Service Manual

Transmissions
Section 1 - General Information
Section 2 - Care and Safety
Section A - Axle Hubs
Section B - Axle Hubs Swivels and Driveshafts
Section C - Axle Integral Brakes
Section D - Axle Drive Heads
Section E - Manual Gearboxes
Section F - Powershift Gearboxes
Section G - Transfer Gearboxes

Publication No.
9803/8610-14

World Class
Customer Support
Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
 Section 1 - General Information

Contents Page No.

About This Manual
Scope ...................................................................................................... 1 - 1
Axles ........................................................................................................ 1 - 2
Axle Sub-assembly Identification ....................................................... 1 - 2
Applicable Machines ................................................................................ 1 - 3
Working Practice ................................................................................... 1 - 10

Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners ................................... 1 - 11
Introduction ....................................................................................... 1 - 11
Bolts and Screws .............................................................................. 1 - 11
Hydraulic Connections ........................................................................... 1 - 15
'O' Ring Face Seal System ............................................................... 1 - 15
'Torque Stop' Hose System .............................................................. 1 - 18

Service Tools
Numerical List ........................................................................................ 1 - 19
Tool Detail Reference ............................................................................ 1 - 21

Service Aids
Sealing and Retaining Compounds ....................................................... 1 - 38

1-i 1-i
 Section 1 - General Information

About This Manual

Scope

The publication is built up in a modular way to include

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

When applicable, procedures in this manual are referred to

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

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 Section 1 - General Information
About This Manual
Axles

Axles

Because axles are modular many axle sizes and types are For this reason the procedures in this manual are for axle
manufactured using a small number of sub-assemblies. sub-assemblies not complete axle assemblies. This
means that procedures appear only once.

Axle Sub-assembly Identification

Sub-assembly Section Typical Axle Assemblies

Axle Hubs (Includes hubs with integral A
brakes)

Axle Hub Swivels and Driveshafts B

Axle Integral Brakes C

Axle Drive Heads (Includes drive heads D

for 1 piece axles (A) and 3 piece axles
(B))

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 Section 1 - General Information
About This Manual
Applicable Machines

Applicable Machines

The tables show which transmission dismantle and

K Gearbox Procedures ( T 1-3)
assembly procedure is applicable to which machine. Use
the cross references to the procedures in this manual. K Front Axle Procedures ( T 1-4)
K Rear Axle Procedures ( T 1-6)
Important: One machine model can have more than one
K Brakes Procedures ( T 1-8)
transmission option. Always cross check the
Transmission Techinical Data in the applicable Machine K Transfer Gearbox Procedures ( T 1-9)
Service Manual for the correct transmission component
information.

Table 1. Gearbox Procedures

Machines Service Procedures
Manual Manual Gearboxes(1) Powershift Gearboxes(1)
Backhoe Loaders Section E Section F
2CX, 212 - 930000 on 9803/7130 SS500 Synchro Shuttle -
3CX - 960001 on 9803/3290 SS700 Synchro Shuttle -
3CX - 960001 on 9803/3290 SS700 Type 2 Synchro -
Shuttle
3CX, 4CX 960001 on 9803/3290 - PS766 and PS764 - 2004 model
Powershift
Loadalls
Side Engined 768740 to 1185999 9803/3630 - PS700 Powershift
Side Engined 768740 to 1185999 9803/3630 - PS750 Powershift(2)
Side Engined up to 10.5m lift height - 9803/3730 - PS750 Powershift, PS750
1186000 to 1507999 Powershift MkIII, PS766 and
PS764 - 2004 model Powershift
Side Engined over 10.5m lift height - 9803/3730 - PS750 Powershift , PS750
1186000 to 1507999 Powershift MkIII
Side Engined - 506-36, 507-42, 509-42, 9803/3740 - PS750 Powershift MkIII, PS750
510-55 - 1402000 on Powershift MKIV
Side Engined Construction Machines 9803/3750 PS750 Powershift MkIII, PS750
1508000 on Powershift MKIV, PS766 and
PS764 - 2004 model Powershift
Side Engined Agricultural Machines 9803/3760 SS700 Type 2 Synchro PS750 Powershift MkIII, PS750
1508000 on Shuttle Powershift MKIV, PS766 and
PS764 - 2004 model Powershift
Rear Engined 1182000 on 9803/3710 SS600 Synchro Shuttle PS750 Powershift, PS750
Powershift MkIII
Rough Terrain Fork Lifts
921, 926, 930, 940 - 600001 on 9803/5100 SS600 Synchro Shuttle -

(1) Includes procedures for 2WD and 4WD gearboxes if applicable

(2) Includes the 5 speed variant

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 Section 1 - General Information
About This Manual
Applicable Machines
Table 2. Front Axle Procedures
Machines Service Procedures
Manual Drive Head Hub Swivel and Hub
Driveshaft
Section D Section B Section A
Backhoe Loaders
Midi 9803/9400 40 Series Drive - 40 Series Hub
Head (3 Piece
Axles)
2CX, 212 - 930000 on 9803/7130 55 and 80 Series - 55 and 70 Series
Drive Head (1 Piece Hub
Axles)
3CX (2WS, 2WD) - 960001 on 9803/3290 - Refer to Hub Dead Steer Hub
3CX, 4CX (2WS, 4WD) - 960001 on 9803/3290 55 and 80 Series 55 Series Hub 55 and 70 Series
Drive Head (1 Piece Swivel and Hub
Axles) Diveshaft
3CX, 4CX (4WS, 4WD) - 960001 on 9803/3290 55 and 80 Series 55 Series Hub 80 Series Hub
Drive Head (1 Piece Swivel and
Axles) Diveshaft
Loadalls
Side Engined - 768740 to 1185999 9803/3630 80 Series Drive 55 Series Hub 80 Series Hub
Head (3 Piece Swivel and
Axles) Diveshaft
Side Engined - 1186000 to 1507999 9803/3730 80 Series Drive 55 Series Hub 80 Series Hub
Head (3 Piece Swivel and
Axles) Diveshaft
Side Engined - 506-36 - 1402000 on 9803/3740 80 Series Drive 55 Series Hub 55 Series Hub
Head (3 Piece Swivel and
Axles) Diveshaft
Side Engined - 507-42, 509-42, 510-55 - 9803/3740 80 Series Drive 55 Series Hub 80 Series Hub
1402000 on Head (3 Piece Swivel and
Axles) Diveshaft
Side Engined `low boom'- 1186000 to 9803/3730 80 Series Drive 55 Series Hub 80 Series Hub
1507999 Head (3 Piece Swivel and
Axles) Diveshaft
Side Engined Construction Machines - 9803/3750 80 Series Drive 55 Series Hub 80 Series Hub
1508000 on Head (3 Piece Swivel and
Axles) Diveshaft
Side Engined Agricultural Machines - 9803/3760 80 Series Drive 55 Series Hub 55 and 70 Series
1508000 on Head (3 Piece Swivel and Hub, 80 Series
Axles) Diveshaft Hub
Side Engined Hydrostatic Machines - 9813/0200 55 Series Drive 55 Series Hub 55 and 70 Series
527-58 - 1473000 on Head (3 Piece Swivel and Hub
Axles) Diveshaft

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 Section 1 - General Information
About This Manual
Applicable Machines

Machines Service Procedures

Manual Drive Head Hub Swivel and Hub
Driveshaft
Section D Section B Section A
Rear Engined 1182000 on 9803/3710 80 Series Drive 55 Series Hub 80 Series Hub
Head (3 Piece Swivel and
Axles) Diveshaft
Compact - 515-40,520-40 from 1012000 9803/3690 40 Series Drive 40 Series Hub 40 Series Hub
Head (1 Piece Swivel and
Axles) Driveshaft
Compact 524-50,527-55 from 1068000 9803/3690 55 and 80 Series 55 Series Hub 40 Series Hub
Drive Head (1 Piece Swivel and
Axles) Diveshaft
Rough Terrain Fork Lifts
921, 926, 930, 940 - 600001 on 9803/5100 80 Series Drive 70 Series 55 and 70 Series
Head (3 Piece Driveshaft Hub
Axles)

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 Section 1 - General Information
About This Manual
Applicable Machines
Table 3. Rear Axle Procedures
Machines Service Procedures
Manual Drive Head Hub Swivel and Hub
Driveshaft
Section D Section B Section A
Backhoe Loaders
Midi 9803/9400 40 Series Drive 70 Series 40 Series Hub
Head and Drop Box Driveshaft
(3 Piece Axles)
2CX, 212 - 930000 on 9803/7130 80 Series Drive 70 Series 55 and 70 Series
Head (3 Piece Driveshaft Hub
Axles)
3CX (2WS, 2WD) - 960001 on 9803/3290 80 Series Drive 70 Series 55 and 70 Series
Head (3 Piece Driveshaft Hub
Axles)
3CX, 4CX (2WS, 4WD) - 960001 on 9803/3290 80 Series Drive 70 Series 55 and 70 Series
Head (3 Piece Driveshaft Hub
Axles)
3CX, 4CX (4WS, 4WD) - 960001 on 9803/3290 80 Series Drive 55 Series Hub 80 Series Hub
Head (3 Piece Swivel and
Axles) Driveshaft
Loadalls
Side Engined up to 10.5 metre lift height 9803/3630 55 and 80 Series 55 Series Hub 55 and 70 Series
- 768740 to 1185999 Drive Head (1 Piece Swivel and Hub
Axles) Driveshaft
Side Engined over 10.5 metre lift height 9803/3630 55 and 80 Series 55 Series Hub 80 Series Hub
- 768740 to 1185999 Drive Head (1 Piece Swivel and with Integral
Axles) Driveshaft Brake
Side Engined up to 10.5 metre lift height 9803/3730 55 and 80 Series 55 Series Hub 55 and 70 Series
- 1186000 to 1507999 Drive Head (1 Piece Swivel and Hub
Axles) Driveshaft
Side Engined `low boom'- 1186000 to 9803/3730 80 Series Drive 55 Series Hub 80 Series Hub
1507999 Head (3 Piece Swivel and
Axles) Driveshaft
Side Engined - 506-36 - 1402000 on 9803/3740 55 Series Drive 55 Series Hub 55 Series Hub
Head (1 Piece Swivel and
Axles) Driveshaft
Side Engined - 507-42, 509-42, 510-55 - 9803/3740 80 Series Drive 55 Series Hub 55 Series Hub
1402000 on Head (3 Piece Swivel and
Axles) Driveshaft
Side Engined over 10.5 metre lift height 9803/3730 55 and 80 Series 55 Series Hub 80 Series Hub
- 1186000 to 1507999 Drive Head (1 Piece Swivel and with Integral
Axles) Driveshaft Brake

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 Section 1 - General Information
About This Manual
Applicable Machines

Machines Service Procedures

Manual Drive Head Hub Swivel and Hub
Driveshaft
Section D Section B Section A
Side Engined Construction Machines - 9803/3750 55 and 80 Series 55 Series Hub 80 Series Hub, 80
1508000 on Drive Head (1 Piece Swivel and Series Hub with
Axles), 80 Series Driveshaft Integral Brake
Drive Head (3 Piece
Axles)
Side Engined Agricultural Machines - 9803/3760 55 and 80 Series 55 Series Hub 55 and 70 Series
1508000 on Drive Head (1 Piece Swivel and Hubs
Axles) Driveshaft
Side Engined Hydrostatic Machines - 9813/0200 55 and 80 Series 55 Series Hub 55 and 70 Series
527-58 - 1473000 on Drive Head (1 Piece Swivel and Hub
Axles) Diveshaft
Rear Engined 1182000 on 9803/3710 80 Series Drive 55 Series Hub 80 Series Hub
Head (3 Piece Swivel and
Axles) Driveshaft
Compact 515-40,520-40 from 1012000 9803/3690 40 Series Drive 40 Series Hub 40 Series Hub
Head (1 Piece Swivel and
Axles) Driveshaft
Compact 524-50,527-55 from 1068000 9803/3690 55 and 80 Series 55 Series Hub 40 Series Hub
Drive Head (1 Piece Swivel and
Axles) Diveshaft
Rough Terrain Fork Lifts
921, 926, 930, 940 2WD - 600001 on 9803/5100 - - Dead Steer Hub
921, 926, 930, 940 4WD - 600001 on 9803/5100 55 and 80 Series 55 Series Hub 55 and 70 Series
Drive Head (1 Piece Swivel and Hub
Axles) Diveshaft

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 Section 1 - General Information
About This Manual
Applicable Machines
Table 4. Brakes Procedures
Machines Service Procedures
Manual Axle Integral Brakes Hub Brakes
Section C Section A
Backhoe Loaders
Midi 9803/9400 40 Series Integral -
Brakes (3 Piece Axles)
2CX, 212 - 930000 on 9803/7130 70 Series Integral -
Brakes (3 Piece Axles)
3CX ,4CX - 960001 on 9803/3290 70 Series Integral -
Brakes (3 Piece Axles)
Loadalls
Side Engined up to 10.5 metre lift height - 768740 9803/3630 70 Series Integral -
to 1185999 Brakes (3 Piece Axles)
Side Engined over 10.5 metre lift height - 768740 9803/3630 70 Series Integral 80 Series Hub with
to 1185999 Brakes (3 Piece Axles) Integral Brake
Side Engined up to 10.5 metre lift height - 9803/3730 70 Series Integral -
1186000 to 1507999 Brakes (3 Piece Axles)
Side Engined `low boom'- 1186000 to 1507999 9803/3730 70 Series Integral 70 Series Integral
Brakes (3 Piece Axles) Brakes (3 Piece Axles)
Side Engined - 506-36 - 1402000 on 9803/3740 70 Series Integral
Brakes (3 Piece Axles)
Side Engined - 507-42, 509-42, 510-55 - 1402000 9803/3740 70 Series Integral
on Brakes (3 Piece Axles)
Side Engined over 10.5 metre lift height - 1186000 9803/3730 70 Series Integral 80 Series Hub with
to 1507999 Brakes (3 Piece Axles) Integral Brake
Side Engined Construction Machines - 1508000 9803/3750 70 Series Integral 80 Series Hub with
on Brakes (3 Piece Axles) Integral Brake
Side Engined Agricultural Machines -1508000 on 9803/3760 70 Series Integral -
Brakes (3 Piece Axles)
Side Engined Hydrostatic Machines - 527-58 - 9813/0200 70 Series Integral -
1473000 on Brakes (3 Piece Axles)
Rear Engined 1182000 on 9803/3710 70 Series Integral -
Brakes (3 Piece Axles)
Rough Terrain Fork Lifts
921, 926, 930, 940 - 600001 on 9803/5100 70 Series Integral -
Brakes (3 Piece Axles)

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 Section 1 - General Information
About This Manual
Applicable Machines
Table 5. Transfer Gearbox Procedures
Machines Service Manual Procedures
Section G
Backhoe Loaders
Midi 9803/9400 The drop box is part of the rear
axle drive head. K Rear Axle
Procedures ( T 1-6)
Loadalls
Side Engined - 768740 to 1185999 9803/3630 Bevel Gearbox
Side Engined - 1186000 to 1507999 9803/3730 Bevel Gearbox
Side Engined - 506-36, 507-42, 509-42, 510-55 - 1402000 on 9803/3740 Bevel Gearbox
Side Engined Construction Machines - 1508000 on 9803/3750 Bevel Gearbox
Side Engined Agricultural Machines - 1508000 on 9803/3760 Bevel Gearbox
Rear Engined 1182000 on 9803/3710 70 Series Drop Box
Compact 515-40,520-40 from 1012000 9803/3690 HG 310
Compact 524-50,527-55 from 1068000 to 1069457 9803/3690 HG 700

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 Section 1 - General Information
About This Manual
Working Practice

Working Practice

This publication is designed for the benefit of JCB

Distributor Service Engineers who are receiving, or have
received, training by JCB Technical Training Department.
These personnel should have a sound knowledge of
workshop practice, safety procedures, and general
techniques associated with the maintenance and repair of
earthmoving transmissions.

Renewal of oil seals, gaskets, etc., and any component

showing obvious signs of wear or damage is expected as
a matter of course. Cleanliness is of the utmost importance
when servicing transmission assemblies, be sure to take
every precaution to prevent the ingress of dirt and debris.
Finally, please remember above all else SAFETY MUST
COME FIRST!

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