pressure ог согпргее
air to drive out the piston
assembly.
Тогще Setting Соде
WARNING: Ensure that the
епд сар 1 is securely in
position during this operation
а evere injury сап Ье caused
Ьу а suddenly ге1 еабес piston rod.
А
В
С
D
гп
408
522
780
1051
Torque
cylinder
Воге
kgf т
41.5
53.2
79.5
107.2
Setting
in.
—
4.0
4.5
5.0
Соде
А
В
С
D
1bf ft
300
385
575
775
When AssemЫing
Гепе'у а11 seals and 'О' rings,
lubricating а11 internal parts
with ]СВ 'Special hydraulic
Л и iсi.
* Рог веа1 fitting see раде Е 7-10
Position опе split seal and опе
wear ring оп each side Ы seal В.
Веоге fitting aluminium Ьгопе
type еаг rings (rams агдег 1 аап
102тт. (4in.) bore оп1 у), ensure
that sharp согпег Х аге removed,
leaving а radius Ы 0.5тт.
(0.020in.)
9803/3200
lssue 3*
Е
7-6
9803/3200
HYDRAULICS
Е
7-6
1 ssue 1
Е
Е
НУДААи[1СЗ
7-7
7-7
RAM—Two Piece Piston Неад
(Тур iса 1)
Dismantling апд AssemЫy
The numerical ещепсе shown
оп the illustration is intended
as а guide to dismantling а
typical гагл. Components Ы
зресс rams тау агу in
uantity, for details
shape ап
геег to раг catalogue.
[оаег аггл апд shovel rams
to Ье overhauled in pairs.
Г\ ОТЕ: 1 егП5 9 to 12 are
fitted to dipper апд bucket
rams оп Iу.
Рог assemЫy, the sequence
should Ье reversed.
When Dismantling
1t тау Ье necessary to це
hydraulic pressure or
согпргее air to drive out
the piston assembly.
WARNING: Ensure that the
еп сар 1 is securely in position
during this operation, as е 'еге
injury сап Ье caused Ьу а
suddenly released piston rod.
* Епd сар item 1 is to Ье fitted to
суНпег with 4 гор of Loctite
242 (Service Too1s) оп Ьоюогп
3 or 4 threads.
Аепе еп сар lockwire апд
secure to ее pipe.
Piston Неад Torque Setting
Piston Ао
D iameter
тт.
38
51
64
64
76
in.
1.5
2.0
2.5
2.5
3.0
cylinder Torque
Воге
Setting
тт. in.
Соде
А
В
102 4.0 С
114 4.5 D
127 5.0 Е
Torque Setting Соде
А
В
С
D
Е
[\ гп
420
408
522
780
1051
kgf т
42.9
41.5
53.2
79.5
107.2
1ЬЛt
310
300
385
575
775
When AssemЫing
Аепе а1 еа15 ап 'О' rings,
lubricating а11 internal раг
ith
JCB 'Special' hydraulic fluid.
*
Рог seal fitting ее ране Е 7-10
Веоге fitting aluminium Ьгопе
туре еаг rings (rams larger
than 102тт. (4in.) Ьоге only),
ensure that sharp согпег Х
are removed, leaving а radius Ы
0.5тт. (0.020in.)
If replacing еуе епд bushes,
position the splits У as shown.
9803/3200
lssue 3*
Е
7-8
9803/3200
HYDRAULICS
Е
7-8
lssue 3
Е
HYDRAULICS
7-9
7-9
RAM—Loctite retained Неад
(Тур iсаi )
Яепе
епд сар lockwire апд есге
to ее pipes.
Dismantling апд AssemЫy
The numerical sequence shown
Piston Неад Тогще Settings
оп the illustration is intended а
а guide to dismantling а typical гап .
Соглропепт. Ы specific гагп тау
Piston Rod
Cylinder
Тогсе
vary in shape апд quantity, ог details
О а гтiеег
Воге
Setting
геег to раг
catalogue.
Рог assemЫy, the есрепсе should
тт.
in.
тт.
in.
64
2.5
127
5
Соде
А
Ье reversed.
Torque Setting Соде
VVhen Dismantling
гТ1.
1t тау Ье necessary to use hydraulic
А
408
kgf т
1bf ft.
41.5
300
pressure ог соргее air to drive
out the piston assemЫy.
МАШ\НГ\ С: Ensure that the епд сар
1 is securely in position
is
гп
operation, а evere injury сап Ье
caused Ьу а suddenly гееае piston
rod.
ое that it is necessary to use heat
(180оС-356оЕ) to break the loctite
Ьоп
Ьеееп the piston rod апд
head.
When Assembling
Яепе
а1
еа1 апд '0' rings,
lubricating а11 internal раг
ith
]СВ 'Special' hydraulic fluid.
* 1f rebuilding а piston иеа /го assemЫy
use Loctite 601 оп the piston rod
threads апд torque set within 3
minutes Ы applying Loctite.
Рог еа1 fitment see рае Е 7-10.
1f replacing еуе епд bushes, position
the splits У а shown.
Епд сар item 1 i$ to Ье fitted to
cylinder with 4
гор Ы Loctite 242
(Service Тоо1) оп bottom 3 ог 4
threads.
9803/3200
1ббе 2'
HYDRAULICS
Е
*7-10
Е
7-10*
ГАМ 5ЕА[ FITMENT
ТЬе following service tools
should Ье used 1о assist the
fitment Ы ram seals.
Lubricate seals with ]СВ
Special hydraulic fluid
Ьеоге fitting.
1t is important Ьа the
seals до по turn inside out.
3640А
Wiper 5еа1 Fitting Тоо1 — А
64тт. (2.5in.) dia. го 892/00024
5еа1 Еирапдег 51ее',е — R
Fitting Selemaster seals
92тт.
101тт.
114тт.
127тт.
9803/3200
(3.625in.) Ьоге 892/00012
(4in.) Ьоге
892/00013
(4.5in.) Ьоге
892/00031
(5in.) Ьоге
892/00102
lssue 1
Е
Е
HYDRAULICS
8-1
8-1
19
15
9803/3200
3860
НУЕЖА1[1С
Е
Е
8-2
ВЕСЕ
8-2
ЕА[1Г'1С COUPLII\1G
Dismantling апд AssemЫy
ТЬе numerical sequence
Ьо'мп оп the illustration is
intended а а guide to
Dismantling.
Рог АбегпЬ1 у the sequence
should Ье reversed.
Note that оп machines with
о couplings fitted, detaching
the excavator п 1 wi11 leave
the егпа1 е half (А) Ы опе
coupling ап the та1 е half (В)
Ы the other attached to the
excavator unit.
1)ррег illustration Ьо'мб Dowty
туре coupling, оег
illustration бЬо'м Lockheed
туре.
When Dismantling
Use Service tool 892/00067 to
согпргеб ‚,а1' е seat 3 against
its spring to a110
рН pin 1
to Ье withdrawn. ОН Lockheed
units, grip the projecting егд Ы
‚,а1',е 14 in а vice (use soft
jaw clamps) апд unscrew Ьоу
15 anticlockwise.
Use Service tool 892/00066 to
turn sleeve 8 апд 19.
When AssemЫing
Check а11 parts ог
агпа9е.
еаг ог
Аепе'м `0' rings апд (оп Dowty
units) split pin 1.
9803/3200
1
е1
HYDRAULICS
Е
Е
9-1
9-1
FAULT Е1 О1 Г]С
FAULT
1.
2.
О i АСГ'i 05 i 5
Hydraulics — Го unctioning
а.
Оi 1 1е~е1 1ow.
Ь.
1 ncorrect он .
с.
Drive Coupling broken
д.
Ритр defective.
е.
Drive Shaft broken
f.
М. R.V. defective.
g.
M.R.V. incorrectly adjusted.
h.
Suction Ное adrift.
i.
Main ее hose adrift.
а.
Oi 1 1 е~е1 1оу .
Ь.
1ncorrect oi1.
с.
Cleaner blocked.
д.
Engine defective.
е.
Ритр—excess 5[ ррае.
f.
Ритр 'О' ring leaking.
g.
M.R.V. defective.
h.
M.R.V. incorrectly adjusted.
i.
Suction pipe leaking.
.
Ееес pipe/hose 1eak.
Hydraulics function — S1ow1y — Lack Power
980313200
issue 1
Е
Е
HYDRAULICS
9-2
9-2
FAULT FINDING
FAULT
3.
4.
5.
DIAGNOSIS
Loader Va1ve Block — Not Functioning
Excavator Va1ve Block — Not Functioning
а.
Веего 1.
а.
А11 Вагпз failed.
Ь.
Опе lift ram опе tip ram faulty.
с.
'0` ring/seal 1eak.
д.
Va1ve Ьос сгасес internally.
а.
Ram seals defective.
Ь.
Ram '0 rings defective.
с.
'0' ring оп A.R.V. зеа
д.
A.R.V. defective
е.
Va1ve В1 ос '0' ring defective.
f.
Ram hose/pipework leaking.
Loader Va1ve Block — Not Functioning
Functions S1ow1y — Lacks Power —
Excavator Va1ve Block — Functioning
Опе Service оп Va1ve B1ock
— Г\]о unctioning
— Functions slowly—Lacks power
Other Services Functioning
9803/3200
efective.
Е
~-~
нYDRAULICS
_;
9-3
Е
9-3
FAULT FINDING
Ед1[Т
6.
7.
8.
DIAGNOSIS
Excavator \/а1 е В1ос1с — Not Functioning
Loader Va1ve — Го Functioning
а.
Аеего 1.
а.
Carryover tube defective.
Ь.
Excavator ',а1',е feed pipe damaged ог
leaking.
с.
Va1ve Ыос[ cracked internally.
а.
Air trapped in A.R.V. cavity
Ь.
Dirt trapped оп A.R.V. seat.
с.
Dirt trapped оп anti-cavitation
~а1iе еа1.
д.
A.R.V. defective.
е.
Anti-cavitation а1~е defective
f.
Ram еа1 defective.
g.
S1ew 9еагЬох логп.
Excavator \/ а1' е B1ock — 1\1о1 Functioning
Functions S1ow1y — [ас1 б Power
Loader Va1ve В1ос1с — Functioning
S1ew Over-ride—Excessive
980313200
lssue 1
~~,~
~`'>
НУОЕА111СЗ
9-4
9-4
FAULT FINDING
FAULT
9.
10.
11.
DIAGNOSIS
Clamps — Not Functioning
а.
Pressure in main circuit 1ow.
Ь.
Pipework leaking.
с.
Clamps seized.
д.
Maloperation Ы сопго1.
е.
Air in system,
а.
lnsufficient clearance.
Ь.
Clamps seized.
а.
Air in system.
Ь.
1 псоггес он in main system.
с.
Non-return iе1iе faulty.
Clamps — Not Releasing
С1атр Operation — Зропду
9803/3200
Е
нУДААиL1С$
10-1
С1 ГС1)1Т 01АСГАМ — СВ 20, 3 and ЭС
The illustration оп the right shows the
standard circuit with the Напог11пу
Shovel Va1ve.
The illustration below shows the optional
Shovel circuit with the Сепа Shovel \'а1 е.
Fitted гогп т/с о. 100000.
Excavator ог Shovel Operated
The neutral circuit is blocked Ьу the selected
spool and ы' is diverted under pressure ю the
ram. Oi1 exhausted гогп the ram is returned
Ьу the оюЬег епс Ы the spool to the Л1 ег and
hydra-chassis.
Neutral Circuit
Oi1 in the neutral circuit ( Ьо 'п in bold
rom the
line оп the illustration) Ноу
Hydra-chassis А ю the Ритр В and рае
11пгощЬ the centre Ы the Shovel \'а1 е С
via the Main Relief Va1ve D. The он hen
Лоу
rough the centre Ы the Excavator
Va1ve Е and returns ю the hydra-chassis via
the Filter F.
А Hydra-chassis
В Ритр
С Shovel Va1ve В1 оск
D Main Relief Va1ve
Е Excavator Va1ve В1 оск
F Filter
R Воот Аат
Dipper Ram
S
Т
и
W
Bucket Ram
Slewing Ram
Shovel Аггп
Х
У
Shovel Ram
Stabiliser Ram
С1 ат Ram
(Optional)
Ram
3162А
9803/3200
Е
10-1
W
Ю11
1е 1
Е
нУДААи11Св
10-2
C1RCUIT О1 АОГАМ —ЗСВ 3D.
Excavator ог Shovel Operated
The illustration оп the right бЬоуб the circuit
with the На i ог1Ьу Shovel Va1ve.
The illustration below shows the Shovel Circuit
with the Сепа Shovel Va1ve. Fitted гогп
т/с о. 100000.
Neutral Circuit
Oi1 in the neutraf circuit ( Ьоу'п in а Ьоl д
line оп the illustration) flows from the
Hydra-chassis А to thë Ритр В апд рае
through the centre Ы the Shovel Уа1 е С via
the Маi п Relief Va1ve D. The он юЬеп flows
through the centre Ы the Excavator Уа1 е Е
апд returns to the hydra-chassis via the
filter F.
The neutral circuit is blocked Ьу the selected
spool апд oi1 is diverted under pressure to the
ram. Oi1 exhausted гогп the ram is returned
Ьу the other епд Ы the spool to the filter апд
hydra-chassis.
А
В
С
D
Е
Нус га-с iаббi
Ритр
Shovel Va1ve 6lock
Маi п Relief Уа1 е
Excavator Va1ve
R
S
Т
U
W
Воот Ram
Dipper Ram
6ucket Ram
Slewing Ram
Shovel Аггп
Х
У
Z
Shovel Ram
Stabiliser Ram
С1 ат Ram
(Optional )
В1 ос
F
G
Н
J
Filter
Kingpost С1 агпр
Clamping Va1ve
СЬес Va1ve
Ram
s
3162А
9803!3200
Е
10-2
1028А
TRANSM 1SS1ON
F
F
Contents
Contents
Ttansmission/Steering Ритр
ее Section Н
Description
Removal and Replacement
1-1
2-1
Dismantling and Assembly
Dismantling and Assembly
Dismantling and Assembly
Dismantling and Assembly
Dismantling and Assembly
Dismantling and Assembly
Dismantling and Assembly
Dismantling and Assembly
3-1
3-3
3-5
3-6
3-7
3-9
3-10
3-11
3-11
4-1
5-1
Clutch
Аеглоа1 and Replacement
Dismantling апд Assembly
6-1
6-3
Gearbox/Fina1 Drive
Description
Removal and Replacement
Dismantling and Assembly
Dismantling and Assembly
Dismantling and Assembly
Removal and Replacement
Removal and Replacement
Re-setting
Removal and Replacement
7-1
Тоге Converter
Driving She11
(То Converter 24110/4167)
(From Converter 24110/4168)
Reaction P1ate
Output/Clutch Shaft
Нудгаи1гс Clutch
Direction Control Va1ve
Modulating Vaive
Lubrication Va1ve
Pressure Va1ve
Fau1t Diagnosis
Ргеввиге F1ow Testing
Fina1 Drive
О iНегепiiаi
СоУег5 and Selectors
Primary Shaft
Маiп Shaft/Centre Bearing
Layshaft/Reverse
еаг
*3упсгое5
earbox/Fina1 Drive
( Егогл Machine No. 130302
*3упсго е5
Description
Description
Operation
8-1
9-1
9-3
10-1
10-6
10-8
10-10
10-11
11-1
11-3
11-4
Gearbox/Fina1 Drive
Removal апд Replacement
8-1
Fina1 Drive
Dismantling апд Assembly
9-1
Dismantling апд Assembly
Removal апд Replacement
Removal апд Replacement
R e-setting
Testing
Removal апд Replacement
Removal апд Replacement
Епд F1oat Re-setting
Testing
Removal апд Replacement
Testing
Еа 11 Finding
12-1
12-3
12-5
10-10
* Соуег and Selectors
*Primary and Reverse Shafts
*Маiп Shaft
*Маiп Shaft Bushes ( Вапде
*Centre Bearing
* Layshaft
еаг5)
*1ауа Bushes (Ratio беагб)
*Ratio Selectors
9803/3200
13-1
12-7
12-9
12-11
13-1
12-12
13-1
14-1
lssue 5*
F
F
TRANSMISSION
Contents. Powertrain
Contents. Powertrain
15-1
Service Тоо15
Torque Converter
Removal апд Replacement
16-1
Shuttle Transmission
Description
17-1
Dismantling апд АssетЫу :—
сеагьох
Рита
Reverse Clutch
Forward Clutch апд Drive Сеаг
Pinion Саде апд Оыры Shaft
Shuttle \ а1 е
Рге5 ыге Testing
Раы' Finding
17—З
17-4
17-6
17-8
17-9
17-11
17-12
Description
Synchromesh—Description
—Operation
18-1
18-2
18—З
Dismantling апд Assembly:—
Gearchange AssemЫy
Casing
Gearshafts апд Selectors
Mainshaft
Layshaft
Selectors
Епд Соег
Mainshaft апд Layshaft Епд F1oat
Рао1 Finding
* Drive АхIе
9803/3200
Тогще Settings
То М/с по. 138621/5
Егогя М/с по. 138622/5
18-5
18-6
18-8
18-10
18-12
18-13
18-14
18-15
18-17
19-1
19-1А
Differential— 6earing Рге1оад
19-2
— Pinion Depth Setting
— Pinion 6earing Рге1оад
Crownwheel 6acI iash
Crownwheel апд Pinion АсЩгяеп
Агт 6earing Рге1оад
19—З
19-4
19-5
19-6
19-8
Metallic Еасе Sea1s
Ви11 Pinion Епд Е1 оа
19-9
19-10
lssue 2*
F
TRANSMISSION
1-1
F
1-1
DESCR1PT1ON
The torque converter unit
attaches to the геаг Ы the engine
апд replaces the clutch unit,
reverse еаг and
/ оу ratios
Ы the manual transmission.
This allows selection о orward
апд reverse direction without
disengagement Ы the manual
gearbox.
The engine 1упее1 is mechanically
соир1 ед to the torque converter
impeller 2. Oi1, а moderate
pressure is introduced into the
torque converter and directed
Ьу the impeller into the Ь1 ае
Ы the turbine 4, thus causing
the turbine to rotate. Reaction
member 3 which at 1ow speeds
is stationary, directs the оП back
into the сепге Ы the impeller.
This circulation utilises the
momentum о the он to impart
additional turning еНог1 to
the turbine.
Упег light 1оад, high рееd
conditions, impeller and
turbine turn а
e same рееd
апд the reaction member
гоЁаЁе reely in the same
direction, 1 по giving а direct
drive, without torque
multiplication.
smooth clutch engagement Ьу
allowing а 9гаоа11 у increasing
amount о он to Ло rom
the direction \'а1~е to the clutch.
Whenever the direction ‚,а1',е
is operated, он рае to the
Ьа5е о huttle 'а1'е 22В. The
pressure difference асго the
~а1~е, сгеае Ьу а restrictor
drilling, саое the ‚,а1',е to
shut-off pressure to the clutch
1ine. ОП 'Ь1 ее
through the
restrictor drilling, moving the
accumulator роп (22А)
against the spring until
pressure is Ьа1 апсе асго the
shuttle 'а1'е. А1 this stage the
shuttle 'а1'е is opened to the
clutch line Ьу its own ас1оа1 п9
рГi П 9.
Lubrication ‚,а1',е 21 ensures that
the torque converter always
remains Л11 е
ith оН. А 1ow
pressure feed ог clutch
lubrication is а1 о taken from
this point.
converter output is
transmitted to the gearbox Ьу
way Ы hydraulically
actuated forward/reverse
clutches 6 and 7.
Hydraulic оН 1о is initiated
Ьу the ритр 13 which supplies
он to the torque converter Ьу
way Ы pressure '‚а1"е 15, and
to the clutches Ьу way Ы
direction 'а1'е 16 and
modulating 'а1'е 22. А о11
Ло
ilter 14 is incorporated
into the pressure 1ine. The
modulating ' а1' е епоге
9803/3200
lssue 1
TRANSMISSION
1-2
1-2
1
22А
1.
Torque Сопиегнег.
11.
Reverse idler.
2. 1тре11ег.
12. Reverse gear.
3. Reaction тетЬег.
13. Ритр.
4. ТпЫпе.
14. Filter.
5. Turbine Shaft.
15. Pressure ',а1',е.
6. Forward clutch.
16. Direction ',а"ле.
7.
17. Соо1ег.
Reverse clutch.
8. Output shaft.
22
18. Relief Va1ve.
9. Turbine shaft gear. 19. Gallerytoforward clutch.
17
10. Layshaft.
20. Gallery ю reverse clutch!
21. Lubrication ',а1',е
22.
Э Э Э ЭЭЭ ЭЭЭЭЭЭЭ1111ЭЭiЭ1ЭЭ11{ЭЭЭЭiЭЭ ЭiЭ1
{ 1 { {{{ {
{11 1111{ 111111 {{
Modulating ',а1',е.
iii~ЭЭЭЭЭ-1iЭЭiЭЭЭЭ1ЭiiЭЭЭ~ЭЭЭ~Э~ii1ЭЭЭЭЭiiii
Pressure Circuit.(Engaged)
21
r
Pressure Circuit.(Disengaged)
Тоге Сопиегнег Circuit.
С
L
9803/3200
i-
1 о'
д, Pressure Returns.
г,
11-
Lubrication Circuit.
~еы
/
F
ТйАЗМ 1331Оi\i
2532
11
Кеу
1.
Driving she11 assembly.
2.
Ритр. (Engine driven)
З.
Reaction plate assemЫy.
4.
Output shaft and clutches.
5.
Layshaft assembly.
6.
Reverse idler деаг.
7.
Pressure \,аК,е.
8.
Filter.
9.
Directional \'а1\'е.
10. Modulating \'а1\'е.
11. Strainer.
12. Lubrication \'а1\'е.
9803/3200
1
е1
F
2 -1
F
ТЧАГ\1 М 11ОГ]
2-1
3847
980313200
lssue 1
F
ТЕАГ' М 11ОГ]
F
2-2
2-2
TORQUECONVERTER
Removal апд Replacement
Веоге the torque converter
сап Ье removed и wi11 Ье
песеагу ю take out the
engine, see Section К.
ТИе numerical sequence
Ьоп оп the illustration is
intended а а guide ю
Removal.
Рог Replacement the sequence
should Ье reversed.
When Removing
* Drain Torque converter он
(see Section 3 рае 5-2).
Disconnect реда1 return
springs 1 and transmission он
filler hose 2 (accessible from
underneath the machine).
Рог inside the machine wi11
Ье таде easier if the driving
seat is 1аеп out.
Disconnect control го clevis 8
and он pressure gauge line 9.
Disconnect bonnet зюау and не
Ьас bonnet in the vertical
position.
Fit lifting еуеб ю threaded
Ьобеб ( Ьаююегу югау mountings)
and аююасН hoist slings.
Unbolt the torque converter
from the gearbox, remove
torque converter from the
machine.
*When Replacing
Саге to Ье аеп when entering
torque converter бЬа 1 into
gearbox shaft а splines сап Ье
tight fit. Во по use undue
огсе аб damage сап Ье
caused to the gearbox bearings.
Withdraw dipstick, Unbolt
floorplates 3 and 4 and томе
them clear Ы the working агеа.
Remove Ьеаег 5 (if fitted)—
accessible гогл underneath
the machine.
Remove steering hose соег 6
and оер1 ае 7.
9803/3200
1 ввие 2*
F
3-1
9803/3200
TRANSM1SS1ON
F
3-1
Issue 1
F
TRАNSM1SS1ON
3-2
3-2
ТОВО1.!Е CONVERTER—Driving She11
(1)р to Converter [\ о.
24110/4167)
Dismantling and AssemЫy
ТЬе numerical sequence
shown оп the illustration is
intended аб а guide to
Dismantling.
Рог АббеглЫу the sequence
should Ье reversed.
V11hen Dismantling
Install lifting bolts А in driving
sheIi, remove holding bolts В.
When AssemЫing
Аепе ЫбЬеб 8, 13 and 17,
and gasket 16.
[осае аЬ Х оп ЁЬгыб
washer 9 into holes У in
reaction member 7.
Аепе '0' гГп9 4, lubricate
with transmission он Ьеоге
fitting. (Take саге по o
damage'0' ring ‚ Ьеп bringing
together driving shell апд
impeller).
1 гба11 пе
ab plates 2, огяе
tighten bolts evenly to
specified ',а1 ие, гп down
согпег Ы 1аЬ plates.
Check that the reaction member
сап ыгп гее1 у.
Тоще Settings
ltem
1
14
F
1bf ft
► 1 1-8-- 2
7 --8—
9803/3200
kgf т
)л
1 1-а 9--
F
3-3
9803/3200
TR/NSMISSION
F
3-3
1ssue 1
TRANSMISSION
3-4
Г
3-4
ТОО1)Е CONVERTER—Driving She11
( Егогл Converter No.
24111/4168).
Dismantling and AssemЫy
ТЬе numerical sequence
shown оп the illustration is
intended а а guide to
Dismantling.
Еог АеглЫу the ещепсе
should Ье reversed
When Dismantling
lnstall lifting bolts А in
driving she11, геглое holding
Ьо11 В.
When Assemhing
*Renew thrust washers 5
ап 7, ensuring that their
геу side асе the reaction
member 6:
Вепе 'О' ring 4, lubricate
with transmission он Ьеоге
fitting. (Take саге not to
damage 'О' ring when bringing
together driving she11 апд
impeller).
Вепе
ab plates 2, tighten
bolts е~еп1у to specified
~а1ие апд turn down юаЬ
plate согпег .
Check that the reaction
member сап turn гее1у.
Топе Settings
ltem
1
11
1 Ь ft
н 18=12
9803/3200
)
ррΡ
fЧ"
~
kgf т
1.С s
~
. 8 =-1-г1 1' с
игом
~в
сд
1 ввие 2'
F
Т1 АМ1881ОN
F
3-5
3-5
ТОЕЮ1Е CONVERTER (Reaction P1ate)
Dismantling and Assem Ыy
The numerical ещепсе shown
оп Ье illustration is intended а
а guide to Dismantling.
Еог АегпЫу, the sequence
should Ье гееге .
When Dismantling
1 е ехгасог Ьо1
remove plate.
ое 1Ьа
fitted.
Renew он eal 5.
Renew bearings 19 and piston
rings 16 if worn ог damaged.
Ensure 1Ьа piston rings аге
correctly еае n their grooves
with0.076тт (0.003in.)
maximum епд float, а hown
а Х.
а 'А' to
em 8 is precision
Тогсце Settings
1Ь t
ltem
kgf т
37 х-46 8"= 5 >. i
9
а4--2- 25 О
'~ ~-5 ъ -3.
13
When Assem Ыing
Renew gaskets 2, 6 апд 11
апд '0 ring 12.
9803.13200
lssue 2"
F
TRANSM 1SSI ON
3-6
3-6
TORQUE СО
ЕЕТЕЕ (Output/Clutch shafts)
Dismantling and AssemЫy
When AssemЫing
ТЬе numerical sequence
shown оп the illustration is
intended аб а guide to
Dismantling.
Аепеу bearings 14, 16, 18, 20
and 21 i
огп ог damaged.
Assemble idler еаг аб shown
а[ В.
Еог AssemЫy the sequence
should Ье reversed.
[осае thrust ГП9З 10 and 12 оп
рез 13.
When Dismantling
Аепе он seal 17, dimension 'А'
о Ье 0.80in. (20.Зтт).
В1о out the оП
compressed air.
F
ауз using
*Assemble items 6 апд 7
simultaneously.
*Withdraw items 6 апд 7
simultaneously.
цап
9803/3200
1ввие 2*
F
3-7
9803/3200
TRANSM1SS10N
F
3-7
TRAN3M1SS1ON
3-8
3-8
HYDRAULIC CLUTCH
Dismantling and AssemЫy
The numerical sequence
shown оп the illustration is
intended а а guide 1о
Dismantling.
A1ign tooth дар in steel р1ае
with cut-outs in clutch housing.
*Тогяце Settings
Рог АеггЬ1 у the sequence
should Ье reversed.
Item Nm
kgf т
11 64.4 6.6
1bf ft
47.5
When Dismantling
Compress clutch pack to a11ow
пар ring 1 to Ье removed.
When AssemЫing
Репе piston rings 8 and 10
if Ьгоеп or огп. Епд
clearance Ье "ееп ring and
9гоо\'е must not ехсеед
0.076тт. (0.003in.)as а А.
Репе clutch plates 3 апд 4
if scored, distorted, showing
signs оТ о"ег heating or if
огп down to the minimum
thickness д 'еп in the table.
Soak пе '' р1ае in warm
transmission он Тог 30 minutes
ЬеТоге fitting.
СА1Т1О : Later туре
graphite sintered р1 а1е (дгеу
colour) must по Ье mixed
with earlier туре Ьгоп2е
plates in the same clutch pagk.
Clutch Р1ае$
New Thickness
тт.
П.
Stee1
Sintered
9803)3200
1.39-1.52
*231239
0.055-0.060
0.091-0.094
Minimum Thickness
тт.
in.
1.27
2.1
0.050
0.085
1ввие 2*
TRANSM1SS1ON
F
F
3-9
3-9
DIRECTION СОГ\1ТО1 VALVE
Dismantling and AssemЫy
ТЬе numerical sequence
Ьолп оп the illustration is
intended а а ыисе to
Dismantling.
Рог Assembly the sequence
should Ье reversed.
When AssemЫing
Renew gaskets 3, 5 and 12
апд еа1 14.
lnstall роо1 13 in direction
Ы агго'л А. Епыге that
detent groove is positioned in
Нге with detent drilling
Ьеоге fitting items 6 to 9.
1b
Torque Settings
т
ltem
1Ь и
1а
1 91 =2U 2-2В 4
1b 379-=35
14
яв•q-.
4з•44.
13
1С78
9803/3200
1 ввие 2*
F
3-10
TRANSM1SS1ON
F
3-10
МОО11АТ1Г']С VALVE
Dismantling ап AssemЫy
The numerical sequence
shown оп the illustration is
intended аб а 91Лсе 1о
Dismantling.
Еог AssemЫy the sequence
should Ье reversed.
When AssemЫing
Renew'О ring 5 апс gasket 7.
Ensure that shuttle
spools
8 аге fitted with fluted епсб
downwards.
9803/3200
lssue 1
TRANSM1SS1ON
3-11
F
3-11
LUBRICATION VALVE
Dismantling апд AssemЫy
The numerical sequence
shown оп the illustration is
intended as а guide 1о
Dismantling.
1
Рог АззеглЫу the sequence
should Ье reversed.
When AssemЫing
Аепе 'О' ring 3.
РГЕ
1
ЖЕ VALVE
The Pressure - ё is'preset to
operate а1 9.1-1О.5 kgf/ст2
(130-150 1bf/in2) and should
по Ье adjusted ог dismantled.
Аепе ',а1',е as а complete
азеглЫу if failure occurs.
с1 _ 10 •
*Аепе
gasket А апд 'О' ring В
when refitting ‚,а1',е.
9803/3200
lssue 2•
F
F
TRANSM 1S&ION
4-1
4-1
/
с с т
' -х-
FAULT DIAGNOSIS — Тогсре Converter
Г ]ОТЕ:
Веоге attempting to diagnose апу suspected malfunction, ensure that the condition is
по created Ьу 1ow оН 1е~е1, он по а normal working temperature, or он in роог or dirty
condition. Check that there is Но leakage in the external circuit. A1so make sure 1 а
valves апс control linkages аге operating соггес 1 у.
Fau1t
1.
2.
3.
PossiЫe Cause
Fluctuating Oi1
Pressure
[о
Oi1 Pressure
его Oi1 Pressure
а.
Partially blocked suction strainer.
Ь.
Air leaks in suction pipe.
с.
Partially blocked pressure filter.
д,
Worn direction control а1~е spool.
е.
Mechanical defect (e.g. clutch pack епс р1 ае retaining гпд
broken).
f.
Pressure gauge faulty.
а.
Partially blocked suction strainer.
Ь.
Air leaks in suction pipe.
с.
Pressure maintaining а1~е defective.
д.
Worn ритр.
а.
Pressure gauge faulty.
Ь.
Pressure gauge line disconnected ог broken.
с.
Seized ритр.
д.
Direction control а1~е spool broken.
4.
High Oi1 Pressure
а.
Pressure maintaining а1~е sticking.
5.
High Oi1 Temperature
а.
Excessive 1оад (causing converter
Ь.
1 псоггес operating technique (e.g. оо high деаг ог site
conditions.
с.
Dirty ог blocked он соо1 ег.
д.
Relie
е.
Worn ритр.
f.
Seized reaction тетЬег.
9803(3200
а11).
а1~е sticking орел.
lssue 1
TRANSMISSION
F
F
Fau1t
PossiЫe Gause
6.
а.
Тогще converter оП 1о гес iiсес ($ее also'Low он
pressure') — саггу out Лом глеег test.
Ь.
Clutch piston ring
с.
Clutch plates ‚(ОГП.
д.
Clutch он galleries restricted.
е.
Torque converter damaged or
f.
Relie
а.
Engine requires servicing.
Ь.
Torque converter reaction глегпЬег incorrectly fitted.
с.
Direction control а1~е
огп or damaged.
Difficulty in selecting
Forward, АеУег5е or
а.
Direction control а1~е
огп or seized.
Neutral.
Ь.
Modulatin
с.
Clutch он galleries blocked.
а.
Modulating а1~е
Ь.
Clutch рае seized.
с.
Clutch он gallery blocked.
а.
Clutch piston rings
Ь.
Turbine thrust bearing
7.
8.
9.
10.
11.
High engine speed with
machine stalled.
[ом engine speed with
machine stalled.
Machine wi11 по томе
with еаг engaged and
direction Clutch
selected.
Transmission squeals
ипдеr1оад.
МасЫпе road speed
erratic
9803/3200
а.
огп or damaged.
огп.
а1~е sticking орем.
а1~е
огп or damaged.
огп or damaged.
огп or damaged.
огп or damaged.
ее Е1iiс iiа i п9 Oi1 Pressure and high and 1о engine
рее
ith machine stalled.
lssue 1
TRANSN11SS10N
5-1
5-1
PRESSURE/FLOW ТЕЗТ1 ГЮ
Elow Rдte
Веоге commencing test
ensure that the ОП is at the
соггес е iе1 апд at working
temperature (80°-100°С,
176°-212°F).
Check that clutch pressure is
between 120 and 150 1bf/in2
(8.4-9.8 kgf/ст2).
Connect flow meter НТ100
(Service оо15) into он cooler
line гогл torque соп"егег
(as at А). Make sure Ьа he
flow meter loading iа1iе is
ОЕЕ.
Run engine at maximum speed,
flow meter геасПгщ should Ье
between 8 апд 8.5 1.) К ga1/min
(36-38 1 itres)~
Lubrication Ргеыге Test
Remove он cooler temperature
transmitter (as at В) and соппес
глаег gauge 892/00003,
(Service оо15).
Run engine at maximum
speed, pressure gaugadгngshould Ье between 10 апд 25
у.)
1bf/in2 (0.7-1.7 kgf/ст2)
9803/3200
1551 е 1
F
F
тRANsмissio~v
6-1
6-1
4968
9803/3200
F
TRAN8N11881ON
F
6-2
6-2
С[1)ТСН
Removal апд Replacement
Torque Settings
The numerical зещепсе shown
оп the illustration is intended as
а guide to removal.
1 егп
13
14
Рог Рер1асегпеп the ещепсе
should Ье reversed.
When Removing
The Ьа1 егу гау, air cleaner
and sedimenter assembly 6
should Ье removed as опе unit.
НОТЕ: The sedimenter was
по itted prior to т/с Но.
110552.
1f а саЬ heater is fitted, this
must Ье removed Ьу taking
out bolts 10. Cover р1аез
11 апд 12 shou 1д then Ье
removed to give clearance ог
the removal Ы the clutch
housing 16.
Take out the retaining pins 18
and slide forward sleeve 19.
Remove plug 20 and slide
transmission shaft 21 rearwards.
Clutch assembly 26 is removed
together with transmission
shaft 21 and thrust bearing.
When Replacing
Fit the driven plate with its
long сепге Ьо
acing аау
гогп the flywheel.
1.)зе the transmission shaft to
centralise the driven plate.
Adjust clutch реда1 ( бее ране
36-1).
9803/3200
Nm
57
130
kgf т 1bf ft
5.8
42
13.3
96
F
F
TRANSMISSION
6-3
6-3
CLUTCH
1
Dismantling and Assembly
The numerical sequence оп
the illustration is intended as а
guide to dismantling.
Рог assembly 11-ю sequence
should Ье reversed.
When Dismantling
Mark pressure plate апд clutch
соег to ensure correct
assembly.
Соглргебб clutch using tools
18G99A апд 18G99C.
Eyebolt adjusting nuts 1 аге
реепед over ог security.
When AssemЫing
Яепеу pressure springs as а set
е1 release lever height using
tools 18G99A and 18G99C.
Рееп over adjusting nuts 1 to
lock in position.
4969
9803/3200
lssue 2
F
ТРА 5М 1551ОГ
7-1
7-1
MANUALGEARBOX
Description
The gearbox сапд contains
the тain gearbox апд the
high•1ow gearbox а he гопt
апд the differential деаг а
the геаг. Те деагЬохор
со' ег contains the selector
mechanism ог both раг Ы
the gearbox.
Роег from the clutch is
гап
1ес from the primary
shaft 3 through either the
high ог 1ow ratio деаг54 ог 5
to the layshaft 6.
When деаг 1st to 4th аге
selected the power from the
layshaft is transmitted through
the selected gear to the main
shaft 11.
When 5th gear is selected the
power is transmitted direct
from the high-1ow ratio to the
main shaft.
The reverse gear shaft 14 is
глоыпе а he side Ы the
layshaft towards the геаг Ы
the gearbox.
Selection Ы reverse gear slides
the main shaft first gear 7
rearwards to eпgage with the
reverse gear. Power is then
transmitted from layshaft
1Ыгс gear 9 to the reverse
gear shaft, then to the mainshaft
through the first gear.
The гпа г I'а сгле$ сПгесу
опю the crownwheel 13 in
the differential деаг5.
9803/3200
1.
2,
3.
4.
5.
6.
7.
Ratio Lever
Рап9е Lever
Primary Shaft
High Ratio Gear
1о Ratio Gear
Layshaft
1st Gear
8.
9.
10.
11.
12.
13.
14.
2nd Gear
3гс Gear
4th Gear
MainshaftlPinion
5th Gear
Сгоп Whee1
Reverse Gear
1ssue 1
TRANSMISSION
7-2
7-2
ТОРСЮЕ СОГУЕРТЕР СЕАНВОХ
Description
The 9еагЬох casing contains
the main 9еагЬох at the гоп1
апд the differential gears at
the геаг. The деагЬох top
cover contains the selector
mechanism ог the gears.
Роеег from the torque
converter is transmitted гогО
the primary shaft 2, through
transfer gears to the layshaft 8.
When gears 1st to Згд аге
selected the power гогт the
layshaft is transmitted through
the selected деаг to the main
shaft 7.
When 4th gearisselected the
power is transmitted direct
from the primary shaft to the
main shaft.
Г\ о reverse деаг is fitted to the
деагЬох, reverse being provided
Ьу the torque converter.
The main shaft drives directly
onto the crown wheel 9 in the
differential gears.
1. Ratio 1.еуег
2. Primary Shaft
3. 1б1Сеаг
4. 2п Gear
5. 3г Gear
6. 4th Gear
7. Mainshaft/Pinion
8. Layshaft
9 Сго'лп Whee1
9803!3200
1е 1
/
F
F
TRANSM1SS1ON
7-3
7-3
TORQUE CONVERTER СЕАРВОХ
Suffix 'R' Bui1d
Description
Torque converter machines
have Ьееп built using modified
10 speed manual 9еагЬохе5.
These machines сап Ье
recognised Ьу а suffix'R' in
the гласппе number.
The differences Ье1 ееп the
standard 10 speed апд the
suffix'R' 9еагЬохе is а
То11о :
9803/3200
1.
Primary shaft А is changed
апд the high ratio еаг
and он linger оп the
layshaft are replaced Ьу
расег В.
2.
8расег С and D are fitted
о prevent engagement Ы
first gear Е and гееге еаг
F. These расег глы
а1 ау Ье replaced when
servicing the 9еагЬох .
lssue 1
F
ТйАГ\18М 1881ON
8-1
8-1
4987
9803/3200
TRANSM 1SS1ON
8-2
GEARBOX/FINAL DR1VE
Removal апд Replacement
The numerical seQuence оп
the illustration is intended as
а guide to dismantling.
Еог assembly, reverse the
sеq иепсе.
When Removing
Raise machine оп stabiliser
legs and Support as А
Drain transmission оН апд
remove геаг road wheels.
Remove the Ьа1 егу гау,
аг cleaner and sedimenter
assembly (8ее ране К 1-1).
Remove the seat assembly
from the transmission.
Items 8 and 9 арр1 у to manual
machines on1y.
Support епдпе under clutch
or torque converter housing В.
Support transmission assembly
with trolley jack С or as follows.
Мае ир lifting plate D to fit
seat mounting оп transmission.
Р1 асе lifting Ьаг Е асгоб inner
fenders and fit ри11еу block F
to lifting Ьаг апд plate.
Remove remaining bolts 10
from transmission/clutch housing
or а11 bolts from transmission/
torque converter.
When Replacing
Саге to Ье taken when entering
torque converter shaft into
gearbox shaft as splines сап Ье
tight fit. Оо по use undue
огсе as аглае сап Ье caused
to the gearbox bearings.
Refi11 transmission with он .
9803/3200
F
8-2
F
ТЕ дГ\ М 1 10 1\I
9-1
9-1
12
9803/3200
F
7
TRANSM1SS1ON
9-2
9-2
Е1Г\]А1. DR1i/ Е AND
REDUCTION GEARS
Dismantling апд Assembly
Bearing Рге-1оад
The numerical sequence оп
the illustration is intended as
а guide to dismantling,
With оiд bearings 0.05тт.
(0.002in).
With new bearings : 0.175тт.
(0.007in.)
Рог аегтЬ1 у the есрепсе
should Ье reversed.
Spring Ва1апсе Reading
'Nhen Dismantling
0 to 1.3kg. (0 to 31b) is equal
to 0.05тт. рге-1оад.
Screw two housing bolts 1
into tapped holesA and
tighten equally to гееае the
сге pinion гогл Г splines.
5.5 to 8.2 kg (12 to 181b) is
equal to 0.175тт. pre-1оад.
Аеглое the Ьгаеб and
housings as section G pagel-1.
Аеглое bearing 12 using
tools 1854-7'С and 18С 47АР.
When AssemЫing
1 пбрес bearings for wear and
renew` if песеагу.
Аер1асе он eals 13 and е1t
washer 14.
4974
8е bearing рге-1оад Ьу
tightening nut 8.
\
Check рге-lоад as о11о
:
1~
1.
Attach а length Ы cord to
а wheel stud and wrap
around the studs three ог
four times.
2.
Attach а spring balance
to the гее епд Ы the со;д.
З.
Ри11 оп the spring balance
апд пое the reading whilst
the shaft is rotating.
9803/3200
f
lssue 1
F
F
TRANSM 1SS10N
9-3
9-3
13
9803/3200
4975
F
TRANSMISSION
F
9-4
9-4
О1 ЕРЕЕГТ1А1
Dismantling and AssemЫy
The numerical sequence оп
the illustration is intended as
а guide to dismantling.
Рог assembly the sequence
should Ье reversed.
When Dismantling
Support differential assembly
as at А.
1)бе 1' о bolts to remove item
2 as at В.
When AssemЫing
5е1 bearing рге-1оад as follows:
Fit differential assembly into
transmission case.
Assemble bearings 7 into
housings 2 and fit to
transmission case without
shims. Secure with four
equally spaced bolts, finger
tight.
Check crown wheel backlash
as follows:
Remove деагЬох ор соег
and lock ир еагб to prevent
transmission turning. Take
three equally spaced crown
wheel backlash геасНпдб.
NOTE: 1f апу reading is in
ехсебб Ы 0.7тт. (0.028in.)
reset the mainshaft as раде
F 10-10.
From the average backlash
reading subtract О.33тт.
(0.013in.), divide Ьу 3 and
multiply Ьу 5. The answer
wi11 дуе the number Ы shims
to Ье removed гогл the right
hand housing and fitted to
the 1е 1.
Adjust оП catcher trough 6 to
give 0.05 to 0.07тт.
(0.002 to 0.003in.) с!еагапсе
between the геаг 6СООР and
crown wheel.
Tighten 1е 1 hand bolts and
гоа1е differential to check
that bearings аге fitted
correctly.
Fu11y slacken right hand bolts
and measure the ар between
the housing and casing in four
positions. Remove housing
and fit shims 0.076тт.
(0.003in.) less than the
measured 9ар. Refit housing
апд fu11y tighten bolts.
9803/3200
ю
1
е1
F
10-1
9803/3200
ТйАЗМ IЗЗ1О
70-7
lssue 1
7
TRANSM ISS1ON
10-2
СЕАЕВОХ — 61а9е 1
Nlanual апд Suffix 'R' Gearbox
Cover апд Selectors
Dismantling апд АегпЫу
Те numerical sequence оп
the illustration is intended а а
guide to dismantling.
Рог аеглЬ1у, the sequence
shou 1d Ье ге"егес .
Г\]ОТЕ: ОН Suffix `R' Ьохеб
расег 28а is additional and
item 17 is герасе Ьу 17а.
When Dismantling
Саге to Ье taken when
removing selector rods from
37 по o 1ое ееп1 Ьа11
апд springs апд inierlock pins.
When Assembling
Assemble item 37 and selector
rods using tool 18G 1020.
Ensure соггес брасегб 27 and
28а аге fitted to Suffix 'R'
builds.
Аепе а11 lockwire оп selector
retaining screws.
9803/3200
Г
10-2
Т1 АГ\]$М 1$$1О
7 0-3
9803/3200
F
70-3
F
F
тRAn~Sм1SS1ON
10-4
10-4
СЕАГВОХ— а9е 1
Тоге Converter Machines
Соег and Selectors
Dismantling апд Assembly
The numerical ещепсе оп Ъе
illustration is intended аб а guide
о dismantling.
Рог assembly, Ъе sequence
should Ье reversed.
When Dismantling
Саге to Ье taken when removing
selector гоб from interlock
housing 23 по o lose еепt
ba11s ап
prings ап interlock
р i п.
When Assembling
АегпЫе item 23 ап selector
го using оо1 18G 1020.
Аепе'л а11 lockwire оп selector
retaining screws.
9803/3200
4994
F
F
ТдГ\15М ISS1ON
10-5
10-5
СЕдВОХ — 51а9е 2
Nlanual Gearbox Опlу
High/Low Selectors
Dismantfing апд Assembly
The numerical sequence оп
the illustration is ?пепе а
а guide 1о dismantling.
Еог аегпЫу the sequence
should Ье reversed.
When Dismantling
Саге to Ье аеп по o
lose items 5 ап 6.
When Assembling
епе
lockvvire оп item 1.
4978
9803/3200
lssue 1
F
TRANSMISSION
10-6
9803/3200
F
10-6
1 ssue 1
7
2
F
10-7
GEARBOX
Primary Shaft
Removal and Replacement
Те numerical sequence оп
the illustration is intended а
а guide to removal.
Рог replacement, the ещепсе
shou 1д Ье reversed.
NOTE: The illustration о\s
а тапиа1 9еагЬох. Тпе
following changes should Ье
noted for а torque сопегег
апд Suffix 'R' Ьохе .
1 егл 1 to 4 апд 7 to 11 аге
deleted апд item 6 is гер1 асе
Ьу item 6а.
When Removing
То remove item 4 use Ъе
sliding еаг а ап impulse
п а гл гле г.
When Replacing
lnspect bearings for 'еаг апд
гепе ' if песеагу. Сгеае
roller bearings ЬеГоге аеглЫу.
Веглое sharp edges and
Ыгг Ггогл splines, shafts and
еаг using а fine аЬгауе
• опе.
9803/3200
TRANISM 1SS1ON
F
10-7
F
ТАГ\]8М 1SS1ON
10-8
10-8
4980
20
9803/3200
lssue 1
7
F
ТА[\]ЗМ IЗЗIОГ\I
F
10-9
10-9
ОЕАВОХ
Main Shaft and Centre bearing
Removal and Replacement
When Replacing
The numerical sequence оп
the illustration is intended as
а guide to removal.
1 пбрес bearings for еаг,
апд гепе ' if песеагу.
Рог replacement, the sequence
should Ье reversed.
Г\ ОТЕ: Сеаг 8 is оп1у fitted
to тапиа1 9еагЬох.
Веоге removing mainshaft
4 remove differential
assembly ( бее ране F9-4).
When Removing
Remove mainshaft nut 1 using
оо 1861139.
Drive out shaft 4 using а
soft drift, removing items 2, 3
апд 5 to 8 as the shaft is
withdrawn.
Remove sharp edges апд
Ыггб from splines, shafts
еагб using а fine
ап
abrasive опе.
When assembling сепге
bearing,if tapped hole В апд
сге ' hole С до по align,
redrill item 20 3.9тт. дiа.
апд ар 2 ВА.
Аебе main shaft as ране
F 10-10.
Torque Settings
1 нет
гг1
1bf ft
(9 ГТ1
1 244 24.9 180
То remove bearing assembly
18, unlock ЬоЪ locknuts апд
1 асеп anti-rotation pin 17
half а turn.
Unscrew the геаг bearing
locknut 13 whilst pushing the
bearing assembly forwards.
Remove anti-rotation pin 17.
Аоае bearing housing 18 to
ith
line its location 1о
uppermost tooth Ы layshaft
third еаг (second еаг оп
torque сопегег Ьохе ).
Unscrew the гоп bearing
locknut 15 whilst pushing the
bearing assembly rearwards
апд then remove bearing assembly.
9803/3200
lssue 1
F
TRANSM 1SSION
F
10-10
10-10
GEARBOX — 3Ёауе 5
Mainshaft Resetting
Position оо1 186477 against
the inner асе Ы the housing
Ьоге$, а$ 1ОП, with the
30.16тт. (1.1875in.) long
side Ы the ре owards the
пп аiп Ii аii.
Slacken the anti-rotation pin
and using tool 186474 ас ]1
the centre bearing locknuts
until the ground асе о the
pinion just touches the gauge
ре with ЬоЪ locknuts fu11y
tightened.
1пеп the setting is соггес
tighten the anti-rotation pin.
4995
9803/3200
F
F
ТАГ бМ 166 10
10-11
10-11
2а
18 17
S
14
2а
А-►
4981
9803!3200
lssue 1
F
F
ТйАГ\ М ISS1ON
10-12
10-12
СЕАЙВОХ
Layshaft апд йеегбе Сеаг
Removal апд Replacement
The numerical sequence оп
the illustration i пепе as
а guide ю removal.
Рог replacement, the sequence
should Ье ге"еге .
[\ ОТЕ: The illustration shows
а manual Ьох. The following
changes should Ье noted.
Suffix 'R' Gearboxes.
егл 2 deleted апд replaced
with item 2а.
Тогяце Converter Gearboxes.
юегп 2 Deleted апд replaced
with item 2а апд items 4 ю 8
апд 19 to 20 deleted.
When Removing
Аегло"е shaft 5 Ьу fitting
bolt 4 into the арре епд.
Drive out shaft 9 using а soft
drift, removing items 10 ю
14 as shaft is withdrawn.
When Replacing
lnspect bearings ог еаг
апд гепе if necessary.
Remove sharp ее ап Ыгг
гогл splines using а fine
abrasive юопе.
Ае5е еп
loat as follows:
АеглЬ1 е layshaft 9 with а11
9еаг5, bearings ап
pacers оп
the bench, using the smallest
spacer З.
9803/3200
Меа5 ге ар А, if it exceeds
0.38тт. (0.015in.) fit larger
spacer to bring below this
ге.
расег Sizes
19.05тт.
19.ЗОтт.
19.56тт.
19.80тт.
20.07тт.
(0.75in.)
(0.76in.)
(0.77in.)
(0.78in.)
(0.79in.)
F
9803/3200
TRANSM1SS1ON
F
1~~ие 2
тйАГ1sм1ss1оГ'1
11-2
11-2
СЕАЙВОХ (бУГСНйО)
Manual Clutch Machines
Description
The опе piece casing contains
the ratio gearbox at the гоп1,
the range gearbox in the сепЁге
апд the differential gears at
the геаг. The gearbox Ёор со''ег
contains the selector mechanism
ог both рагЁз Ы the gearbox.
А11 gears аге constant mesh,
the ratio gears having sliding
dog engagement with
synchromesh апд the range
gears sliding dog engagement
оп Iу.
Роуег гогл the clutch is
transmitted Ьу the primary
shaft 3, through the selected
ratio gear 4, 5 or 6 to the
layshaft 8. From the layshaft
the power is transmitted through
the range gears 10, 11 or 12 to
the mainshaft 9 апд pinion.
Reverse gear 7 is mounted at
the гоп1Ы the gearbox, Ьу
the side Ы the primary shaft,
running in constant mesh with
2пд gear оп the primary shaft.
When reverse is selected power
разез гогл the primary shaft,
through reverse gear shaft to
reverse gear оп the layshaft.
From the layshaft the power
is transmitted through the
range gears 10, 11 or 12 to
the mainshaft апд pinion.
9803/3200
1
Range Lever
Ratio Lever
2
3
Primary Shaft
4
3гс Ratio Gear
2пд Ratio Gear
5
1st Ratio Gear
6
7
Reverse Gear
8 Layshaft
9 Mainshaft/Pinion
10
High Range Gear
11
Medium Range Gear
12
[о Range Gear
13
Сгоуп Whee1
Т1 АГ]8М 1SS10N
11-3
11-3
СЕАЕШОХ (SYNCHRO)
Synchromesh — Description
ТЬе 9еагЬох is fitted with
'Blocking Pin' synchromesh
оп forward апд reverse 9еаг ,
comprising the following
ра rts.
8УСНКО HUB(А) сопго1
the operation of the synchroеаг selection,
mesh цnit ап
the selector fork fitting into
the outer 9гооУе. гегга 1 у
are dog ееЪ ЫсЬ link the
е1 ес1е gear to the drive shaft.
ТЬгопфп the synchro hub
centre are two зе1$ of holes юг
the Blocker Рг (С) апд the
Sp1it Energiser Pins (D), расеd
*SYNCFiR0 С1РЗ ( Е )take
the frictional drive гогл the
synchro ring оп their inner
асе . ТЬе synchro cups are
splined юо drive their respective
еаг whilst synchronisation is
taking р1 асе.
а1 еггаеу.
8УСНКО К1 С (В) are
rigidly joined Ьу the blocker
pins, with the split energiser
pins he1d, in counterbores,
between the two synchro rings.
В [ОСКЕА PINS (С) have а
пагго ' neck in the centre
against 'ЫсЬ the synchro hub
гапт'
radial drive during
еаг changes. The edges of the
blocker pin neck апд their
гла1 пд synchro hub иоие are
designed ю that, а the гаса1
loads are reduced, the synchro
hub сап Нсе оег the shoulder
of the blocker pin.
ЗР [1Т ЕЕКС18ЕК PINS (D)
take the initial axial 1оад of
the synchro hub оп the shoulder
of the split energiser pin neck.
А the axial 1оад геасЬе арргох
400 N (40.8 kg; 90 1b) the
internal springs a11ow the split
energiser pin to collapse апд
the synchro hub ю томе
axially.
9803/3200
5171
lssue 2"
F
F
TRANSM1SSION
11-4
11-4
о
5154
9803/3200
lssue 1
F
TRANSMISSION
11-5
11-5
ЕАГВОХ (SYNCHRO)
Synchromesh — Operation
Diagram F бЬоб the деагЬох
with second gear engaged.
Synchro ring D is in contact
with synchro сир Е апд the
synchro hub dog teeth are
linking second gear to the
shaft gear. 1 п this position
the split energiser pins С are
collapsed.
'(Ьеп selecting third gear
the synchro hub А slides
along the split energiser pins
until the pin гесебб апд the
synchro hub flange are in 1ine.
А this point the split energiser
pins ореп апд the synchro
rings are то\Iед Ьу the synchro
hub pushing оп the split
energiser pin shoulder.
lnitial contact between the
synchro ring апд the synchro
сир starts to synchronise the
бреес of the shaft and 3rd gear.
ТЬе rotational force of the
synchro ring is taken Ьу the
neck of the blocker pin адапб
the есде of the synchro hub ho1e,
asatG.
As the axial 1оад оп the synchro
hub increases the split energiser
pin'collapses апд the conical faces
of the blocking pin апд synchro
hub hole соме into contact, аб
а Н.
Further increases in the axial
loads increase the frictional
grip of the synchro ring апд
synchro hub causing the shaft
апд gear speeds to become
closer.
9803/3200
F
As the speeds are synchronised
the radial 1оад оп the blocker
pin апд the synchro hub is
reduced. This а11об the
synchro hub Ю slide freely
along the blocker pin and to
епаде its dog teeth with 3rd
gear, see diagram J.
F
F
ТПАГ'3М 133 1ОГ
12-1
12-1
38
5153
9803/3200
lssue 1
F
12-2
TRANSMISSION
F
12-2
GEARВOX (SYNCHRO)
Manual Clutch Machines
Соег5 ап Selectors
Dismantling ап AssemЫy
The numerical ещегсе оп
the illustration i п1епсес а
а guide to dismantling.
Рог assemЫy the ещепсе
should Ье reversed.
When Dismantling
Саге to Ье taken when
rom
removing selector го
interlock housing 39 по1 to
lose е1еп1 ba11s 41, springs 40
апд interlock pins 42.
When AssemЫing
Assemble 11егл5 30 to 43 together
апд fit to gearbox ensuring а11
selectors аге correctly positioned.
Assemble item 39 апд selector
го 38 using tool 18G 1020.
Fit cover 7 to gearbox а 1ег
fitting selector аеглЬ1 у.
Insert 150 тт. (6 in.) length
Ы 8 тт. (5/16 in.) а. rod
through hole А to align slot В
when replacing cover.
9803/3200
lssue 1
F
Т14ANSMISSION
F
12-3
12-3
18
9803/3200
Issue 1
F
12-4
TRANSNIISSION
F
12-4
СЕАЙВОХ (SYNCHRO)
Manual Clutch Machines
Primary and йеег5е Shafts
Removal and Replacement
The numerical sequence оп
the illustration is intended аб
а guide ю removal.
Еог replacement the sequence
should Ье reversed.
When Removing
Епае third and reverse
Ьеоге removing Primary
Shaft.
Fit bolt 11 into the аррес епд
Ы shaft 12 to aid removal.
When Replacing
1 пбрес bearings ог wear
апд гепе if necessary.
Remove sharp есеб and burrs
from splines, shafts and еагб
using а fine abrasive stone.
Renew'О' ring 18 оп reverse
shaft.
9803/3200
1ssue 1
F
12-5
9803/3200
ТйА 3М 133IО
F
12-5
lssue 1
F
ТРА
F
Мi1ОГI
12-6
12-6
СЕАНВОХ (SYfVCHRO)
Мапиа1 Clutch Machines
Main Shaft
Removal апд Replacement
Remove соглропепт and assemble
mainshaft into деагЬох.
The numerical sequence оп the
illustration is intended а а guide
* Арр1 у 1осте 222 to locknut 1.
to removal.
Tighten with tool LC279 апд а
Еог replacement the sequence
torque wrench set а 190Nm
should Ье reversed.
(140 1Ь
).
N ОТ Е: lncreased leverage ргосес
When Remoыing
Ьу the lenyth Ы tool LC279 9ives
ап actual torque Ы 244Nт (180 Ьf
ft1.
Lock mainshaft, Ьу selecting high
and 1о
, remove nut 1 using tool
Аее mainshaft а рае F 10-10.
LC279. Drive mainshaft out
геагагс using tool LC280.
Mainshaft gear enci 1оаt
When Replacing
0.127 to 0.254тт.
(0.005 to 0.010in.).
lnspect Ьеагпд or wear and гепе
if песеагу.
Mainshaft gear расег sizes
Remove sharp есе and Ыгг rom
3.55 to 5 58гпгл . (0 140 to 0.22in.)
splines, shafts and деаг using а fine
abrasive
п
ер Ы 0.127тт. (0.005in.).
опе.
Реег to рае F 13-1 ог bush
ltem 12 to Ье fitted with thru
асеs
tightness test (items 16 and 11)
outwards апс item 17 with thrust face
оагс 1ow gear.
[ е tool [ С281 to replace bushes 11
and 16 ensuring holes in bushes апс
деаг аге in 1ine.
1f the mainshaft, ог апу рагтб, have
Ьееп гепе 'ес] the епс 1оат must Ье
checked а ollows.
AssemЫe mainshaft components
а
hown, using smalle
расег 18
and sleeve from сепге bearing А
item 7, раде F 12-7.
Tighten locknut 1 to secure assembly
and check епд 1оа n еаг .
Selec
расег to give соггес епд
1 оа а below.
980313200
lssue 2*
F
F
TRANSM1SS1ON
12-7
12-7
5149
9803/3200
lssue 1
F
ТйАГбМ 1551ОГ'
12-8
12-8
GEAR6OX (SYNCHRO)
Мапиа1 Clutch Machines
Centre bearing
йегпоа1 апд RepIacement
The numerical есрепсе оп
the illustration is intended as
а guide ю removal.
Аегпое the assembly гогп the
mainshaft and assemЫe into
gearbox. Оо not tighten items
2 and 4 until the mainshaft is
е1, ее page F 12-6
Рог replacement the sequence
shou 1д Ье reversed.
Тогсще Setting
When Removing
Item Nm
kgf т
284 163 16.6
Slacken рп 1 half turn апд
unscrew item 2 using tool
18G474A.
Г4ОТЕ: е1 torque wrench ю
the figure $1:агт1рес оп
tool 18G474A.
When Replacing
1nspect bearings for
гепе и necessary.
1 ЬПю
120
Centre Bearing Тогые
еаг апд
With Г4е'' Bearings —
1.35to2.81 Nm (13.8 юо 28.7
kgf ст; 12 to 15 1bf in).
Reset centre bearing preload
as follows.
*
АбеглЫе согпропеп1 опо
mainshaft, using original
spacer 10, as а А, апд tighten
п1 В ю соггес orque,.see
page F 12-6
With Original Bearings —
*0.67to1.41 Г' гп (6.9 юо 14.3
kgf ст; 6 to 12.5 Ibf in.
Wind а length Ы согс around
the bearing assembly апд
attach ю а spring balance,
as at С.
Ри11 оп the spring balance and
поюе the геасПп9 whilst the
bearing is turning, if и
incorrect
( геег ю са1а opposite),
dismantle, change spacer 10
апд recheck preload.
Веоге assembling centre bearing
into gearbox, lightly 9геабе
bearing гасеб 8 апд 11.
9803/3200
Spring Ва1апсе Reading
With New Bearings —
24 ю 49 N (2.5 ю 5 kgf;
5.4 to 11.1 1b).
With Original Веагп9$ —
12 ю 24 N (1.25 ю 2.5 д ;
2.7 ю 5.4 1b).
5расег$
7.772 ю 8.1 79глгл.
(0.306 ю 0.322in.) in steps Ы
0.051тт. (0.002in.).
1
е 2*
F
12-9
9803/3200
тRA1VsмISSIoN
F
12-9
lssue 2
F
12-10
TRANSM1SS1ON
F
12-10
СЕАЕВОХ (SYNCHRO)
Manual CIutch Machines
Layshaft
Еето~а1 and Аер1асетепн
The numerical sequence оп the
illustration is intended аб а guide
to removal.
Рог replacement the sequence
shou 1d Ье reversed.
VVhen Removing
Drive layshaft out rearwards
using оо1 [С280.
VVhen Replacing
1 бе оо1 [С281 to гер1асе
bushes 23, 18, 12 апд 7
ensuring он holes in bushes
and деаг аге in 1ine.
If the layshaft ог апу component
has been гер1асе he end Лоа
ГГШб Ье checked(see раде F
12-11).
Items 4, 13, 15 and 24 to Ье
fitted with thrust [асе5 towards
the деаг5.
#Fit bearings 26 and 36 into
деагЬох casing, ensuring bearing
26 is flush with геаг асе Ы
casing а11.
Негпое components and
assemble layshaft into gearboк.
Неег to радеб F 13-1 ог bush
tightness check (items 23, 18,12
and 7).
9803/3200
Issue 2*
F
F
ТРА \]ЗМ 13310 Г.]
12-11
12-11
GEАRBOX (5УСНА0)
Мдпиа1 Clutch Machines
Layshaft
End F1oat
*Bui1d ир layshaft with items
24 to 32 using shortest spacer
29 and gauge tube (tool Но.
[С282) as а1 А.
Fit circlip 1 and check the
clearance between the tool and
the circlip.
5е1 ес spacer to give the
correct end Лоа А as below.
Remove gauge tube and
continue building ир the
layshaft using components
as а В. 1бе smallest
spacer 14.
Fit circlip 1 and check the
clearance between the circlip
and bearing.
Select spacer 14 to give the
correct end 1оа as below.
End 1оа1А
*0.254тт. (0.010in.) тах.
Available spacers 63.75 to
65.79тт. (2.51 to 2.59in),
36
3
9
20
End 1оа В
0.254тт. (0.010in.) тах.
Available spacers 2.29 to
3.81тт. (0.090 to 0.150in.).
9803/3200
lssue 2"
F
F
ТйАГ\$М 1$51ОГ
12-12
12-12
СЕАЕВОХ (SYNCHRO)
ManuaI Clutch Machines
Ratio 5е1есог5
Еето~а1 and Rep1acement
The numerical sequence оп
the illustration is intended
а а guide 1о removal.
Рог replacement the sequence
should Ье reversed.
When Replacing
Lockwire selector securing
screws.
Check Selector сееп position
зеерадеЕ 13-1.
5148
9803/3200
lssue 1
F
TRAN3N11SS1ON
F
13-1
13-1
СЕААВОХ (3УСНйО)
Мапиа1 Clutch Machines
Test Procedures
After деагЬох repair the
following еб procedures must
Ье carried out.
Checking Detent Position
Check prior to filling transmission
with он апд with engine stopped.
Епдаде Лгб gear, томе gear lever
slowly into neutral апд continue
into reverse.
Оееп should Ье heard operating
when the lever is passing through
neutral. If it is biased towards
either gear the selecter arm
must Ье reset сепга 1у оп rod.
Маiп Shaft Bushes ( Еапде Gears)
Аереа the procedures аб ог
the ratio gears, with the range
change lever in neutral and
reverse gear selected.
Checking Operation
5е1 ес Лгб ог second gear and
with the machine travelling
check for noise Феп reverse
is selected.
Finally road еб the machine
checking а11 gears.
Аереа the above procedures
with есоп and third gears.
Checking ,.,r Tight Bushes
Layshaft Bushes (Ratio Gears)
After filling transmission with
он , аг engine апд release
Ьгае5.
Ensure gear change lever is in
neutral, епдаде 1о range апд
increase engine speed to
1000 rev/min.
1f the bushes аге гее the
machine wi11 remain stationary
with the engine speed steady.
1f а bush is partially seized the
machine \i11 сгеер.
1f а bush is totally seized the
machine wi11 томе а1 а speed
relative to the seized gear ratio.
9803/3200
1ssue 1
F
TRANSMissiON
F
14-1
14-1
СЕААВОХ (ЗУГ\ЮНВО)
Fau1t Finding
Веоге carrying out the checks listed, if possible, the machine should Ье орегае ю
fault агеа and bring the systems to their normal working temperatures.
etermine the
The gearbox should also Ье checked ю ensure that the соггес rade Ы он is used and is at the
correct 1е~е1 and that there аге Но obvious leaks.
А
1f the gearbox is noisy, start at check 1.
В
1f the gearbox is jumping out Ы gear, start at check 11.
С
1f the gearchange is hard, start at check 18.
D
1f the gearbox is sticking in gear, start at check 21.
Е
1f the gearbox is'crash changing', start at check 23.
СНЕСК
АСТ10N
1.
1s the noise а growl, шгл or grinding?
YES:
N0:
Check gearbox ог damage or
Check 2.
еаг
2.
Is the noise а hiss, thump or bumping?
YES:
N0:
Check bearings ог аглде or
Check 3.
еаг.
3.
1s the noise а squeal?
YES:
N0:
Chec гее running gears ог seizure.
Check 4.
4.
Is the noise in neutral or when in gear?
1N NEUTRAL:
1N GEAR:
5.
Is the flywheel pilot bearing
огп?
YES:
N0:
Renew
Check 6
6.
Is the layshaft or иб bearing
damaged?
огп or
YES:
N0:
Renew
Check 7
7.
1s their excessive backlash in the gears?
YES:
N0:
Adjust
Check 8
8.
1s the сепге bearing worn?
YES:
N0:
Renew
Сес ear teeth for scuffing.
9.
1s the mainshaft геаг bearing worn?
YES:
N0:
Renew
Check 10
YES:
N0:
Renew gears
Check mainshaft епс float.
10. Аге the sliding gear teeth
9803/3200
огп or damaged?
Check 5
Check 9
lssue 1
F
TRANSMISSION
F
14-2
14-2
СНЕСК
ACTION
11.
Are the selector forks loose?
YES:
N0:
Tighten wire locked screws.
Check 12
12.
Are the selector forks or гооеб in
gears worn?
YES:
N0:
Rene
огп parts.
Check 13
13.
Are the dog gear teeth worn?
YES:
N0:
Renew
Check 14
14.
Are the selector го рорре springs
Ьгоеп?
YES:
N0:
Renew
Check 15
15.
Are the selector го
YES:
N0:
Renew
Check 16
16.
Are the selector огб out Ы position?
YES:
N0:
Reposition or гепе
Check 17
17
Is there excessive епд float in gears or
shafts?
YES:
N0:
Adjust
Check thrust washers an
18.
1s the synchroniser bronze worn?
YES:
N0:
Renew
Check 19
19.
Are steel chips етЬеддед in the bronze?
YES:
Continue using, chips wi11 either
етЬед Ье1 о bronze or Ье rejected.
Check 20
orn or агг'а9е ?
N0:
асеб.
20.
Are the synchroniser components
damaged?
YES:
N0:
Renew
Chec гее running gears ог seizure or
damage.
21.
Are the sliding gears tight оп the splines?
YES:
N0:
Егее or Renew
Check 22
22.
Are chips еде between splines Ы
shaft ап деаг?
YES:
N0:
Remove chips
Check that gears аге по locking
behin огще 1ос .
23.
Are steel chips етЬеддед in the bronze?
YES:
N0:
Continue using, chips wi11 either
етЬед Ье1 о bronze or Ье rejected.
Check 24
24.
Are the synchroniser spring pins damaged?
YES:
N0:
Renew synchro
С1пес 25
25.
1s the synchroniser bronze
YES:
N0:
Renew synchro.
Check Ь1 осег pins.
980313200
огп?
lssue 1
F
F
ТЕАГ13М1331ОГ1
15-1
15-1
SERVICE ТОО18
POWERTRAIN
сеагЬох
Тоо1 Го.
Description
992/07608
992/07609
992/07610
992/07611
992/07612
992/07613
Mainshaft геаг bearing соне remover.
Mainshaft геаг bearing соне гер1 асег.
Mainsha
гог bearing соне remover.
Рге аарег ring.
Mainshaft/layshaft епд float gauge.
5реео housing оН seal гер1 асег.
В 11 сеаг АхIе
Тоо1 Го.
992/07601
992/07602
992/07603
992/07604
*992/07605
992/07606
992/07607
*992/07614
Description
На1f shaft nut wrench.
Pinion bearing соне remover/гер1 асег.
Pinion bearing сир гер1 асег
Сгоп wheel bearing соне гер1 асег.
г3и11 pinion bearing сопе remover/гер1 асег (Dry Вгае$).
Pinion bearing measuring сир.
Pinion bearing рге-1оад gauge.
Ви11 Pinion bearing сопе remover/гер1 асег(Oi1 1гтнлег$е Вгае ). IО( j4
ГГ
The above seriice оо1$, ог the деагЬох апд Ьи11 еаг ахiе, аге а11 contained in опе kit раг по. 992/07600.
1 п а iiоп the following existing оо1 аге required
18G а7АЕ
992/04800
ог
131
892/00098
*992/06700
НаИf shaft bearing remover
Pinion Лап9е ап раппег
1N.,;еп Leer„tg ее,,,~
lievc.
*М547
Напд
9803/3200
Агт seal гер1 асег . shorten Ьу 15тт (0.6in).
Bearing Сир Replacer
ress
Pr
УУш'е=
lssue 2 "
F
TRANSM1SS1ON
16-1
F
16-1
TORQUECONVERTER
Непоа1 апд Replacement
When Replacing
Attach torque converter to drive
plate А, tighten bolts finger tight
опI у.
Во1 drive plate to flywheel апд
check гип out Ы ритр drive Ьа t
B,maximum 0.254тт (0.010in.)
1
псоггес ap torque converter,
Ьу hand, to герооп.
When соггес mark position Ы
flywheel апд drive plate апд
гегпо'е drive plate гогп юЬе
flywheel.
Tighten torque converter/drive
plate bolts to 4ОГ\ гп (5 kgf т;
30 Ы ft).
Fit torque converter/drive plate tc
filywheel, ensure marks align, апд
torque Ьо11 to 19Nm (2 kgf т;
14 Ы ю).
9803/3200
lssue 2
F
17-1
9803/3200
TRANSMISSION
F
17-1
lssue 1
F
TRANSM1SS10N
F
17-2
17-2
SHUTTI_Е TRANSM1SS1ON
Description
The shuttle transmission is а
1 п neutral the flow о pressurised он
forward-neutral-reverse 9еагЬох,
is Ыоскед а he shuttle а1~е апд
дитред to the sump causing complete
comprising а planetary gear set А,
forward multi disc clutch В,
interruptioп Ы power through the
reverse multi disc clutch С ап
transmission.
shuttle а1~ е D.
When reverse is selected он lows
through the shuttle а1~е апд case
Mounted оп the front о` the
раае into the reverse clutch
transmission is а сге5сеп туре
ритр Е, driven а engine speed
Ьу
piston.
converter F drive 1ugs.
The piston clamps the clutch plates
ОН гогл the ритр is fed through
together locking the ring gear to the
раае in the case to the shuttle
'iа1 уе. The converter is supplied он
casing. With the ring gear locked
гогл the shuttle а1~е through
the planetary gear set pinions rotate
about their own axis causing the
external pipework. А pressure
outpu
regulating а1~е is fitted, dumping
the inpu
иа1Ё to rotate in reverse to
иа1.
oi1 from the converter Нпе to the
sump.
Oi1 епег he converter between
the converter hub апд the
аог
support апд 1еае5 between the
аЮг апд the input shaft.
Он rom the converter is fed back to
the sump through ап external оН
соо1 ег.
Chaпges between forward апд
reverse сап Ье таде when the
engine is running below 1500 ге /
min. Occasional chaпges аге
allowed а higher speed provided
the transmission temperature does
по rise аЬое its limit.
With forward selected,oil а regulated
pressure flows through the shuttle
',а1 уе, case рааде апд the output
shaft into the forward clutch piston.
The piston огсе5 the clutch plates
together locking the ring gear to the
input shaft, causing the input апд
output shafts to rotate together.
980313200
Issue 1
F
ТяАNЗМ 1SS10N
17-3
F
17-3
SHUTTLE TRANSM1SS1ON
Р1)МР
Dismantling апд AssemЫy
When Dismantling
Mark асасео ear teeth, to еооге
соггес гер1 асегоео , using indeliЫe
ink ог paint. Во по ое centre
punch.
Тоге Setting
его
Nm
kgf т
1
26
2.7
19
4
3.5
0.4
2.6
980313200
1bf ft
lssue 1
F
F
ТРАГМ 11ОГ'i
17-4
17-4
5
9
10
-12
-~1111111111i1f!
111101тiiiiiиiЕ110 I iIII1
5404
9803/3200
lssue 1
TRANSM1SS10N
F
F
17-5
17-5
8Н1ТТЕЕ ТйАМ1881ОГ
йЕ\ Ей8Е С[МТСН
Dismantling апд AssemЫy
When Dismantling
Use compressed air ю огсе рюп 5
гогл adapter 3,
When AssemЫ ing
Fit dowels 1 еоге fitting clutch
plates, пое position Ы offset 1ug С
оп plates.
When fitting р1 ае 9 align notch А
with hole В.
Torque Setting
1 егл
Nm
(9 гл
1 Ь ft
2
43
4.4
32
9803/3200
lssue 1
F
17-6
9803/3200
тRANsмission~
F
17-6
lssue 1
ТйА1\]3М1331О1\
17-7
17-7
SHUTTLE ТАГ18М1881ОГ\1
FORWARD С[МТСН АГЮ DR1VE
ЕАН
Dismantling апд AssemЫy
When AssemЫing
AssemЫe items 22 to 24 опю shaft
8.
When assemЫing items 9 to 11 апд
13 to 20 into дгит 1 ensure the
following:
1.
F1a асе Ы items 18 апд 20
аге оагс clutch р1 ае$.
2.
Snap ring 17 is positioned
against the епд Ы the internal
splines.
3.
Clutch spring 16 is fitted
concave side down.
Тигп assemЫy over апд check clutch
pack clearance Ьу pressing down оп
pressure plate 20 with а огсе Ы
4.5 kg. (101b). Measure clearance
Ьеееп ргеввиге plate and rin еаг
еЬ а а А.
Select snap гёп 21 to гедисе the
clearance to 0.3 to 1 .2гт'гт'. (0.011 to
0.046in.).
Fit drive а1 8 into clutch дгит 1
Ьеоге fitting items 3,4,6,7 апд 12.
Fit thrust washer 2 апд clutch assemЫy
into casing апд check dimension Х
selecting расег 5 а ollows.
5407А
Snap Ring ldentification
* 1f Х is ипдег 12.7тт (0.501in.) use
врасег 04/500242 ог if over use
расег 04/500243.
ltem
9
17
21
Сгееп
Pink
Огап9е
В не
White
980313200
Thickness
Егее Diameter
тт.
in.
тт.
in.
1.9-2.0
2.3-2.4
0.074-0.079
0.090-0.093
149
142.1
5.7/8
5,19/32
1.27-1.37
1.57-1.68
1.88-1.98
2.13-2.24
2.44-2.54
0.050-0.054
0.062-0.066
0.074-0.078
0.084-0.088
0.096-0.100
145.5
145.5
145.5
145.5
145.5
5.11/16
5.11/16
5.11/16
5,11!16
5:11/16
lssue 2"
F
TRANSMISSION
17-8
17-8
SHUTTLE TRAIVSM1SS1ON
PIN10N САСЕ АГО OUTPUT SHAFT
4ismantling апд AssemЫy
When AssemЫ ing
Рге$$ 1ее 'е Ао the bottom Ы сае
Ьоiе апд bearing 6 to 3.2тт.
(0.125in.) below casin
асе.
5408
9803/3200
Issue 1
F
17-9
9803/3200
ТАГ\13М13$1ОГ\1
F
17-9
lssue 1
TRANSM1SS1ON
F
17-10
17-10
SHUTTLE TRANSMISSION
SHUTTLEVALVE
Dismantling апд AssemЫy
When Dismantling
Саге to Ье taken when removing
пар ring 14 as spring 16 is ипдег
1 оад.
When AssemЫing
Assem Ыe with notch А in епд Ы
spool 13 in lowest position.
То епге that seal 22 remains
соггес 1 у 1осае
оп spool 23 utilize
tube F (supplied in seal kit) as
follows:
Position
Ье F оег fitted seal апд
push the assembly по spool 13
until the tube contacts shoulder G.
Continue to push spool 23 until
seal 22 епег the sma11 diameter Ьоге
Аеглое tube F.
Sea1 21 i пепе to ргеуеп dirt
епгу. [осае its metal асе against
shoulder G.
5е
итр spool 23 as follows.
Fit return spring to lever С апд
рге
итр spool into
transmission against its пор,
Ас 15 button В to obtain
о.25—о.76тт. (0.о1 о—о.озогп.)
movement Ьеееп the button В
апд lever С.
Fit transmission to machine апд
attach operating год , adjust nuts Е
until реда1 ор touches the
underside Ы the floor.
Соппес pressure gauge to ог "агс
clutch test point апд аг engine,
with уеагЬох in neutral select
ог "агс ,
When the дитр редв1 is depressed
the pressure should дгор to его апд
rise as the реда1 is released.
9803/3200
1е 1
TRANSMISSION
17-11
17-11
PRESSURE ТЕТ1Г1С
Shuttle Transmission
PRESSURE ТЕ$Т POINTS
А
Forward Clutch
В
Ребеге Clutch
Рог pressures see Service Оаа
When checking pressures епге
9еагЬох is in neutral апд handbrake
is applied. $е епфпе геб and select
огагс ог reverse а$ ге .йгес .
9803/3200
lssue 1
F
TRAIVSM1SS1ON
F
17-12
17-12
FAULT FINDING
ShuttIe Transmission
Веоге carrying out the checks tisted, if possiЫe, the machine should Ье орегае o determine the fault агеа ап o
Ьring the systems to their погта1 working temperatures.
The shuttle transmission should а1 о Ье сесе o ensure that the соггес дгасе Ы он is used ап it is а
e соггес
1 е~е1 апд that there аге по obvious leaks.
аг а check 1.
А
If the transmission is noisy,
В
1f the а1~е is noisy,
С
1f the transmission overheats,
D
1f the transmission wi11 по ри11,
аг а check 4.
аг а check 8.
аг а check 10.
СНЕСК
1.
2.
З.
4.
5.
6.
7.
8.
9.
10.
11.
12.
1 п what condition is the transmission noisy?
Is the shuttle transmission misaligned?
Are the ритр bushings worn?
Is there air гп the hydraulic уегт1?
1s there ап air leak оп the ритр suction side?
Are the oi1 раае restricted?
1s the oi1 сгееп restricted?
Are the оП раае restricted?
1s the ритр pressure 1о ?
In which condition is transmission по pulling?
1s the converter driving the ритр?
Are the clutch sealing rings damaged?
9803/3200
ACTION
FORWARD & REVERSE
See сес
Г\ ЕТ8А ОГЛУ
See check 3
YES:
Replace mountings ап
NO:
Check universaI joints.
2.
соггес position.
YES:
Renew
NO:
Check converter ог
еаг.
YES:
Continue running ап
the air wi11 Ье ехре11 ед.
NO:
Check 5
YES:
Find еа
NO:
Check 6
ап
сиге
YES:
Find restriction ап
NO:
Check 7
YES:
Аеглое ап
NO:
Check i
YES:
Еп
NO:
Check 9
clear
с1 еап
а1~е is sticking
restriction ап
clear
YES:
Renew ритр
NO:
Check converter sprag clutch for
FORWARD & REVERSE
Check 11
FORWARD ОР REVERSE
Check 12
YES:
Check ритр pressure
NO:
Rene
агтаде
еаг ог slip
parts.
YES:
Renew
NO:
Check clutch р1 ае$ ог сагладе
lssue 1
F
F
TRANSMISSION
18-1
18-1
СЕААВОХ
Description
The gearbox casing contains the ratio еагз апд the
selector mechanism А.
The ratio 9еаг гг~п in сопап mesh апд have sliding
dog епдадеглеп
ith synchromesh.
Егогл the countershaft power is transmitted through
the selected gear to the mainshaft Н апд then to the
геаг ах{е.
When fourth gear is selected the main drive gear апд
the mainshaft аге соир1 ед together Ьу the
When first В, second С ог third gear D is selected
power гогя the shuttie transmission is fed through
the main drive gear Е апд countershaft drive gear F
to the countershaft G.
9803/3200
synchromesh hub апд power раззез directly through
the gearbox to the геаг ах1 е.
Reverse is provided Ьу the shuttle transmission.
Issue 1
F
F
тRANsмISsio(I
18-2
18-2
СЕАГВОХ (SYNCHRO)
Synchromesh — Description
8УГ'СНГО С1Р8 ( Е ) ае the
The 9еагЬох is fitted with
frictionaI drive from the synchro
'Blocking Pin' synchromesh,
ring оп their inner 1асе . The
comprising the О1 О '1П9 раг $.
synchro cups аге splined to drive
8УГСНГО Н1) В ( А) сопго1
e
орегаоп Ы the synchromesh
their герес i\ е еаг
hilst
synchronisation is taking р1 асе.
unit апд еаг selection, the
selector fork fitting into the
outer дгоо 'е. lnternal СО9 teeth
link the selected уеаг to the
drive shaft. Through the
synchro hub centre аге two sets
Ы holes for the Blocker Pins ( С)
апд the Sp1it Епегег Рп (D),
врасед alternately.
SYNCHRO RINGS ( В ) аге rigidly
joined
Ьу
the blocker pins, with
the split епегрег pins he1d, in
counterbores, Ьелееп the ло
synchro rings.
Р1 Г\8 ( С) have а
В[ОСКЕ
пагго neck in the centre
against which the synchro hub
transmits radial drive during еаг
сиапе
Тне ес! е Ы the
Ыод<er р! п neck апс1 their mating
synchro hub holes аге designed ю
that, а
he radial 1оа
аге
гедисед, the synchro hub сап
slide о 'ег the shoulder Ы the
Ыocker рi п .
8Р[1Т ENERGISER PINS (D)
take the initial ахга1 1оад Ы the
synchro hub оп the shoulder Ы
5771
the split energiser pin neck. А
the axial 1оад reaches арргох.
400N (40.8 kg; 90
1b)
the internal
springs a11ow the split energiser pin
о collapse апд the synchro hub to
томе ахга11 у.
9803/3200
Issue 1
TRANSM1SS1ON
18-3
9803/3200
18-З
lssue 1
F
F
TRANSM 155 1О
18-4
18-4
СЕАПВОХ ( УГСНПО)
Synchromesh — Operation
he speeds are synchronised
Diagram F shows the деагЬох
А
with first gear engaged.
the гасЛа
Synchro ring D is in contact
апд the synchro ниЬ is reduced.
оад оп the Ыocker pin
with synchro сир Е апд the
This allows the synchro hub to
synchro hub dog teeth are
slide freely аоп the blocker pin
linking есопс gear to the shaft
апд to епдае its dog teeth with
gear. п this position the р1[
есопс gear, ее diagram J.
energiser pins С are со11 арес .
When selecting second gear the
synchro hub А slides а!опд the
split energiser pins until the
pin гесе
апд the synchro hub
1 апде are in 1ine. А
is point
the split energiser pins ореп апд
the synchro rings are то 'ед Ьу
the synchro hub pushing оп the
split energiser pin shoulder.
lnitia1 contact Ьеееп the
synchro ring апд the synchro сир
аг
to synchronise the реес Ы
the shaft апд есогк] gear. The
rotational огсе о he
synchro ring is taken Ьу the
пес о the Ыocker pin against
the есе о
e synchro hub ho1e,
а а G.
А
he axial 1оад оп the synchro
hub increases the split energiser
pin 'collapses' апд the conical
асе Ы the Ы ocking pin апд
synchro hub hole соме по
contact, а а Н.
Further increases in the axial
оа
increase the frictional grip
Ы the synchro ring апд synchro
hub causing the shaft апд gear
speeds to synchronise.
9303J3200
lssue 1
F
ТГАГ ]бМ 1бб1 О \]
18-5
18-5
GEARBOX
GEARCHANGEASSEMBLY
4
5
Dismantling апд AssemЫy
When AssemЫing
aces Ы да (е with
Соа Ьо
jointing сотроипд.
Fit р1 ае 3 with rivets А to тие right
hand side Ы the 9еагЬох.
Во1
1 аге fitted with а пу1 оп
locking patch. These тау Ье
ге-ивед providing that а torque
Ы 2 гл (0.2 kgf т; 17.5 1Ь in) is
required to оегсогле Ье patch
геапсе.
АН bolts should Ье coated with
Ну1 отаг ( ог similar) prior to
аssетЫу.
Тоге Setting
Item
Г\ гл
(дгл
1 Ь ft
1
41
4.1
30
4399 А
9803/3200
lssue 1
F
F
ТАА 8М I8IОГ
18-6
18-6
5410 А
9803Г3200
lssue 1
F
TRANSMISSION
F
18-7
18-7
3ЕАНВОХ
CAS1 NG
®ismaпtling апд AssemЫу
VUheп ® ismantliпg
Аегло'е bolts 1 leaving two
diagonally оррое
Ьо1
n to
retain the casing.
8 ап
уеагЬох in а vertical position,
аб shown, геглое items 2 to 13
Ьеоге the two remaining Ьо
,
VVhen AssemЫiпg
Coat Ьо
aces Ы уае with
jointing сотроипд.
Replace он eal 10 using tool f\1о,
992/07613, pressing the seel
9.4тт. (0.37in.) into housing 9.
Рог гер1 асеглеп Ы items 15 to 21
ее рауе 18-1б
1 апд 8•аге fitte
Ш пу1оп
locking patches. These тау Ье
Во1
ге-used providing that а огще Ы
2Nт (0.2kgf т; 17.5 1Ы п) is
required Юоегсогле the patch
resistance.
1 апд 8 should Ье соае
ith
Ну1отаг (ог similar) prior to аssетЫу.
Во1
Тогцце Settings
ltem
f\1т
kgf т
1
27
2.8
20
2
78
8
57.5
8
44
4.5
32.5
9803/3200
1 Ь ft
lssue 1
F
18-8
980313200
TRAIVSMISS1oN
F
18-8
lssue 1
F
TRANSM1SS10N
18-9
F
18-9
СЕАГВОХ
GEARSHAFTSANDSELECTORS
Removal апд Replacement
When Removing
Аегтюе items 4 аг 5 together Ьу
егп 6.
tilting
When Replacing
Ti1t item 6 to a11ow items 4 аг 5
to Ье гер1 асед together.
Егоге synchro сир with integral
расег А is fitted in position
о' п.
9803/3200
1ssue 1
F
18-10
9803/3200
F
ТАМ1 З1ОГ
18-10
1
ые 1
г
TRANSM1SS10N
18-11
F
18-11
СЕАЙВОХ
MAINSHAFT
Dismantling апд AssemЫy
When Dismantling
Retain synchro cups оп their
respective synchro rings, Во по
stand shaft оп bearings, use
support сир аз а С.
Аегпое bearings using ргезз раг по.
47 in conjunction with the following
аарегз:
Item
2
3
7
Мащег
о.
992/07608
992/07610
992/07608
When AssemЫ ing
Епзиге synchro сир with integral
эрасег А is fitted in position
5h0ИП.
Соа mainshaft агеаз В with
Mobilube Н0140 Ьеоге fitting
деагз.
Press bearing З onto shaft using
зее1 иЬе 30тт. (1.187in.) тах. о/
апд 22тт. (0.875in.) пНп. 1/д.
Press bearings 2 апд 7 onto shaft using
tool по. 992/07608 апд 992/07609.
9803/3200
lssue 1
F
F
ТАМ1бб'ОГ1
18-12
18-12
СЕААВОХ
1АУНАЕТ
Dismantling апд AssemЫy
When AssemЫing
Рге bearings onto shaft using steel
tube 43тт. (1.6875in.) тах.
outside diameter апд 36тт.
(1.4375in.) min. inside diameter.
5414
9803/3200
Issue 1
F
F
ТГАГ]ЗМ1ЗЗ1ОГ\]
18-13
18-13
СЕ АйВОХ
ЗЕ IЕСТОЙЗ
Dismantling and AssemЫy
When Dismantling
When removing selector fork 3
гол rai1, саге to Ье taken по o
loose ba11 4 апд spring 5.
5415А
980313200
155116 1
тRAnisмISSIO i
18-14
F
18-14
СЕАВОХ
END СО\'Е
Dismantling апд AssemЫy
When AssemЫing
аг bearing 1ее 'е 4 into the епс
со 'ег апд ри11 соп using Ьо1 Ё 1
апд retainer 2.
Во 1 is fitted with а пу1 оп locking
patch апд тау Ье re-used ргосЛп9
that а огщле о 2Nm (0.2 kgf т;
17.5 1Ь n) is required Ёо о 'егсогле
the patch resistance.
Соа bolt 1 with Hylomar (ог similar)
prior to assemЫy.
Torque Setting
1 егл
1
Nm
(9 гл
1bf ft
27
2.8
20
эвоЗ/З2оо
lssue 1
F
18-15
9803/3200
TRANSMISSION
F
18-15
lssue 1
TRANSM1SS10N
F
18-16
18-16
СЕЛЕВОХ
MAINSHAFT AND 1АУНАЕТ
Епд Е1оа Setting
Аег rebuilding the gearbox the
mainshaft and 1ауа
ггш
епд f1оан
Ье checked а oIIows:—
Bolt асарег р!ае А to the уеагЬох.
Еер асе bearing sleeve 1 апд расег
ring 2 апд с1атр in position using
tool В, part Но. 992/07612
Tighten Ьо1 o 6.7П1 т (0.7 kgf т;
5 Ы ft) апд гоае mainshaft to
settle the bearings. Аереа until
bearings have finally settled.
Measure the depth Ы the расег
ring Ьео " the casing. Take two
геасЛпу diametrically opposed.
Take the average Ы the two readings
апд адд 0.127тт. (0.005in.) to give
the thickness Ы shim(s) required.
Fit shims ипдег the расег ring.
Еереа he above procedures for the
layshaft.
9803/3200
Issue 1
F
F
TRANSM1SS10N
18-17
18-17
А11Т FINDING
СеагЬох
Веоге carrying out the checks listed, if possiЫe, the machine should Ье орегае o determine the fault агеа and to
bring the уЁегт1 o their normal working temperatures.
The gearbox should also Ье checked to ensure that the соггес rade о он is used and it is а the соггес 1е \,е1 and
there аге Но obvious leaks.
А
1f the gearbox is noisy,
аг а check 1.
В
1f the gearbox is jumping out Ы gear,
С
1f the gear change is hard,
D
1f the gearbox is sticking in gear,
Е
1f the gearbox is 'crash changing',
аг а check 11.
агЁ а check 18.
аг а check 21.
аг а check 23.
СНЕСК
АСТ1 О
1.
1s the noise а growl, hum ог grinding?
YES:
N0:
Chec еаг
Check 2
2.
Is the noise а hiss, thump ог bumping?
YES:
N0:
Check bearings for damage ог wear
Check 3
3.
1s the noise а squeal?
YES:
N0:
Chec гее running еаг
Check 4
4.
1s the noise in neutral ог when in gear?
1N NEUTRAL:
IN ЗЕАВ:
5.
1s the countershaft ог its bearing worn ог
агла9е ?
YES:
N0:
Renew аглае раг
Check 6
6.
1s there excessive backlash in the 9еаг5?
YES:
N0:
Adjust
Check 7
7.
1s the mainshaft pilot bearing worn?
YES:
N0:
Renew
Check gear teeth ог scuffing.
8.
1s the mainshaft геаг beaгing worn?
YES:
N0:
Check 9
or damage ог
Аге the sliding gear teeth worn ог damaged?
YES:
N0:
Renew еагs
Check 10
10.
Аге the реео еаг
YES:
N0:
Renew
Check mainshaft.en
9803/3200
or seizure
Check 5
Check 8
Renew
9.
orn ог damaged?
еаг
1 оаt
lssue 1
F
TRANSMISSION
F
18-18
18-18
FAULT F1NDiNG
СеагЬох
ACTION
СНЕСК
11.
12
13.
14.
Аге the selector forks loose?
YES:
Tighten screws
NO:
Check 12
Аге the selector fork рас ог дгоое n деаг
YES:
Renew worn parts
worn?
NO:
Check 13
Аге the dog еаг teeth worn?
Аге the selector год рорре prings broken?
YES:
Renew
NO:
Check 14
YES: Renew
NO:
15,
Аге the selector го worn ог damaged?
YES: Renew
NO:
16.
17.
18.
19.
Аге the selector fork рас out о1 position?
1s there excessive епд float in еаг ог shafts?
Is the synchroniser Ьгопге worn?
Аге steel chips етЬеддед in the bronze?
Check 15
Check 16
YES:
Reposition ог renew
NO:
Check 17
YES:
АЩо$
NO:
Check thrust washers апд mating асе$.
YES:
Renew synchro рас
NO:
Check 19
УЕS:
Continue using,chips wi11 either embed below
NO:
Check 20
bronze ог Ье rejected.
20.
Аге the synchroniser соглропег damaged?
YES: Renew
NO:
21.
22.
Аге the sliding еаг
оп the splines?
Chec
гее running деаг or seizure ог damage.
YES:
Егее ог renew
NO:
Check 22
Аге the chips wedged between splines Ы shaft
YES:
Ееглое chips
ог еаг?
NO:
Check tha
еаг аге по ocking behind
огсе осk
23.
Аге
ее1 chips embedded in the bronze?
YES:
Continue using, chip 'i1I either embed
below bronze ог Ье rejected.
NO:
24.
25
Аге the synchroniser spring pins damaged?
1$ the synchroniser bronze worn?
9803/З 200
Check 24
YES:
Renew Synchro
NO:
Check 25
YES:
Renew synchro
NO:
Check Ыоскег pins
lssue 1
56Nm (6 kgf т; 44 Ы ft)
Loctite 222
98Nт (10 kgf т; 72 1Ы ft)
Loctite 222
э-Iх`д эпiаа
98Nm (10 kgf т; 72 'Ь' ft)
160Nm (16 ' д т; 118 1Ы )
Loctite 222
NoissiwsNdal
98Nm (10 kgf т; 72 ‚Ь' ft)
Loctite 222
490Nт (50 ' ц т; 360 1Ы ft)
98Nт (10 kgf т; 72 ы ft)
Loctite 222
Loctite 573
э1хе эпiаа
56 Nm (6 kgf т; 44 1bf ft)
98 Nm (10 kgf т; 72 'Ь' ft)
98 Nm (10 kgf т; 72 1Ь' ft)
Loctite 222
NoissiwsNdыl
91 Nm (9.3 kgf т; 67 1bf ft)
Loctite 222
Loctite 573
98 Nm (10 kgf т; 72 1Ь' ft)
Loctite 222
490 Nm (50 kgf т; 360 'Ь' ft)
Loctite 573
98 Nт (10 kgf т; 72 1Ы ft)
Loctite 222
ш
ТЕАбМ iббiОГ
F
Е
19-2
19-2
DRIVE АХ[Е
DIFFERENTIAL BEARING
Рге1 оас Setting
Fit differential аssетЫу пю casing
апд support оп piece Ы 25тт. (1in.)
timber.
Е eft hand housing А with four
bol
91 епе ] to 98Nm (10 kgf т; 72
Ы ft) апс right hand housing with
four bolts left 1оове.
Тшп casing оп its 1е
and side,
геглое timber support апд шгар а
согс around Ье differential саггег.
Tighten the four housing bolts
е~еп1у апд in turn until а moving
ри11 Ы 36-40N (8-91Ь) is гесогсес .
Select shims to fit gap В, reassem Ыe
housing with shims апд tighten bolts
о 98Nm (10 ф т; 72 1Ь ).
1f
ри11 is incorrect adjust Ьу ассЛп9
ог subtracting shims. Кеер finа1 shims
То9е 1ег ог backlash setting ( ее
ране 19-5).
9803/3200
це 1
F
Е
TRANSMISSION
19-3
19-3
DR1VE АХI
Е
О1 ЕЕЕЕТ1 А1. Р1 Г11О
Depth Setting
А11 dimensions аге in millimetres.
Remove inner bearing from the
pinion using нол1 по
апд рге
раг по.57.
[ДZ
1
I
цл
Меа 1] ге дар А, using tool по.
992/07606 оп а Ла urface, апд адд
36.4тт. ю give bearing depth.
Те оа1 should Ье 36.51236.71 2гпгп.
Гое the mounting distance В
etched оп the pinion апд С stamped
оп the casing. These аге in units Ы
0.01тт.
1f.dimension В is positive ADD ю
bearing depth, if negative 81) ВТРАСТ
from bearing depth.
1f dimension С i$ positive 81)ВТРАСТ,
г
from оа!, if negative ADD ю оа1.
The ге$111 should Ье subtracted from
37.44тт. ю give the shim thickness.
Ехатр1е
Dimension А
Адд оо1 depth
0.302
36.400
36.702
Адд dimension В if
positive. (8 Ьгас if
negative).
0.010
36.712
11
Адд dimension С if
negative. (Subtract if
positive).
0.110
36.822
Standard ёа1ие
[е
otal аЬое.
Н 1 МТН1 СКГЕESS
9803/3200
37.440
36.822
0.618
Issue 2
ТЕАГ]3М 1SS10N
F
19-4
19-4
Е
DRIVE АХI
DIFFERENTIAL P1N10N
Bearing рге1оад setting
Fit tool А Г'о. 992/07607 to pinion,
assemЫe into casing without он
еа1 апд torque pinion nut to
488 Ггп (50 kgf т; 360 1bf ft)
Measure pinion еп
оа апд ас
* 0.10тт (0.004in.) рге 1оад.
Subtract апег гогп 1 1.5гпгп.
(0.453in.) апд fi
расег to this
thickness. ReassemЫe, without он
sea1, апд ге torque nut.
Wrap а согд агоипд the pinion flange
апд а moving ри11 Ы 20-33 N
(4.5-7.5 Ib) should Ье гесогдед.
Соггес Ьу changing расег.
When reading is соггес гегпо 'е flange,
fit он sea1, ге torque согпр1 ее
assemЫy апд stake pinion nut.
9803/3200
lssue 2"
F
TRANSMISSION
19-5
F
19-5
DRIVE АХ[Е
CROWN
НЕЕ [
Backlash
Е
1 е hand сагоеi without s]п ims
апс1 right напс1 with shim pack а
с]ееггл ] пес] оп рауе 19-2.
Тоглце carrier Ьо1
o 98 Г\] гл
(10 сд т; 72 Ы ft)
С] ес ]с backlash а our еgиа1 points
оп the crown wheeI апс1 calculate
the аеегае . Г\] ОТЕ: If Ьас ]с 1 а ]п
readings vary
Ьу
логе с ]пап 0.1тт.
(0.004in.) check сгошп wheeI diff
carrier ог гопоос.
Subtract 0.З3тгп. (0.013in ) fiom
the аеегауе, divide
Ьу
Ьу
3 апс1 гоо ] р1 у
5.
The гео1 с is the the thickness of
shims То Ье гегооее ] from the right
hand carrier апс1 fitted со the left
hand carrier.
Асег fitting shims check backlash
геасипс is 0.25-- 0.33тт. (0.0100.013i n. )
9803/3200
lssue 1
F
TRANSMISSION
19-6
19-6
AXLES (.юВ POWERTRAIN)
crownwheel and Pinion Adjustment
Meshing Ы the еаг
ould Ье checked
marking three pinion teeth with
oiled гед 1еад ог engineers marking
compound ап rotating the pinion.
Ьу
The marking wi11 then Ье гапеггеd
Ю the crownwheel teeth.
Соггес ooth bearing,
5615
Pinion оо деер1 у in mesh.
1 псгеае. iiе shim,thickness'between
thebе1 е1 casing` апд р!~inion,' housing
Мое the crownwheel оуаг
e
pinion to соггес backlash.
5616
9803/3200
lssue 2
F
TRANSM1SS10N
F
19-7
19-7
Pinion оо аг out Ы mesh.
Decrea$е thё shim thickness between
the bevel casing ahd pihion housing. !
Мое the crownwheel аау from
the pinion to соггес backlash.
5617
980313200
lssue 2
TRANSMISSION
19-8
19-8
DRIVE АХI
Е
АНМ
Bearing рге 1оад
AssemЫe ах1е агт апд tighten nut
to 6.9-8.8 Nm (0.7-0.9 kgfm;
5.0-6.5 'Ь' ft) using tool о.
992/07601. Яоае shaft а interva1s
to еа bearing
Attach а length Ы согд to а wheel
stud and вгар агоипд the studs three
ог four times. The spring balance
reeding, whilst shaft is rotating
should Ье 80-97.5 N (18-22 1Ы .
'Меп соггес reading is achieved stake
nut.
9803/3200
15sue 1
ТЕАГ'1ЗМ1381ОГ\
19-9
F
19-9
МЕТА[[1С ЕАСЕ ЗЕА[З
Removal
Caution: Avoid skin contact with surface А
а corrosion тау Ье caused.
Retain seals in pair
Ьеп they are removed.
Fit а а matched pair if suitable ог further
и se.
1nspection
1f contact surface А is undamaged, estimate
remaining life а ollows.
New seals.
contact агеа is а пагго band
at outer edge.
Рагн1у
seals.
contact агеа is wider but
does not extend fu11 width.
огп
8сгар seals.
contact агеа i
width.
огп ю u11
Аепе pair Ы seals if contact surface is
scratched, pitted or corroded.
Examine outer edges В, housing гаглр С and
1ip D. Carefiully polish аау light damage or
corrosion.
Thoroughly clean and dry seals, 'О' rings and
housings before fitting seals а5 follows:
NOTE:
Оо not а11о' он ю соте into
contact with the 'О' rings or
housings until assembly is complete.
Ри
'О' rings оп ю the seals, check that
they seat еуеп1у and are not twisted.
Modify tool Е (Рагн Го. 892/00098) Ьу
own. F it the modified
removing 15тт. а
tool ю each seal assembly. Press'О' ring past
нр D. check that dimension F is соп 1ап1
round circumference Ы sea1.
1mmediately before Гпа1 assembly с1 еап dust
etc. гогл surface А and lightly coat with
clean он Ы the appropriate grade.
980313200
lssue 1
ТАГМ 1SSION
19-10
19-10
DRIVE АХIЕ BULL P1N10N
Епд F1oat
Select shims 1 тт. (0.04in.) thicker
than previously used апд fit Ьасе
back р1ае (without 'О' ring оп су
brake► . бесцге with а11еп сге .
Check епс float Ы bu11 pinion апд
сесс 0.03 to 0.08тт. (0.001 to
0.003in.). The result is the thickness
Ы shims to Ье rето~ед.
* Мое: 'АЦ,еп checking епд float, 1,е
pinion тust Ье гоае to еа he
bearings.
•АррIу Loctite 222 to а11еп сге s
апд tighten to 1 е specified torque
setting. Check that еп 1оа i$
0.03 но о.овтт. (0.001 to о.0о3гп.).
Тогgие Setting
Nт kgf т 1bf ft
Item
160 16
118
А (Оу brake)
67
В (Oi1-iттersed Brake) 91 9.3
9803/3200
lssue 2'
G
BRAKES
Соп1еп1
Transmission Вгаеб
Master Cylinder
Contents
Dismantling апд Assem Ыy—
Skid Builds to т/с по. 129502
1-1
Skid Build
1-3
гогл т/с по. 129503
Powertrain to т/с по. 138621/5
1-3
Powertrain гогл т/с по. 138622/5 (oi1-immersed brake)
1-5
Dismantling апд Assem Ыy—
Powertrain гогл т/с по. 138622/5
2-1
2-2
Dismantling апд АssетЫу
2-3
Powertrain ю т/с по. 138621/5
S1ave Cylinder
Hydraulic Circuit
Bleeding—
Powertrain гогл т/с по. 138621/5
3-1
3-2
Dismantling апд АвветЫу (Powertrain)
4-1
Powertrain to т/с по. 138621/5
Parking Вгае
9803/3200
с
1ssue 5
G
G
В1 АКЕ
19
20
4982
9803/3200
1ssue 1
G
1-2
ВЕ{АКЕ
G
1-2
TRANSM1SS1ON BRAKES
Dismantling and AssemЫy
The numerical sequence оп
the illustration is intended аб
а guide Ю dismantling.
Рог assembly, the sequence
should Ье reversed.
When Dismantling
Аегпое floorplates for ассебб
апд disconnect linkage а А.
Маг the actuator plates 18
апд 20 to ensure соггес
assem b 1у.
1f removing brake drum В
use оо1 183 1036 to ргоес
оН еа1 С.
When AssemЫing
Reпew linings and он seal if
«огп ог damaged.
Fit brake drum using tool
183 1036.
Adjust Ьгаеб а рае 3 7-1
and 3 7-2.
9803/3200
lssue 1
G
1-3
9803/3200
В ГАКЕб
G
1-3
lssue 1
ВЖАКЕ3
1-4
о
1-4
TRANSM1SS1ON ВААКЕ
Dismantling and AssemЫy
The numerical sequence оп
the illustration is intended аб а
guide to dismantling.
Рог assembly the sequence
shou 1д Ье reversed.
UUhen Dismantling
Remove floorplates ог ассебб
and ссоппес1 linkage at А.
Mark the actuator plates 20
and 22 to ensure correct assembly.
1f removing backplate 10 use
tool 1861036 to protect он
seal В.
UUhen AssemЫing
Аепе linings and ы! еа1 if
огп ог damaged.
Р 1 backplate 10 using tool
1861036 to protect оП еа! В.
Ensure that locating расегs
5 and 11 аге fitted correctly.
Арр►у Loctite 275 to the
mating faces Ы backplate 10
and the ах1е casing, and brake
housing 4.
Аррiу Loctite 242 to bolts 9.
Adjust brakes а радеЗ 7-3 ш'
Torque Settings
ltem
Г\ гл
(9 ГЛ
1bf ft
З
78
8
58
9
115
11.7
85
9803/3200
ВРА КЕЗ
с
1-5
G
1-5
TRANSM1SS1ON ВЙАКЕ
гогп т/с по. 138622/5
Dismantling апд AssemЫy
When AssemЫing
1)$е оп1у )СВ Special Hydraulic
F1uid ог Mobi1 DTE11 ог cleaning
апд lubrication of hydraulic
components 2, 3 апд 4 — 0О NОТ
1) Е NORMAL ВЕАКЕ FLU1D.
Fi
еа1 4 into гооле А.
Л]еаг limit Ы friction plates 6 is to
depth Ы circumferential гооле С
ог when plate thickness is 4.4тт.
(0.175in.).
Renew friction plates апд counter
plates 5 together in complete sets.
Soak friction plates in СВ Special
Сеаг Oi1 Ьеоге assemЫy. Fit
friction апд counter plates
alternately, ensuring that there is а
counter plate а each епд Ы the
рас апд that holes В аге aligned to
a11ow гее он Ло .
Арр1у Loctite 573 to join асе Ы
солег 2. Ensure that Ыеед сге '
асе$ upwards апд pressure рог
асе ах1е агт.
Аррiу Loctite 222 to bolts 1.
Torque Settings
ltem
1
Nm
kgf т
1bf ft
98
10
72
980313200
lssue 2
ВНАКЕЗ
2-1
2-1
COMPENSATING МАЗТЕЯ CYLINDER
• to т/с по. 138621/5
Dismantling апд AssemЫy
When Dismantling
Согпргеяя со11аг 10 against spring 11
to a11ow retaining pin in епс сар 9
to Ье removed.
•Use соггес Ьгае fluid ог cleaning
апд lubrication. (фее Lubricants,
Section 3).
9803/3200
1
ые 2•
2-2
2-2
MASTER CYLINDER
from т/с по. 138622/5
Dismantling апд AssemЫy
When Dismantling
Lift Ieaf Ы thimЫe 7 to ге1еае it
from piston 14.
When AssemЫing
1) е only )СВ Special Hydraulic
F1uid ог Mobi1 ОТЕ 11 ог cleaning
апд lubrication — DO NOT 1) Е
ОАМА1 ВААКЕ Е 11Л0.
Ensure tha еа1 13 апд thimЫe 7
аге fitted а а А.
Ensure that seal 10 апд washer 9
аге fitted а а В.
9803/3200
Issue 1
BRAKES
G
2-3
G
2-3
SLAVE CYLINDER
Dismantling апд AssemЫy
When AssemЫing
Fit seal 7 with the flat Ьас against
the shoulder Ы piston 6.
Smear сЮбЁ cover sealing агеаб with
grease (supplied Л ' service kit).
Fi11
об сар with remaining grease.
9803/8200
lssue 1
G
G
В АК
3-1
3-1
HYDRAULIC CIRCUIT
о т/с по. 138621/5
Bleeding Ргосеге
Епоге that соггес brake fluid is
оес . (Зее Lubricants, Section 3).
Latch pedals together апд серге
10 times with both Ыеед сге
А
орел. Unlatch реса1, с1 ое опе
Ыеед сге апд серге апд hold
реда1 оп 1 е оррое side to
арргох. half не ауа i1аЫе реда1
travel. Еерге remaining реда1
5 times to солпр1 ее b eeding
ргоседиге.
9803/3200
15sue 2'
V
ВРАК Еб
3-2
3-2
НУОГА111С CIRCUIT
from т/с по, 138622/5
Bleeding Ргоседиге
Fi11 reservoir with соггес fluid ( ее
Lubricants Section 3).
СА1Т1 О : 1] Е ОЕ INCORRECT
Еышо W1LL СА1
Е SERIOUS
ЕАМА Е.
1п1 ас реа1 апд Ыеед each brake
separately а ollows:—
Attach tube to Ыее
сге
А
гее епд Ы tube is
ensuring tha
immersed in fluid contained in а
ыиаЬ1 е аг.
Ореп Ыее
сге ' апд арр1 у опе
rapid fu11 stroke Ы the appropriate
brake pedai с11 ое Ьу three
гогл the half
rapid short stroke
ау реда1 position. After the third
short stroke, аПо
he реда1 to
return quickly to its stop Ьу
removing the оо rom the реда1.
Continue Ыeeding погта11 у until
а11 air is dispelled, closing the Ыеед
сге
Аереа
the реда1 fu11y сергее .
e ргоседиге ог the
есопс brake.
9803/3200
1е 1
G
4-1
ВiЧАКЕЗ
G
4-1
PARKING ВВАКЕ
Dismantling апд AssemЫy
UVhen AssemЫing
Renew ра if friction material
thickness is less than 6 тт (0.25 п )
9803/3200
Issue 1
М
$ТЕЕА IГ\Ю
Contents
Contents
т/с Г\ о.
Мапиа1 Clutch
Топе Сопегег
Machines
Machines
1-1
1-2
2-1
2-2
2-4
2-5
Steering/Transmission Ритр
Removal апд Replacement
Dismantling апд AssemЫу
* Removal
апд Replacement
Егогл 131320
Dismantling апд Assembly
Relief \ а1уе
Removal апд Replacement
То 131319
3-1
3-2
Dismantling апд Assem Ыy
Hydraulic Steering Unit—Plessey
Removal апд Replacement
Dismantling апд AssemЫy
lnspection апд Repair
Bearing Replacement
То 106460
From 106461
То 106460
Егогл 106461
From 106461
4-1
4-2
4-5
4-4
4-8
4-7
4-1
4-2
4-5
4-4
4-8
4-7
4-9
4-11
4-9
5-1
5-3
5-1
5-3
6-1
6-1
6-3
6-2
6-2
6-3
7-1
7-5
7-3
7-7
7-1
7-5
7-3
7-7
Hydraulic Steering Unit—Danfoss
Removal апд Replacement
Dismantling апд AssemЫy
4-1 1
Steering Ram
Removal апд Replacement
Dismantling апд Assembly
Реце Testing
Ритр апд Relief Va1ve
Steering Units апд Рагл
Relief \1а1 е Adjustment
Front Ахiе
Removal апд Replacement
То 68150
From 100000
Dismantling апд Assembly
То 68150
From 100000
9803/3200
1 ые 3*
Н
STEERING
-
Н
1-1
1-1
Р1)МР
Аегпоа1 and Аер1 асеглеп
After Аер1 асеглеп
Те гшппегса equence оп
the illustration is intended а
а guide to геглоа1.
СесГ ydraulic fluid 1е~е1,
аг епдпе and
4-цъ^n
steering whee гогл lock to
lock until steering Ьесогле5
positive.
Еог гер1 асегяеп , гееге the
sеq иепсе.
When Removing
Check relie а1~е setting
( ее раде Н 6-1).
Raise апд support lift аггл .
Connections
В1 ап
ose апд pipes to avoid
о Ы hydraulic fluid.
1
2
3
9803`3200
Feed гогл Tank
Relief Va1ve to Tank
Pressure Feed to Steering
Unit
lssue 1
Н
sтEERINc
Н
20
11
10
12
2050 д
9803/3200
STEERING
Н
1-3
1-3
РИМР
Dismantling апд Assembly
When AssemЫing
The numerical sequence оп
Ье illustration is intended а
а guide to dismantling.
Renew а11 seals and '0' rings
using . СВ 'Special' Hydraulic
F1uid а а lubricant.
Еог аегпЬ1 у, reverse the
ес ыепсе.
When Dismantling
Fit bearing Ь1 ос 12 with
гесе55 Kpositioned оп the inlet
side Ы Ье ритр and facing the
еаг5.
Маг housings and со 'ег o
ensure соггес ге-аегпЫу.
A1ign housings and covers using
глаг таре оп dismantling.
Remove Ьагр есе and burrs
from shaft t0 avoid seal damage.
Torque Settings
Inspection
1 егл
'Ы ft
kgf т
7 25-30 3.5-4.1
Сес
ousing Ьоге diameters
а А and В. 1f А ехсеес В Ьу
more Ьап 0.004in. (0.1тт),
or hеа iц scoring is present, the
согпр1 ее ритр must Ье
renewed. Light scoring тау Ье
removed with very fine emery
cloth.
Ensure that bearing Ьос аге
free гогл scoring or damage,
especially in Ьоге С and оп
асе D. 1) е fine emery cloth
to remove scoring and to ensure
free movement in the ритр Ьоду.
Renew еаг i ЛШ]5 Е vary
Ьу more Ьап 0.0002in.
(0.005тт) or journal diameters
F vary Ьу more Ьап 0.0005in.
(0.013тт). Polish out light
scoring оп side асе usin 'егу
fine emery cloth and а сгар
bearing Ыос а shown а G.
Ensure that dimension Н is
0.004 to 0.008in. (0.012 to
0.203тт) е55 than dimension J .
3803/3200
1ssue 1
8ТЕЕГ 11\ С
Н
Н
2-1
2-1
Р1)МР
Removal агв Replacement
д 1е Replacement
Тпе numerical sequence оп
the illustration is intended а а
guide to removal.
Спес
ydraulic fluid 1е~е1,
аг епфпе ап
steering wheel from 1ос to
1 ос until steering becomes
positive.
Рог гер1 асегпеп , гееге the
sequence.
When Removing
Check relief а1~е setting
(нее ране Н 6-2)
Raise ап
Connections
upport lift аггп .
Вап hoses to аои oss Ы
hydraulic fluid.
9803/3200
1
2
3
Рее rom Тап
Тогсще Converter Suction
Рее o еегп Relief
Va1ve
4
Pressure Реес to Torque
Converter
lssue 1
Н
Н
6ТЕ Е Г 1Г С
2-2
2-2
7
1Т
222З
11i
2029А
9803/3200
lssue 1
Н
Н
STEERING
2-3
2-3
PUMP
Dismantling апд AssemЫy
When AssemЫing
The numerical sequence оп
the illustration is intended as
а guide to dismantling.
Renew а11 seals апд '0' rings
using . СВ 'Special' Hydraulic
F1uid as а lubricant.
Еог assembly, reverse the
sequence.
When Dismantling
Fit bearing blocks 10 and 22
with гесебб К positioned оп the
inlet side Ы the ритр and
facing the gears.
Mark housings апд covers to
ensure соггесю re-assembly.
[\ ОТЕ: ТЬе inlet side has the
larger diameter рогюб.
Remove бЬагр edges апд Ыггб
1гогл shaft to avoid seal damage.
Renew а11 seals апд '0' rings.
lnspectioп
Check housing Ьоге diameters
at А апд В. 1f А exceeds В Ьу
more than 0.004in. (0.1тт),
or heavy scoring 1s present, the
complete ритр must Ье
renewed. Light scoring тау Ье
removed with ,егу fine emery
cloth.
Ensure that bearing blocks аге
free гогл scoring or damage,
especially in Ьогеб С and оп
faces D. 1. бе fine emery cloth
to remove scoring and to ensure
free movement in the ритр Ьосу.
Renew gears, if widths Е vary
Ьу more than 0.0002in.
(0.005тт) or journal diameters
F vary Ьу more than 0.0005in.
(0.013тт). Polish out light
scoring оп side faces using very
fine emery cloth апд а scrap
bearing block as shown at G.
Ensure that dimension Н is
0.004 to 0.008in. (0.102 to
0.203тт) less than dimension J .
9803/3200
A1ign housings and covers using
marks гаде оп dismantling.
Torque Settiпgs
ltem
7
1 Ь ft
д1 т
25-30 3.5-4.1
Н
втЕЕАiNс
2-4
2-4
Р1)МР
Removal апд Replacement
Connections
When Removing
1.
Feed from tank
2.
Тогсе Converter Suction.
3.
Feed to беегг19 а1~е.
4.
Pressure Feed to Torque Converter.
5.
Return to Tank.
Raise апд support lift аггл .
Аег Replacement
Check hyд raulic fluid 1е~е1,
агt
engine апд rapidly spin steering
wheel from Iock to lock until
steering Ьесогле positive.
9803/3200
lssue 1
ЭТЕЕ й 1 ГЮ
2-5
9803/3200
н
2-5
Issue 1
5ТЕЕЕ 11\Ю
Н
2-6
2-6
р1Мр
Dismantling апд АssетЫу
When Assemhing
When Dismantling
Fit bearing Ыocks 10 апд 22 with
гесе
К positioned оп the inlet
side Ы the ритр апд facing the
lnspection
gears.
Check housing Ьоге diameters а А
ап
апд В. 1f А ехсеес В Ьу more
NOTE: The inlet side has the larger
0.1тт. (0.004in.) ог heavy scori пg
сНагпеег рог .
is ргееп , the ритр ггш
Ье
гепеес . Light scori пg тау Ье
removed with
Тогяце Settings
егу fine етегу cloth.
Ensure that bearing Ь1 ос
аге гее
•
Ite т
Nm
7
37
9 ГТ
3.7
1bf ft
27
гогп scori пg ог damage, especially
in Ьоге С апд оп асе D. [ е fine
етегу cloth to remove scori пg апд
о ensure гее movement in the
ритр body.
Аепе gears, if widths Е vary Ьу
тоге than 0.005тт. (0.002in.) ог
journal
агпеег F агу
Ьу more
than 0.013тт. (0.0005in.). Polish
out light scoriпg оп side асе using
егу fine emery cloth апд а сгар
bearing Ыоск а
own а G.
Ensure that dimension Н is 0.102
но о.2озтт. (0.004 но о,оовгп.)
е
than dimension J.
9803/3200
Issue 1
Н
Н
ТЕЕЕН \]С
3-1
3-1
RELIEF УА[ УЕ
(Torque Converter т/с's оп Iу)
Removal апд Replacement
ТЬе numerical sequence оп
the illustration is intended а5
а guide to removal.
Еог replacement, гееге the
sequence.
When Removing
Blank hoses to avoid loss of
hydraulic fluid.
Аег Аер!асетепн
Ёаг engine апд
steering wheel гогл lock to
lock until steering Ьесогле5
positive.
Check pressure setting
(5ее ране Н 6-2)
Connections
1
2
3
То Tank.
Егогл Ритр.
То Steering Unit.
3759
9803/3200
Н
SТЕ Е R 1 N G
Н
3-2
3-2
RELIEF \ А1\ Е
(Torque Converter т/с's оп1у)
Dismantling ап AssemЫy
The numerical sequence оп
the illustration is intended а
а guide 1:о dismantling.
Рог assembly reverse the
sequence.
When Dismantling
Remove plug 1 using ред
раппег раг1 по. 892/00068.
lnspection
6
Ensure that there is а оос
sliding fit Ье1'ееп iа1iе роо1
10 апд its housing 13. Slight
stiction тау Ье гегпоес using
metal polish Ы1: апу serious
damage гтш 1: Ье remedied Ьу
replacement Ы the iа1iе
assembly 7 а а unit.
13
12
11
7
When AssemЫing
Renew еа1 2 апд 8.
10
9
8
2068
9803/3200
Н
4-1
9803/3200
ТЕЕНГ\К
Н
4-1
1е 2
SТЕ Е R 1 N G
Н
Н
4-1А
4-1А
НУЕЖА111С STEERING UN1T — РI
Е88ЕУ
Вегпоба1 and Еер1асегпеп1
The numerical sequence оп
the illustration is intended а
а guide to removal.
Рог replacement the sequence
should Ье геегес .
When Removing
Do not hammer the епд Ы
the steering shaft to release
'Ьее1 from арег. Уе puller
ring раг по. 892/00069
( ее Service Тоо1 in conjunction
with а general purpose puller.
ldentify Ьое to ensure
соггес replacement, plug епс
to prevent ingress ы dirt.
When Replacing
fit three оп1у Ы nut 5 to
ргееп istortion Ы the unit.
Do not hammer steering Ьее1
опю shaft ог the iа1iе тау Ье
internally сагла9ес .
/
1G С/
Connections
А
В
С
D
sry crr
с
сх
Егогл Steering Ритр
Return to Tank
То Аат Неад Sгде
То Вагл Во ide
Топе Settings
Г\ гл
9 Г
1bf ft
ltem
5 27.1 2.8 20
9803/3200
lssue 1
Н
Н
$ТЕ Е Е 1 Iх.] С
4-2
4-2
26
-27
28
29
ЗО
З1
36
З9
2031С
9803/3200
н
ТЕ Е Р 1Г\] С
4-3
н
4-3
* НУОйА [1С ТЕЕР1 ГЮ 1Н'1Т — Р[Е~ЗЕУ
Dismantling and AssemЫy
The numerical sequence оп
the illustration is intended as
а guide 1:о dismantling.
Еог assembly, гееге the
sequence.
Веоге dismantling ensure that
ехрое portion Ы shaft is
гее from paint, rust or burrs,
otherwise damage wi11 Ье
caused to bearing surfaces.
When Dismantling
Оо по use screwdrivers or
еде to remove епд соег .
То remove 4, уеп 1 у tap епд
Ы shaft with о 1 hammer.
ltems 10, 11 апд 12 should Ье
retained with string qr rubber
Ьап А.
То remove 14, use а ооеп
drift раес1 through the Ьоге.
When AssemЫing
Е$1 ba11s апд springs as shown
at В.
When renewing seals 15 апд 20,
дiscard апу Ьаск-ир rings
previously fitted.
Tighten nuts 2 in sequence
С, D, Е, F, G.
Тогсре Settings
*Item
1
Nm
54
kgf т
5.5
1bf ft
40
1 ввие 2"
н
н
8ТЕ Е 1 i\1С
4-5
4-5
-33
36
3459А
9803/3200
11е 1
Н
STEERING
4-6
Н
4-6
*HYDRAULIC STEERING UNIT—PLESSEY
Dismantling and AssemЫy
The numerical ещепсе оп
the illustration is intended а
а guide to dismantling.
Рог assembly, reverse the
sequence.
Веоге dismantling, ensure
that ехрое portion Ы shaft
i гее from paint, rust or Ыгг ,
otherwise damage wi11 Ье
caused to bearing 26.
When Dismantling
Do по use screwdrivers or
wedges to remove епд covers.
То remove 4, деп 1 у ар епд
Ы Ьа with soft hammer.
ltems 10, 11 апд 12 should
Ье retained with string or
rubber Ьап А.
То remove 14 use а wooden
drift рае hrough the Ьоге.
Do по isturb '0` rings 23
апд 25 or Ьеагпд 24 апд 26
unless fluid is leaking аопд
the shaft.
When AssemЫing
1f new bearings 24 or 26 аге
fitted, it is essential to use the
special tool а described оп
раде Н 4-7.
Fit ba11s апд springs а hown
а В.
Tighten пШ 2 in ещепсе
С, D, Е, F, G.
*Тоглые Settings
ltem
2
9803J3200
Г\]гп
54
kgf т
5.5
1 Ь ft
40
1 ввие 2•
н
Н
STEERING
4-7
4-7
*НуОА )11СбТЕЕ 1
С UN1T—PLESSEY
А
Bearing Replacement
This operation requires special
tool раг по. 992/01300,
consisting Ы:
А — Guide Block
В — Mandrel
С — Тотту Ваг
Each епд Ы the mandrel must
Ье це or its specified
function:
1 — Fitting.
2 — Sizing.
Во1
uide Ыоск to control
~а1~е епд cover D, ensuring
that dowels аге соггес 1 у
located.
Fit пе bearing Е опо the
mandrel, with the лаНе 1
diameter Ы the bearin еаеd
firmly in гесе F.
Епег the mandrel into the
guide block апд mount the
аеглЬ1 у in а vice а hown.
Tighten the vice until а
resistance is fe1t, indicating
that the bearing is fu11y home
in the епд cover.
Position the assemЫy vertically
in the vice апд гееге the
mandrel so that the sizing епд
2 епег he bearing.
ГОТЕ; It тау Ье песеагу to
lightly ар the mandrel with а
soft асе mallet to епдаде Г [
in the bearing.
Rotate the mandrel through
а1 least six turns in each
direction to size the bearing.
Аеглое the tool гогл the
епд cover апд thoroughly с1 еап
out а11 1 оое bearing material
гогл the Ьоге .
Fit '0' ring G а hown.
9803/3200
3463
1ввие 2
sтEER1NG
Н
Н
4-8
4-8
*НУОАШ 1С бТЕЕЕ 1Г'Ю UNIT — Р[Е88ЕУ
Inspection and Repair
Remove burrs апд light scoring
[ГОгТ1 components using fine
emery cloth.
Ensure that vanes 10 томе
гее1 у in their slots.
']еаг Limits
Millimttres lnches
\Л]еаг а А
0.013
0.0005
Clearance В
0.061
0.0024
to
to
0.076
0.0030
Clearance С 0.010
0.0004
9803/3200
to
to
0.013
0.0005
1 ввие 2`
Н
Н
STEERIПIG
4-9
4-9
4419
9803/3200
1ssue 1
Н
Н
STEERING
4-10
4-10
HYDRAULIC STEERING UNIT—DANFOSS
Removal апд Replacement
The numerical sequence оп the
illustration is intended а а
guide to геггюа1.
Рог гер1 асегпеп the ещепсе
should Ье геегес .
When Removing
Do по hammer the епд
Ы the steering а11 to release
wheel from арег. 1) е pufler
ring рагн по. 892/00069
( ее Service Too1s) in
conjunction with а general
purpose puller.
* Оп 1аег machines the ри11ег
ring wi11 require modification
to fit the аег туре steering
wheel.
ldentify hoses to ensure
соггес replacement, plug
епс o ргееп ingress Ы dirt.
When Replacing
Do not hammer steering wheel
опо shaft ог the а1~е тау Ье
internally damaged.
* Check hydraulic fluid 1е~е1,
1аг engine апд turn the steering
wheel from lock to lock until
the steering Ьесогпе positive.
Connections
А — From Steering Ритр
В — Return to Tank
С — То Ram Неад Side
D — То Ram Аос Side
Torque Settings
Item Nm
kgf т 1bf ft
5 20.3 2.1 15
9803/3200
1
е 2*
Н
Н
ТЕ ЕА 1Г'Ю
4-11
4-11
14
9803/3200
13
lssue 2
$ТЕЕЕ 1Г\Ю
Н
4-12
4-12
HYDRAULIC $ТЕЕЕ 1Г\Ю 1Л\НТ — ОдГ\ ЕОЗ$
Dismantling апд AssemЫy
The numerical sequence
shown оп the illustration is
intended а а guide to
Dismantling.
Рог АегпЫу the sequence
should Ье reversed.
When AssemЫing
Аепе\'Ё а11 '0' rings апд еа1.
Ensure that the 1о in the
drive shaft 11 is aligned with
the hol lows Ы the гоог а
аЁА.
*Fit'0' ring 21 апд Ьас
20 using tool 1\Л 62А.
ир ring
Ва11 23 is to геЁ against seat
В Ьеоге bolt 1 is fitted.
Springs 13 must Ье осаеd
а а С.
Torque Settings
Г\]гп
егп
1 8. 2 29
kgf т Ьf ft
3.0
21.7
12
13
16
4426
9803/3200
lssue 2*
Н
STEERING
5-1
5-1
зеовд
9803/3200
1ввие 2
sTEER11vc
Н
5-2
5-2
RAM
Removal and Replacement
The numerical ещепсе оп
the illustration is intended а
а guide to dismantling.
Еог аегпЬ1 у, reverse the
ещепсе.
НОТЕ:
Items 1а to 7а — То т/с по.
68150.
1 егп 1b to 8b — Ргопп т/с
Но. 100000.
*Pin апд р1 ае 7с аге alternative
to pin 7b.
When Removing
B1ank пое o prevent 1о Ы
hydraulic fluid and entry Ы
dirt.
ЛЛеп Replacing
*Арр1 у anti-seize рае, раг по.
4003/0211 to pivot pin 5b to
facilitate Ьесщепю removal;
G I~LG GGl
i
After connecting hoses, prirre
е
r
'л' ее4 горгд1у
1оск to
1 вск ыflt+1 вt-еегг -Ьееея~ев
/
у6г 1 ,/‚/7
iсе/г Сиг ~~
пПС1 Е i*
Connections
1а, 1b. Steering Unit R.H. Port
2а, 2b. Steering Unit L.H. Port
9803/3200
lssue 2*
ТЕЕА1 С
5-3
5-3
З
2Ь
С
9803/3200
3791
lssue 1
$ТЕЕС
Г7
5-4
5-4
НАМ
Dismantling апд AssemЫy
The numerical sequence оп
the illustration is intended as
а guide to dismantling.
Рог аегпЬ1 у reverse the
sequence.
Г\ ОТЕ: Лпе two уре Ы
piston rod shown аге по
interchangeaЫe.
2а — То т/с по. 68150
2b — From т/с по. 100000
When Dismantling
Е1ес retaining wire 1 Ьу
turning the gland bearing as
а А. Оп very early гагт , it
тау Ье песеагу to ри11 out
the wire.
When AssemЫing
Аепе
а1
еа1 апд 'О' rings.
Соа а11 internal раг
ith
СВ 'Special' hydraulic fluid.
Ри
iper еа 11 with its Нр
facing circlip 10.
Fit пе retaining wire as а В.
Аррiу Loctite 221 ( ее
Service Too1s) to adjustment
threads Ы piston rod 2а апд
set dimension С to 21.2921.39in. (541-543тт) with
гагт fu11y closed.
Тогс1це Settings
Item
D
4
9803/3200
1 Ь ft
150
100
kgf т
20.7
13.8
3792
ТЕЕН1Г\ЗС
6-1
6-1
РНЕ81
ЖЕ TESTING
Ритр and Relief Va1ve
Disconnect and blank pipe А
and соппес auge В, раг Но.
892/00001.
With engine running а 1700
rev/min. the maximum gauge
reading wi11 indicate the
setting Ы the ге1 е а1~е
(5ее Technical Data).
If the setting is incorrect,
adjust аб described огiране Н 6-3
\ Ьеп the gauge reading is
соггес а 1700 rev/min. а drop
Ы more Ьап 200 1bf/in2
(14 kgf/ст2) with engine idling,
indicates а defective ритр.
Steering Unit and Ram
lnternaI Leakage Check
[\ ОТЕ: In саеб о1 inefficient
steering, this еб wi11 determine
which component is defective,
assuming 1Ьа there are Но
ехегпа1 leaks and Ьа the
ритр and relief iа1iе are
functioning соггес 1 у.
Disconnect and blank Ьобеб
С and D.
lnsert tee piece Е and соппес
gauge раг Но. 892/00001.
With engine running а1 1700
rev/min. check maximum
gauge reading when steering
wheel is turned.
1f the reading is equal to the
relief ',а1',е setting, suspect а
defective гагл.
1f the reading is appreciably
оег Ьап the relie а1~е
setting, suspect а defective
steering unit.
9803/3200
lssue 1
Н
Н
Sт EERING
6-1А
6-1А
PRESSURE TESTING
(" Snap-on" Pressure Те Points)
8уегл Pressure
Соппес pressure ае (5ее Service Too1s
Саа1 о9 е) to test point А usin
пар
соппесог раг Но. 892/00099.
N ОТЕ: У ]Ьеп ле gauge reading is соггес а
1700 геу/ глп , а дгор Ы ппоге Ьап 200 1bf/in 2
\'1ЁЬ engine idling, пс сае а defective ритр.
Run engine а 1700 rev/min. and turn
steering лее1 гого 1ос
o 1ос . ТЬе
maximum gauge геасп а fu11 1оск should
equal ле соггес relie а1iе pressure (see
Technical ОаЁа ).
Steering Unit and Аат
1 пегпа1 Leakage Check
1f ле геаЕЛп 5 аге Ьол псоггес , слес
he
ритр апд relie а1~е pressure. 1f опе reading
only is псоггес , check the steering unit апд
ram ог internal 1еаа9е.
Ритр and Relief \'ае Pressure
With gauge connected to point А, disconnect
апд blank pipe В а shown.
With engine running а 1700 rev/min., ле
maximum gauge reading should equal ле
соггес relie а1~е pressure. 1f incorrect,
adjust the relie а1~е (see ране Н 6-3).
First слес
he ритр апд геНеТ а1~е pressure.
With gauge connected to роп А and pipe В
гесоппесес , disconnect and Ь1 ап ПО55 С
апд D.
Run engine а 1700 rev/min. and check
maximum gauge readin
'Ьеп steering wheel
is turned in еасп direction.
If the reading is equal to пе relief iа1iе setting,
suspect а defective ram. 1f the reading is
appreciably lower Ьап the relief '!а1iе setting,
suspect а defective steering unit.
4070
9803/3200
lssue 1
С) С
_i2
—Г > о
‚с
STEERING
6-2
6-2
PRESSURE TESTING
Ритр and Relief Va1ve
Disconnect and Ыал hose А
and connect gauge f3, раг Но.
892/00001.
'Л1
engine running а 1700
rev/min. the maximum gauge
reading wi11 indicate the
setting Ы the relief уа1~е.
(8ее Technical ВаЁа).
1f the setting is incorrect,
adjust а escribed оп раде Н 6—З
When the gauge reading is
соггес а 1700 rev/min, а гор
of гпоге than 200 1bf/in 2
(14 kgf/ст2 ) with engine idling,
indicates а defective ритр.
Steering Unit апд Ram
1 ггегпа1 Eeakage Check
NOTE: In сае Ы inefficient
steering, thi е 1 wi11 determine
which согпропеп is defective,
assuming that there are по
ехегпа1 еа and that the
ритр and relie а1~е are
functioning correctly.
Disconnect and Ыал hoses
С and D.
1 п5ег tee piece Е and connect
gauge рагЁ Но. 892/00001.
'Л1
engine running а 1700
rev/min., check maximum
gauge reading when steering
wheel is turned.
1f the reading is еща1 1 о the
relie а1~е setting, suspect а
defective гагп.
If the reading is appreciaЫy
lower than the relie а1~е
setting, suspect а defective
steering unit.
9803/3200
lssue 1
STEERING
6-3
~Е11ЕЕ \ААVЕ
(Мапиа1 Clutch т/с's)
Adjustment
Аеглое сар А апд адд or
Ьгас shims В а required.
Опе 0.007in. (0.178тт) shim
гае or 1оег the pressure
Ьу approximately 100 1bf/in2
(7 kgf/ст2).
~Е11ЕЕ 0/А1 1Е
(Тогще Converter т/с°s)
Adjustment
Remove plug С, using ред
spanner раг Но. 892/00068,
апд ас or Ьгас hims D
а required.
Опе 0.020in. (0.508тт) shim
raises or lowers the pressure
Ьу approximately 100 1bf/in2
(7 kgf/ст2).
9803/3200
н
6-3
Н
Н
STEERING
7-1
7-1
3757
9803/3200
Issue 1
Н
7-2
FRONT АХЕЕ
Removal and Replacement
The numerical sequence
оп the illustration
пепсес
а а guide to removal.
Рог replacement, reverse the
sequence.
WARNING : Веоге working
beneath shovel, fit гагп-ргор 1,
раг Но: 102/11600 2D 20S
106/08100 З,ЗС,ЗС ,
30,700.
When Replacing
Lubricate pivot pin 8 with
Mobilgrease орег ог
equivalent.
After fitting гоас wheels,torque
tighten wheel nuts to 300 1bf ft
(41.5 kgf т).
9803/3200
sтEER1NG
Н
7-2
Н
1-1
втЕ Е R i NG
7-3
7-3
16
17
16а
18
~<
17
19
Г
-22
18
22
21
/2
12
с
1
20
- 15
- 14
13
-11
11
3758
9803/3200
1ssue 1
$ТЕЕЕ 11\ С
7-4
Н
7-4
FRONT АХ[Е
Dismantling ап AssemЫy
The numerical sequence оп
the illustration is intended а
а guide to dismantling.
Рог assembly, reverse the
sequence.
When AssemЫing
Аепе gasket 3, еа1 9 апд 15
ап е1
asher 18. Ре11 washer
ю Ье soaked in он Ьеоге fitting.
Адд расег 19 а required ю
achieve minimum епд float оп
swivel pins 20.
Secure nut 16 using Loctite
270, which must Ье kept clear
оГ нарег апд кеушау оп swivel
pin.
Pack hubs 5 with МоЫ19геае
Super ог equivalent.
Вед in bearings 6 апд 10 Ьу
rotating hub in each direction
whilst tightening nut 4.
When соггес orque setting
has Ьееп achieved, back-off
опе Ла1 апд fit split pin.
heels,
After fitting гоа
torque tighten wheel nuts Ю
407 N т, 41.5 kgf т, 300 1 bf ft.
Torque Settings
1 tem
4
*11
9803/3200
Nт
407
kgf т
41.5
1bf ft
300
156
16
115
lssue 3*
Н
7-5
9803/3200
ТЕЕй1 ГЮ
7-5
lssue 1
н
ТЕЕА1N С
Н
7-6
7-6
FRONT АХ[Е
Removal агн йер1 асегпегг
Тпе numerical sequence
оп the illustration is intended
а а guide to removal,
Рог replacement, гееге the
sequence.
А '1 Ю: Веоге \л.'огп9
beneath shovel, fit ram-prop 1,
раг Но: 102/11600 20,205
106/08100 3,3С,3С5,
30,700
When Replacing
Lubricate pivot pin 9 with
Mobilgrease Super ог
equivalent.
Адд washer(s) А а required
о гедисе епд Лоа 8 to а
maximum Ы 0.125in.
(3.2тт).
lG,~iG7 , 4~'е
Г /
After connecting hoses 7,
running, Ьу turnin. е steering
' пее1 rapidl
от 1ocko
lock и
steering Ьесогпе
7у
747
After fitting гоа
eels, torque
tighten пее1 nuts to 300 1bf ft
(41.5 kgf т).
9803/3200
1ssue 1
Н
Н
STEERING
7-7
7-7
23
24
25
30
12
1б
34628
9803/3200
lssue 2
Н
втЕЕАIпG
Н
7-8
7-8
Е
FRONT АХI
Dismantling апд AssemЫy
The numerical sequence оп the
illustгation is intended а а uuide
to dismantling.
Рог аззегпЫу, гееге the
sequence.
ГОТЕ: Pin апд plate 5а аге
alternative to pin 5.
When AssemЫing
* Аеагя bushes 28 апд 30 to 57.01 —
57.Обгягтi. (2.2445-2.2463in.)
diameter.
Renew е11: washer 24 апд soak in
oi1.
Аепе.ti' веа!s 11 апд 20, апд 9аз! е1:
14.
Адд зрасегз 25 аз required to achieve
гяпгтшгя end-float оп swivel pins 26.
ubs 16 with МоЫугеазе Super
Рас
ог ецЫ 'а1ег)1:.
Вед-in bearings 17 апд 21 Ьу
rotating hub in еаси direction whilst
tightening п111 15. When соггес1:
torque setting has Ьееп achieved, back
опе flat апд fit split pin.
о
Аррiу anti-seize ра 1:е, раг1: Но.
4003/0211 to pivot pin 3 to facilitate
subsequent removal.
А 1:ег fitting гоад wheels, torque tighten
wheel nuts to 300 Ы ft (41.5 kgf т).
* Топпе Setting
егя
7
15
Ггя
kgf т
1bf ft
156
407
16
41.5
115
300
9803/3200
Issue 3*
К
Е ['1 01 1Ы Е
Contents
Engine
—Manual Clutch МасЫпеб
—Torque Сопегег Machines
Contents
Аеглоа1 апд Replacement
Аеглоа1 and Replacement
2-1
ж
*ЕОГ Dismantling and AssemЫy Procedures геег to Leyland 38Т0 & 4/98 NТ Engine Service
Manual — РиЫication No. 9803/1200.
9803/3200
lssue 2*'
К
ENGrnIE
1-1
ENG1ПIE
(Manual Clutch Machines)
Removal and Replacement
The numerical sequence illustrated is intended
а а guide to removal.
Рог replacement, the sequence should Ье
reversed.
When Removing
When retaining clips 39 have Ьееп removed,
the clutch withdrawal гасе "i11 Ье гее to Ье
lifted out with the engine, аег removal Ы
the four mounting Ьо1 40.
*When соглгпепспд to litt the engine ensure
that slings are securely attached and а11 раг
are disconnected and гее1 у ерагаГп9.
The Ьаегу гау, air cleaner and sedimenter
аеглЬ1у 8 should Ье removed а опе unit.
When Replacing
NOTE: The sedimenter was по itted prior
to machine Но. 110552.
Adjust clutch реда1 гее travel if required
(нее Section 3 раде 6-1).
After draining the соо1 ая and removing
Ьо1 9, unscrew sleeve 10. The ритр drive
shaft wi11 then divide лйеп the radiator and
mounting 14 are removed.
Refi11 cooling уегл and check engine он
1е',е1.
NOTE: The respective control саЬ1 е апд
tachometer drive connections for the 1ло
уре Ы fuel ритр are shown thus:
1 егл
Г\ гл
Кдгл
1 Ы ft
33
57
5.8
42
34 130 13.3 96
40 130 13.3 96
Torque Settings
C.A.V. D.P.A. Ритр — 15 and 16.
Simms "М1п1 -тес" Ритр — 15А апд 16А.
1)пЬо1 he steering ритр 17 from the timing
соег. The hose connections need по Ье
removed if the ритр is adequately supported.
After removing с1атр 19 and slackening
с1 атр 20, raise the pipes above the олег edge
Ы the bodywork and secure with string.
Вгае and clutch реда1 return springs 27 must
Ье removed Ьеоге unbolting апд lifting clear
the Лоогр1 ае 28 апд 29. 1t тау also Ье
песеагу to disconnect the саЫе гогп the
ассе1егаог реда1.
1f а саЬ heater is fitted, this must Ье removed
Ьу taking out Ьо1 30. Cover р1ае 31 and
32 should then Ье removed to give clearance
Тог the removal Ы clutch housing 36.
Тае out the retaining pins 37 and slide
forward sleeve 38.
1 зе 2*
К
1-1
9803/3200
К
К
ENGINE
1-2
1-2
3906А
9803/3200
1ввие 2
К
К
ENGINE
2-1
2-1
3903
9803/3200
2-2
ENGINE
(Тогсце converter Machines)
Remova1 and Replacement
The numerical sequence illustrated is intended
а а guide to removal.
*When commencing to lift the engine ensure
that slings are securely attached апд а11 рагюз
are disconnected and гее1 у separating.
Еог replacement the ещлепсе should Ье
reversed.
When Replacing
When Removing
То facilitate alignment Ы holes for bolts 37,
locating dowel С should Ье таде from а
3/8 in. 1) Е bolt (раг Но. 1305/3212) Ьу
removing the head and providing а арег and
а screwdriver s1ot.
The Ьаегу гау, air cleaner and sedimenter
assembly 8 should Ье removed а опе unit.
НОТЕ: The sedimenter 'а по
to machine Но. 110552.
prior
After draining the coolant and removing Ьо1
9, unscrew sleeve 10. The ритр drive shaft
'i11 then divide when the radiator and он
cooler 17 are removed in unit with their
crad 1е.
НОТЕ: The respective control саЬ1 е and
tachometer drive connections ог the 1'о
уре Ы fuel ритр are shown thus:C.A.V. D.P.A. Ритр-20 and 21.
Simms 'Мгпг-тес' Ритр-20А апд 21 А.
1)пЬо1 the steering ритр 24 from the timing
соег. The hose connections need по Ье
removed if the ритр is adequately supported.
Support the engine securely prior to removing
engine Ьеагег Ьо11 33 and 34.
То ерагае the engine from the torque
converter impeller, remove plug 36 and гоае
the crankshaft а5 песеагу to permit removal
Ы Ьо1 37. 1f this is по possible (дие to
engine siezure ог ехатр1 е) remove Ьо1 А
and withdraw the engine with the torque
converter В attached.
НОТЕ: То avoid excessive он 1oss, keep the
torque converter upright after its removal
гогл the engine.
То permit the use Ы а socket to оае the
crankshaft, remove adapter 19.
9803/3200
Refill.cooling system and check engine апд
torque converter он levels.
ENGINE
~с
2-2
1ввие 2*