2018-182 IS21 Concrete Spraying Machine Operating Manual - Spare Parts - DRAFT

MODEL : IS21
SERIAL NO : 2018/182
PRODUCT YEAR : 2018
DIESEL ENGINE : 85 kW / JCB
CONTENTS
1. IS21 CONCRETE SPRAYING MACHINE OPERATING
MANUAL
2. ELECTRICAL CIRCUIT DIAGRAM AND REMOTE
CONTROL
3. HYDRAULIC CIRCUIT DIAGRAM AND PARTS
4. AIR COMPRESSOR OPERATING MANUAL
5. DOSAGE PUMP OPERATING MANUAL AND DOSING
TABLE
6. HYDRAULIC PUMP OPERATING MANUAL
7. HYDRAMOTOR OPERATING MANUAL
8. DIESEL ENGINE OPERATING MANUAL
9. TRANSMISSION OPERATING MANUAL
10. FRONT AND REAR AXLES OPERATING MANUAL
11. DROPBOX OPERATING MANUAL
12. IS26 CONCRETE SPRAYING MACHINE SPARE PART
13. MANIPULATOR SPARE PART
14. AIR COMPRESSOR SPARE PART

15. DOSING PUMP SPARE PART
16. HYDRAULIC PUMP SPARE PART
17. HYDROMOTOR SPARE PART
18. DIESEL ENGINE SPARE PART
19. TRANSMISSION SPARE PART
20. FRONT AXLE SPARE PART
21. REAR AXLE SPARE PART

IS21 CONCRETE
SPRAYING MACHINE
OPERATING MANUAL
IS21 CONCRETE SPRAYING MACHINE
Operating Manual
TİTAN MAKİNA LTD. ŞTİ.
Address :1160. Sokak No: 9 Ostim 06370 Ankara Türkiye

Telephone : +90 312 354 99 77
Fax : +90 312 385 56 11
Web : www.titanltd.com.tr
E-mail : titan@titanltd.com.tr
OPERATING MANUALS
CONTENTS
1. PREFACE ................................................................................................. 4
1.1. Terms and Definitions ................................................................................ 4
2. APPLIED DIRECTIVES AND STANDARDS ............................................ 5
3. GENERAL SAFETY INSTRUCTIONS ...................................................... 6

3.1. Safety Signs and Instructions .................................................................... 6
3.2. Manufacturer and Machine Identification Tag ...........................................11
3.3. Chassis Number .......................................................................................11
3.4. Safety of The Operator .............................................................................12
3.5. Operator Suitability ...................................................................................12
3.6. Operator Responsibility ............................................................................13
3.7. Instructions for the Machine’s Owner and Operator..................................14
4. FIRE .........................................................................................................17
4.1. Mobile Fire Extinguisher; ............................................................................17
4.2. Manual and Automatic Fire Suppression Systems .....................................18
4.2.1. Operating Manual’s Fire Suppression .....................................................20
4.2.2. Operating Automatic Fire Suppression ...................................................25
4.3. Fire Suppression System Maintanance ....................................................27
4.3.1. Daily Maintanance ...............................................................................27
4.3.2. Six Monthly Maintanence .....................................................................30
4.3.3. Yearly Maintanence .............................................................................30
4.3.4. 4 Yearly Maintenance ..........................................................................30
5. DESCRIPTION AND OPERATION OF THE MACHINE ...............................31

5.1. Inspection of The Working Area .................................................................31
5.2. Inspection and Operation of the Concrete Spraying Machine ...................32
5.2.1. Seating .................................................................................................33
5.2.2. Machine Start up ..................................................................................34
5.2.3. Driving ..................................................................................................36
5.2.4. Gear Shifting ........................................................................................38
5.2.4. Operating Instructions ..........................................................................39
5.3. Storage of the Concrete Spraying Machine ..............................................45
6. TECHNICAL DATA ..................................................................................50

6.1. Chassis .....................................................................................................51
6.2. Diesel Engine ...........................................................................................52
6.3. Transmission ............................................................................................52
6.4. Axles & Shafts ..........................................................................................53
6.5. Braking System.........................................................................................54
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OPERATING MANUALS
6.6. Operator’s Cabin.......................................................................................55

6.7. Manipulator Arm (Manipulator Group) ......................................................57
6.8. Hydromotors .............................................................................................58
6.10. Technical Data ..........................................................................................60
7. LAYOUT PLAN AND TECHNICAL DRAWINGS .....................................62

7.1. Dimensions ...............................................................................................62
7.2. Turning Circle Diameters ..........................................................................63
7.3. Steering Positions .....................................................................................64
7.4. Manipulator Arm Spraying Range .............................................................65
8. USE OF CONTROL PANEL AND STARTING THE MACHINE ...............66

8.1. Front Console Panel .................................................................................66
8.2. Control Lever (Left) ...................................................................................68
8.3. Control Lever (Right) ................................................................................69
8.4. Side Console Controllers ..........................................................................71
8.5. Stabilizers Control.....................................................................................72
8.6. Hopper Control Levers..............................................................................73
8.7. Manipulator Control Levers .......................................................................74
8.8. Electrical Panel .........................................................................................75
9. MAINTENANCE INSTRUCTIONS ...........................................................77

9.1. General Maintenance ...............................................................................82
9.2. Before Maintenance..................................................................................83
9.3. Daily Maintenance (Every 10 Hours) ........................................................85
9.4. Weekly or Every 100 Hours Maintenance .................................................89
9.5. Every 250 Hours .......................................................................................91
9.6. Every 500 Hours .....................................................................................100
9.7. Every 1000 Hours ...................................................................................101
9.8. After Maintenance...................................................................................105
9.9. Changing the Wheels .............................................................................105
9.10. Replacement and Adjustment of Parts ...................................................111
9.9.1 Replacement of Hydraulic Cylinder ........................................................111
9.9.2 Replacing the Concrete Delivery Cylinders (Chromium Bushing) ...........112
9.11. Lubrication Points ...................................................................................115
10. SCOPE of DELIVERY ............................................................................128
11. CE DECLARATION ..................................................................................129
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OPERATING MANUALS
1. PREFACE
This manual explains the proper operation of IS21 Concrete Spraying Machine. Only
people with proper training are allowed to operate the machine. The operator should
read and understand the Operating Manual thoroughly before operating the machine.
The manual provides information on the structure and operation of the machine required
for proper use and maintenance.
1.1. Terms and Definitions

The following terms used in this manual refer to the corresponding definitions and
meanings as defined below.
Titan : Titan Makina Ltd. Şti.

User : Owner or operator of the machine
The contents of this document may not be reproduced, even in part, without prior written
consent of Titan. This operating manual may not be published, even in part, or used in
any way detrimental to the interests of Titan.
Titan reserves the right to make technical changes/modifications in its design for
improvements.
The intended use of this machine is concrete spraying. Any

other use of this machine with any other material will be
accepted as improper use. In such cases, all the responsibility
belongs to the user.
The safety devices on the machine are installed in order to

prevent any work accident. The removal/deactivation or by-
pass of such devices may lead to work accidents. In such
cases, all the responsibility belongs to the user.
The mechanical parts of the machine are under warranty for 1

year against material and workmanship faults starting from the
date of commissioning. Failures caused by misuse or improper
use of the machine, against the intended use explained in this
operating manual, will be out of warranty.
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OPERATING MANUALS
2. APPLIED DIRECTIVES AND STANDARDS
Titan IS21 Concrete Spraying Machine is manufactured in accordance with the following
directives and standards.
Directives;
2006/42/EC Machinery Directive

Implementing Regulation on Noise Emission in the
2000/14/EC
Environment by Equipment for Use Outdoors
Implementing Regulation on Electrical Equipment
2006/95/EC
Designed for Use Within Certain Voltage Limits
2004/108/EC Electromagnetic Compatibility Directive
Standards;
Safety of machinery - General principles for design

TS EN ISO 12100:2010
- Risk assessment and risk reduction
EN 60204-1:2006 Safety of machinery - Electrical equipment of
machines Part 1: General requirements
Earth-moving Machinery - Roll-over Protective
EN ISO 3471:2008 Structures - Laboratory Tests And Performance
Requirements
Earth-moving machinery - Falling-object protective
EN ISO 3449:2008 structures - Laboratory tests and performance
requirements
Acoustics -- Determination of sound power levels
and sound energy levels of noise sources using
EN ISO 3744:2010
sound pressure -- Engineering methods for an
essentially free field over a reflecting plane
Construction machinery - Electromagnetic
TS EN 13309:2010 compatibility of machines with internal power
supply
Page 5 / 129
OPERATING MANUALS
3. GENERAL SAFETY INSTRUCTIONS

Titan operates with the ”Work Safety First” principle and manufactures the IS21
Concrete Spraying Machine equipped with necessary security equipment with respect
to Machinery Safety Regulations (2006/42/EC) and keeps on renewing and improving.
Corresponding systems are clearly explained in the operating and maintenance manual.
1. This manual is prepared by Titan to provide safety information on installation,

operation, maintenance and repair of the machine.
2. Make sure that everyone who uses the machine is familiar with the manual, the
contents of the safety instructions applying to each case and that he/she has
been trained appropriately before operating the machine.
3. Familiarize yourself with the capacity and limitations of the machine and
equipment and the most efficient operating technique.
4. Familiarize yourself with the use and operation of the machine in detail before
operating it.
5. Familiarize yourself with the danger areas of the machine and prevent people
from entering these areas.
3.1. Safety Signs and Instructions

Symbols shown below with their indications are used on the machine and in this manual
to point out important information and for security purposes.
It is important to pay utmost attention and obey the information provided by these
symbols.
The symbols show the dangerous situations that can cause risk on health and security
when ignored.
The symbols show the proper behavior against situations that can risk health, security
and financial integrity.
Symbols include important technical information not to be ignored.
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OPERATING MANUALS
Symbol Indicates Description
This symbol indicates the risk of

accidents involving death/serious
personal injury and/or severe
Caution
damage to the product in case it’s
not obeyed the operating
instructions.
This symbol indicates the

Electricity electrical danger which may lead
to personal injury or death.
This symbol indicates the fuel

Fuel Tank
tank and the fuel to be used.
This symbol indicates the water

Water Tank
tank.
Protective This symbol indicates that

Clothing protective clothing must be used.
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This symbol indicates that the

Operating
operating manual must be
Manual
studied prior to start operation.
In case of emergency, break the

Emergency
glass with the emergency
Exit
hammer and get out.
Tyre This symbol indicates the ideal

Pressure pressure for the tyres.
While fixing the machine by

means of hydraulic jacks, watch
out your feet and clear off this
Hydraulic
area. Your feet may squeeze
Stabilizer
between the ground and the
hydraulic jack and serious injury
may occur.
Ear This symbol indicates that ear

Protection protection must be used.
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This symbol indicates the drop

Emergency
window. It is used for emergency
Exit
exit.
and
In Case of This symbol indicates the actions

Fire to take in case of fire.
Main This symbol indicates the main

Switch switch.

seatbelt must be used. Always
Seatbelt fasten the seatbelt when the
machine is moving.

Informative
lifting should not be done.
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OPERATING MANUALS
This symbol indicates that

operator cabin is tested
Informative
according to FOPS (Level II) and
ROPS.
This symbol indicates that

Caution objects in mirror are closer than
they appear.
This symbol indicates that load

Informative should not lift.

Informative
“do not touch”.
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OPERATING MANUALS
3.2. Manufacturer and Machine Identification Tag

Do not alter the information on the identity tag. Keep the tag clean and legible. Contact
Titan in case the tag is damaged or has become illegible for the renewal of the tag. The
tag includes information on the machine and it’s equipment.
1- Production Year
2- Mass
3- Type
4- Serial No
Fig.1
3.3. Chassis Number

Chassis number is stamped on the chasis under the operator cabin and covered with
a black protection cover as shown in Fig. 2
Fig. 2
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OPERATING MANUALS
3.4. Safety of The Operator

For safety of the operator;
1. Operator cabin is constructed as to prevent falling objects and rolling. Thus, the
cabin is FOPS (Level2) and ROPS certified.
2. Tempered glasses are used in the cabin. In emergency cases, side glass is
produced in appropriate thickness to break and evacuate. Emergency hammer
is provided in the cabin.
3. There is a door sensor in the cabin and the vehicle will not move when the door
is open.
4. Operator’s seat has an adjustable seat belt that the operator should wear during
the travel.
5. Headlights are provided on the top of the cabin to extend the visibility range.
Beacon lamp is also placed on the top of the cabin. Thus, the vehicle can be
easily recognized in the work zone.
3.5. Operator Suitability

The machine can only be operated and serviced by a person who;
1. Has a valid operator license. It is strictly forbidden for the workers without
operator licenses to use the concrete spraying machine.
2. Is mentally and physically suitable for the job.
3. Has been trained for operating and maintaining the machine and who has
proved to the company to be qualified for this job.
4. Has proved to be skillful and conscientious and thorough in his work.
5. Is responsible and reliable.
6. Follows the instructions provided.
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OPERATING MANUALS
3.6. Operator Responsibility

Occupational accidents often occur under unusual circumstances. It is therefore
important to take all possibilities into consideration, even the most unlikely situations,
which may occur in each job.
1. When using the equipment, the operator is responsible for the safety and danger
zone of the entire operating area of the equipment.
2. The operation safety of the equipment must be inspected every time before
taking the equipment into use. If there are faults or defects detected, they must
be repaired immediately.
3. If it is impossible to avoid the factors that endanger the operation safety, the work
must be terminated.
4. The operator is responsible for accidents due to negligence and carelessness. If

the operator is not sufficiently trained and he/she cannot be held liable, the liability
is transferred to his/her supervisor. It should also be remembered to act in
accordance with both the instructions given by local labor protection authorities
and the laws and statutes of the country.
5. All safety regulations must be observed.
6. All operating and service instructions must be observed.
7. Do not start the machine before reading operating and maintenance manual.
8. Do not let the number of persons in the operator’s cabin exceed the limit set by
Titan Makina.
9. Observe the instructions on the safety tags located on the concrete transmixer.
10. The operator must be familiar with the operation of the equipment and all its
control devices.
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OPERATING MANUALS
11. Use advised personal protective gear with respect to the specifications of the
work during operation and maintenance of the machine.
Fig. 3
12. Maintenance and repair of the machine should be carried out by authorized
personnel.
3.7. Instructions for the Machine’s Owner and Operator

These safety instructions must be complemented with instructions required by the laws
of the country, other minor statutory provisions and the regulations provided for by the
authorities so as not to endanger the safety of the workers and other people or of
property.
Primary information on maintenance operations;
1. Cleanse the machine from oil, dirt and other harmful agents. In case of
pressurized air cleaning, make sure the pressure level cannot damage the
machine or human health.
2. Always position the machine so as to prevent damage to people. Do not attempt

to carry out maintenance while the machine is moving.
3. Take the necessary precautions with the stabilizer and security pins to prevent
the machine to move during maintenance.
4. Make sure that all the safety equipment are sound and working before starting
the operation.
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OPERATING MANUALS
5. Eliminate all external factors which may and/or will limit or block the movement
around the machine. Set a well-organized and safe working environment.
6. While using the machine and moving on the machine, keep the surface under
your feet clean. Clean all slippery surfaces. (Fig. 4)
Fig. 4
7. If any fluid is required to be evacuated from the machine, observe the

environmental safety and pollution rules.
8. Do not keep flammable and scorching materials such as gasoline, diesel oil,
welding tube etc. near the machine. Keep the required maintenance products in
their proper boxes. Deliver waste fluids and contamination boxes to the suitable
environmental recycling corporations.
9. Loose connection points of the machine parts may cause unintended movement
as well as hydraulic oil and air leakages. Secure the moving parts or take
necessary precautions.
10. If a running engine is not required, stop the engine during maintenance. If you
will work on parts with electricity, cut the power connection between the battery
and the machine from the main switch.
11. Some equipment may remain under hydraulic pressure after the machine is
stopped. Pressure may pose danger when it is not controlled or when the safety
measures are insufficient. Interfere with the system after making sure that the
pressure in the system is equivalent to the atmospheric pressure through
system’s and personal manometer.
12. The hydraulic system is hot and under high pressure while working. Hot oil and
the equipment containing hot oil may cause serious injuries. Take required
precautions to avoid the hydraulic oil and equipment from causing damage to the
personnel.
13. Avoid hydraulic oil contact with the skin or eye. In case of contact with the eye,
read the MSDS (Material Safety Data Sheet), take the necessary actions and
consult to an eye doctor.
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OPERATING MANUALS
14. The hoses and pipes are used for transferring pressurized liquids and air. Check
the hose and pipe connection points. Make sure there are no fractures, cracks
or any other deformation. Do not use damaged hoses and pipes. Protect the lines
under pressure from any impact. Check for leakage and fix if any. Leakages may
cause damage, injuries or fire.
15. Any detected malfunction or broken warning lights and sensors may indicate an
electrical leakage. If such electrical error is detected, fix the malfunction before
any maintenance. Check the warning lights.
16. The stability of concrete mixer is calculated based on load and capacity factors.
Overloading the lift would cause a loss of stability.
3.8. Risks Originating from the Machine

The manipulator arm of the Concrete Spraying Machine should be operated carefully
and any collision should be avoided, especially in closed areas.
It should be kept in mind that there is a risk of jamming between the manipulator arm
and external objects while rotating, extending, retracting and performing other
movements of the manipulator.
To prevent any jamming while working on the machine’s hopper, use the grid sustaining
chain.
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OPERATING MANUALS
4. FIRE
4.1. Mobile Fire Extinguisher;

There are two fire extinguishers on the machine. Before operating the machine, make
sure the extinguisher tubes are in place, full and ready to be used. On any case of
deficiency, fix the problem before operating the machine.(Fig. 5)
Fig. 5
Keep the electrical joints clean and well-kept. Do not let any untrained or unauthorized
personnel interfere with the interior of the electrical panel. Keep in mind that electric is
one of the systems with highest fire risk.
Mobile fire extinguisher instructions and cautions;
 Do not keep the extinguisher above temperature of 45 degrees Celsius.
 Check the manometer regularly and often. The indicator must be on the
green area.
 Shake the extinguisher one or two times before using it.
 Pull out the lead seal that locks the trigger mechanism.
 After getting to as close as possible to the fire source, press the trigger.
 Keep the wind on your back.
Page 17 / 129
OPERATING MANUALS
Fig. 6
4.2. Manual and Automatic Fire Suppression Systems

By demand from customer, besides mobile fire extinguisher, there are also manual or
automatic fire suppression systems available for IS21 Concrete Pump Machine.
The fire suppression system is designed to protect particular segments of the machine.
Fig. 7 Fig.8
To activate, remove the safety pin and repress the plunger. When either actuator
plunger is depressed it will puncture the pressurized cartridge and activate the
extinguisher system.
The machine may be equipped with a fire suppression system consisting of one or two
extinguisher bottles, three (3) or more remote spray nozzles and two (2) or more
actuators. Each actuator is fitted to a charging cartridge and a safety pin. Normally one
Page 18 / 129
OPERATING MANUALS
actuator is located in the operator's compartment, the other at or near the engine
compartment.
In the event of fire;
The fire suppression system is designed to protect specific fire hazard areas on the
machine. It is intended to supplement, not replace, a sound fire prevention policy in the
mine. Fire prevention depends on regular inspection and maintenance of those areas
on the machine where a fire is most likely to start; the wheel ends, the engine tub, the
transmission, and the torque converter. Daily shift maintenance should include the
cleaning of areas where flammable materials and combustible debris may collect.
STEP 1: Shut off the ignition.

STEP 2: Set the brakes.
STEP 3: Pull the ring pin on the manual actuator.
STEP 4: Strike the red button.
STEP 5: Evacuate the machine.
STEP 6: Stand by with a fire extinguisher.
Fig.9
When either actuator plunger is pressed it will puncture the pressurized cartridge and
release fire suppression chemicals. The expellant gas pressure makes the dry chemical
extinguishing powder act like fluid. The dry chemical powder is propelled through the
distribution hose after pressure in the dry chemical tank reaches the point to rupture the
bursting disk.
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OPERATING MANUALS
4.2.1. Operating Manual’s Fire Suppression

When the fire started in the risk zone;
 Set the brake.
Fig. 10
 Shut off the ignition.
Fig. 11
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OPERATING MANUALS
3. The machine is equipped with a fire suppression system for two (2) actuators.
 Pull the ring pin on the manual actuator

 Strike the red button.
Fig. 12
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Fig. 13
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When either actuator plunger is pressed it will puncture the pressurized cartridge and
release fire suppression chemicals. The dry chemical powder is propelled through the
distribution hose after pressure in the dry chemical tank reaches the point to rupture the
bursting disk.
Fire suppression of diesel engine;
Fig. 14
Fig. 15
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OPERATING MANUALS
To activate the fire suppression system with the valve;
 Break the seal on the fire extinguisher tube.

 Pull up the part (1) indicated in the Fig 17.
 Open the valve
(1)
Fig. 16
ON
OFF
Fig. 17
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OPERATING MANUALS
4.2.2. Operating Automatic Fire Suppression

Activation of the fire suppression system with a linear cable;
There is linear cable in diesel engine cabin. The linear cable perceive the temperature
inside the engine compartment and activates the fire suppression system automatically
if it reaches 180-185 degrees Celsius.
Fig. 18
CAUTION
If the fire suppression system is activated with the linear cable, stop the machine. If the
machine is moving and set the brake.
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OPERATING MANUALS
Activation of the fire suppression system with a linear cable;
The operator activates the fire suppression system with the button located back the seat
in the cabin. To activate the system, stop the machine and press the button.
Fig. 19
When the automatic fire systems mentioned above are activated, dry chemical dust is
released from three nozzles mounted in the engine cabin. The fire hazard is removed
from the center.
Fig. 20
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OPERATING MANUALS
4.3. Fire Suppression System Maintanance
4.3.1. Daily Maintanance
Tour around the fire suppression system for a general check. The general check will
provide information on the general condition of the system. This general check aims to
avoid major malfunctions on the system.
 Check visually inspect the fire extinguishing system daily.
 Check all oil, hydraulic fluid and gaz lines for cutsi abrasions or undue wear.
Replace as needed.
Fig. 21
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 Inspect all oil, hydraulic and gas line fittings for tightness. Clean off all residue
and tighten.
Fig. 22
 Check the manometers on the fire extinguisher cylinder (mobile fire extinguisher
and manuel fire suppression). Make certain it's in the green zone.
Fig. 23
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OPERATING MANUALS
 Make certain ring pin is inserted through the red actuator button to ensure safe
cartridge installation.
Fig. 24
 Make certain the nozzles are correctly aimed, openings are clean and not
obstructed and the blow off caps are properly installed.
Fig. 25
 If there are any broken or missing lead and wire seals, or any other deficiency is
noted, immediately contact the authorized Titan Makina.
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OPERATING MANUALS
4.3.2. Six Monthly Maintanence

 Check general appearance of system components for mechanical damage or
corrosion.
 Check the fire extinguisher cylinder’s flap. Replace as needed.
 Check the nozzles.
 Check the manual fire suppression system buttons.
4.3.3. Yearly Maintanence

 The following should be carried out after the six months maintenance is
completed.
4.3.4. 4 Yearly Maintenance

 Change the dry chemical powder.
CAUTION
The manual fire suppression system warranted for two years if it is maintained once a
year by Titan authorized services.
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5. DESCRIPTION AND OPERATION OF THE MACHINE
The Titan IS21 Concrete Spraying Machine is manufactured to spray shotcrete concrete
(wet spraying concrete) in tunnels or in open space to every surface within its spraying
range. The working area and the area’s suitability for the machine to work must be
examined prior to operation of the machine.
The machine is 4-wheel-drive with 3 different steering options. The machine runs on a
diesel engine. The diesel engine is used both for the movement of the machine and
hydraulic power by providing power to the pumps. The machine has Power shift
automatic transmission. The power from the transmission is transferred first to the
transfer box, and then to the axles, by shafts.
Hydraulic power is used for the steering and breaking systems. Hydraulic power is
generated by the pumps, which are connected to the diesel engine. The steering system
works as the hydraulic power is transferred to steering cylinders located on the axle,
thus the cylinders, manipulating the wheels.
There also exist priority valves which regulates the priority arrangement for the parking
brakes, hydraulic system accumulator and the operations to be held by the machine.
For a more efficient work, the steering system and the panel can pivot 180 degrees
within the cabin. This way, a safer way to manoeuvre while heading backwards is
guaranteed.
Titan IS21 is designed for efficiency and conformity to hard operating conditions, and
equipped with complete hydraulic and sensitive control systems.
5.1. Inspection of The Working Area

Check the suitability of the working area before operating the IS21 Concrete Spraying
Machine.
Primary dangers to be checked;
 Personnel inside the working area

 Other moving objects in the working area such as other machine
 High obstacles
 Soft ground, pits, inclination, elevations and other irregularities of the surface of
the working field.
If any danger is detected, do not start the operation before eliminating the potential risk.
Keep the other workers aware of cautions taken and detected dangers.
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5.2. Inspection and Operation of the Concrete Spraying Machine

Complete the daily maintenance stated in the maintenance table before operating the
machine. If a problem is spotted, do not start the operation of the machine before solving
the problem. Get help from the related person to solve the detected problem. Problems
should not be solved by unauthorized or uninformed personnel.
Always keep the water tank full located between concrete transfer cylinders and
hydraulic cylinders. Soap can be added to the water to increase the lubricity. In case of
freezing, antifreeze can be added. Water is a basic lubricant.
To pump concrete through electric engine’s power, link the power cable to the main
electrical network after positioning the machine.
PTO is required to pump concrete through diesel engine’s power, on machines with
diesel powered hydraulic system. The PTO can be directed or set to neutral only when
the diesel engine is not running. The PTO cannot be activated or disengaged while the
diesel engine is running. Warm up the diesel engine by running it on idle. Stop the
engine, select PTO Input. Start the engine.
On standard machines, PTO INPUT can be selected without stopping the engine.
On diesel powered machines, stop the engine. Select PTO OUTPUT.
On standard machines, select PTO OUTPUT without stopping the engine.
Caution:
 The machine must be operated only by personnel who are authorized, qualified,
trained as per the health and safety rules and holding a valid licence.
 A test operation must be performed prior to putting the machine in operation.
 Check the levels of all water, fuel and oil tanks and fill or empty to the required
level if necessary.
 Do not run the electric engine and the PTO at the same time in diesel driven
machines equipped with a PTO!
 DO NOT COUPLE the PTO to put into operation while the engine is running!
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OPERATING MANUALS
5.2.1. Seating
Caution:
Right controller arm, steering wheel and other equipment should not be used to climb
to the driver’s cabin. Doing so may cause injuries and/or damage to the equipment.
Fig. 26 Fig. 27 Fig.28
 Open the door of machine and make sure the position of the door is fixed as
shown in Fig. 26.
 Climb on the machine using the first step of the machine and the handle as
shown in Fig. 27.
 While climbing on the machine, make sure that you are supported at least from
the three points shown in Fig. 28.
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5.2.2. Machine Start up

 Seat fore aft adjustment is made using the arm shown in Fig. 29.
 The driving post for optimal driving comfort should be checked and adjusted for
reaching the controls easily. (Fig. 30)
Fig. 29 Fig.30
 Suspension and weight resistance of the seat is adjusted with respect to the
operator as shown in Fig. 31.
Fig. 31
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Fig. 32 Fig.33 Fig. 34
 The seat position for optimal driving comfort should be checked and adjusted for
reaching the controls easily and the seatbelts should always be fastened before
starting machine as shown in Fig. 32.
 To clearly see the area from the mirrors, they should be adjusted according to
driver’s seating position. (Fig. 33)
 Make sure that the warning indicators work properly. (Fig. 34)
Forward
Neutral
Reverse
Fig. 35 Fig. 36 Fig. 37
 The machine should not be driven by the operator without or before fastening the
seat belt properly. (Fig. 35)
 While starting the machine make sure to release the brake pedal. (Fig. 36)
 Before start-up, make sure that no one other than driver is working on the
machine.
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 Control whether the gear position, is neutral or not. If it is not neutral, then bring
the gear to the neutral position. (Fig. 37)
 To prevent injury due to crushing objects outside the cabin, driver should keep
his/her head, body and limbs inside the driver’s cabin.
Fig.38
 Machine can be started with the key as shown in Fig. 38.
 Starting the engine by short-circuiting the starter may cause fire or injuries.
Therefore the engine should never be started by short-circuiting the starter.
 Do not attempt to start the engine by driving the machine down a slope.
 Before starting the engine and using the machine, make sure that no one stands
within the range of action of the machine.
5.2.3. Driving
Caution:
Before proceeding, always read the safety regulations for the operations to be carried
out as mentioned in the previous pages.
 Before moving the machine, check that there is no one in the vicinity.
 It is beneficial to use a horn sequence for starting the engine, driving forward and
driving reverse to warn the personnel around.
 Make sure that driver can clearly see the entire work or maneuver area.
 Check all the components of the machine including the cabin windows, doors and
brakes. Do not use the machine before ensuring that all these components are
ready for the drive.
 To drive the machine properly, the driver must shift the steering selector
according to the road conditions.
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 Turn on all safety devices as indicated in the General Safety Instructions section.
 Set the direction of the driver's seat towards the driving direction.
 Raise the bucket as high as possible and then tie it with the safety cable to lock
the arm.
 Remove the chute extensions
 Bring the chute to retracted position and then lock it with the lever.
 Make sure that all the warning lights are operational.
 Turn on the rotating beacon.
 Regulate the gear level according to the usage area (shift the gear up during
transfers on flat surfaces or moderate slopes and down for medium to steep
slopes).
 Do not shift the gear up before the previous gear’s speed limit is reached.
 Do not attempt to change the gear direction before the machine comes to a full
stop.
 Check the proper functioning of the lights ar regular intervals and immediately
replace any blown bulbs.
 To drive the machine in reverse, the seat should be rotated. To rotate the seat,
first make sure the door is completely opened.
 To rotate the seat use the arm located at the bottom of the seat.
 Keep rotating until the seat reaches the limit (180 0), and then make sure the
driving post is perfectly locked.
Caution:
Make sure the driving post is perfectly locked before starting and driving the machine.
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Fig. 39 Fig. 40 Fig. 41
While driving in reverse;
 Do not reverse at top speed to prevent accidents and drive at a safe speed with
respect to the working conditions.
 While reversing driver must face the direction that the machine is moving
towards.
5.2.4. Gear Shifting

Caution:
Before taking any further action, always read the safety regulations for the operations
to be carried out as mentioned in the previous pages.
 Gear selector is located on the left side of the console.
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Forward
Neutral
Reverse
Fig. 42 Fig. 43 Fig. 44
 Both forward and reverse stages of the gear are located on this selector. To
change the direction, change the position of the arm shown as in Fig. 42.
 There are four gear levels for both forward and reverse (Fig. 43). Set the gear
level according to the work area.
5.2.4. Operating Instructions

 Drive the machine to the working area.
 Extend the hydraulic support legs in order to stabilize the machine. Make sure
that all support legs are stabilized and secured on a hard ground / stable base.
Fig. 45
 Run the cable reel and release the cable up to a ready-prepared electrical plug
panel.
 Check the ground line that is connected to the electrical plug panel. (System
comprises 3 Phases + Ground Line).
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 Plug the power cable and position the main switch from “0” to “1”, located on the
electrical panel.
 Set the emergency stop switch to working position. Ready lamp on the panel will
light. If the ready lamp does not light, one of the supply phases is missing or the
phase sequence is incorrect. Correct the phase sequence of the electrical supply
line.
 Start the main pump by pressing “START” button.
 Set the selection switch to “PANEL” if the desired controller is the electrical panel.
Then, the pump is run via the selector switch (1-0-2) for pumping or reverse.
Dosing pump is run with dosing selector switch.
 Turn on the control switch located on the manipulator in case the remote control
is not desired and the machine will be operated manually with the 6-lever
controller. Keep the switch is turned off for a better performance during concrete
spraying. The 6-lever controller does not function when the switch is turned off
(Remote Control). If the manual control of the manipulator is to be used, press
the button in front of the operator's cabin. (Fig. 46)
 If the operation will be performed with the cable remote control, please do the
following;
a) Plug the sockets of the remote controller box,
b) Start the main pump via electrical panel,
c) Set the selector switch located on the panel to “REMOTE CONTROL”
position. Now, the operation may be performed via the remote control.
Fig.46
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Remote Control;
22
1 3
5 6 7 8
4 9 10 11
Fig. 47
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Switch Forward Manipulator is lifted.

1
Switch Back Manipulator is down.
Switch Left Manipulator is return to left.
Switch Right Manipulator is return to right.
Switch Forward Telescopic is extensioned.
2 Switch Back Manipulator is refracted.
Switch Forward Nozzle is lifted.
3 Switch Back Nozzle is down.
Switch Left Nozzle is return to left.
Switch Right Nozzle is return to right.
4 Emergency Stop the concrete spraying machine.

Stop
5 Switch Forward Compressor gives the air to system
Switch Forward The system reverses the concrete.

6
Switch Back The system pumping the concrete
7 Switch Forward The horn is ring.
8 Switch Forward Dosage (admixture) pomp is worked
9 Switch Forward Nozzle rotation is worked.
10
Switch Forward Concrete and admixture is increased
Switch Back Concrete and admixture is decreased.
(0) situation, command is closed.(1) situation, command
11 Start is opened.
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Caution:
 Always check the main power cable prior to operation. In case of any damage,
peeling or abrasion on the cable, replace the cable immediately.
 Unplug the power cable before any cleaning. Do the cleaning by using the PTO.
 Always check the grounding prior to operation.
 Do not let the unauthorized personnel to be involved in the electrical panel.
 Power must be disconnected prior to any maintenance on the electrical brush
which must be done by qualified personnel.
 Do not run the cable reel when the power cable is connected.
 Do not move the carrier when the power cable is connected.
 Set the main switch to position “0” prior to opening the cover of electrical panel.
The cover is not opened when switch is on position “1” and the switch might be
broken. Risk of electric shock!
Positioning / Setting the Machine:
 The proper positioning of the machine is the operator’s responsibility.

 Do not extend the manipulator arm without fixing and stabilizing all support legs.
Execute all applicable safety measures. Have the working area under control and
prevent any access of unauthorized or irrelevant personnel.
 Always fix the R-clips of lever joints in order to prevent opening.
 Prior to start operation, check the manipulator and connections if they are proper
or not.
 While positioning the machine on an inclined ground, scotch the wheels,
disengage the parking brake and wait until the machine is scotched, then engage
the parking brake and fix the support legs.
 The support pads must not be laid over cavities.
 Stabilizing material may not always be sufficient for the machine.
 Create even surfaces to place the machine if the working area is sloped.
 Wheels should be tangent to the floor at the right elevation.
Fig. 48
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 Work at a safe distance from obstacles such as tower cranes, buildings or

scaffolds.
 Since the support legs may sink in the ground, stay away from slopes,
embankments, holes, hollow spaces, channels and pits.
Fig. 49 Fig. 50
 The support legs create a pressure of up to 15 kg/cm² on the ground. If the
ground is not stable enough, put 2 layers of suitable material placed crosswise
to each other and increase the supporting area.
 On bad ground, support plates that are clear of oil, grease, ice etc. must be used.
Fig. 51
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 The closest support leg must have enough safety distance to any holes or hollow
spaces.
 Level the machine (Max. allowed slope is 3°). Greater slope angles overload the
rack and pinion gear of the manipulator arm and jeopardize the stability of the
machine.
 The supporting girder and hydraulic supports must be locked mechanically.
 Always set up the machine in proper position by adjusting the support legs.
 Support legs must always be observed during extension. Support the
manipulator as required and readjust. The deformation on the chassis caused of
the various positions of the manipulator arm must be overcome by adjusting the
support legs and making them stand stable on the ground.
 The manipulator arm may show malfunction and irregularities if the wind speed
passes 50 kph.
 Close all shutoff valves of the outrigger hydraulic system after it has been
installed.
 When the pumping is completed, place the manipulator to its parking position. If
the concrete spraying was performed by means of diesel drive, set the PTO to
driving position and take measure to prevent any unauthorized use of the
machine, for example: lock the door of operator’s cabin.
 Stop the engine even when leaving the machine for a very short time.
 All support legs must be retracted before moving the machine.
 It is NOT ALLOWED to move / drive the machine while the manipulator arm is
extended.
5.3. Storage of the Concrete Spraying Machine

If the machine will be idle for more than 6 months carry out the following procedure.
Make sure that the controllers are at neutral position. Carry out a general visual
inspection on the machine. Observe the instructions below if the machine will not be
used for a long time.
 Clean all painted surfaces. Re-paint the surfaces with damaged paint.
 Fill up the hydraulic tank completely.
 Cover all non-painted surfaces using proper materials for protection.
 Make sure that the hopper is clean and there are no remnants of concrete inside
it.
Required Equipment;
Spray: An air compressor with spraying equipment can be used to secure the engine.
The nozzle should be suitable for spray or fog variations. The outer parts of the engine
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OPERATING MANUALS
are cleaned by spraying method and the hard-to-reach parts are cleaned by fogging
method.
Paint: Most of the equipment except the parts of the engine can be protected up to two
years by high quality paint. It is mandatory to clean the surface thoroughly before
applying paint.
Plastic Bags: Use dark colored or black plastic bags. Light colored plastic bags decay
in time.
Sealing Tape: Use a 5 cm wide sealing tape with high stickability. Pipe sealing tapes
become loose in a short period of time.
Wax cloth Covered with Tar: Use this kind of protective material when needed.
Oils: Use the oils recommended in this manual.
Greases: Use a multi-purpose grease compliant with the MIL-M-7866 standard that
contains 3 to 5 percent molybdenum disulfate.
Filters: See the spare parts manual.
Antifreeze and Battery Test Device: Use these to lower the freezing temperature of the
cooling liquid and check the status of the battery.
Volatile Oil: Volatile corrosion preventing oils can be used on all tanks such as engine
crankcase, fuel tank, hydraulic tank, transmission oil reserve, steering oil tank and
differential. It prevents rust and enriches the oil. It can be used with every kind of petro-
chemical product. Apply it with the spraying method.
Diesel Fuel: The leftover fuel in in the fuel tank and the injection system is the cause of
breeding of small organisms that cause jamming of the fuel filters, corrosion, stutter of
the fuel pumps or disengagement of the injectors.
Engine;
Cylinder surfaces, segments, main and branch bearings, crankshaft and gears will lack
oil if the engine is not used for a long time. Lack of oil on those parts will cause contact
with air which will lead to corrosion.
In order to keep the moist from damaging the engine parts, volatile anticorrosion oil
should be used. This oil vaporizes and condenses on the inner surfaces of the engine.
This protects the unreachable surfaces of the engine and the allows the engine to be
cleaned and made ready to get back to operation. The condensed layer on the inner
surface can be cleaned by starting the engine and making it reach to the regime (work)
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OPERATING MANUALS
temperature. The leftover mineral oil is evacuated and the engine oil and the oil filter is
changed.
Wrap the air filters with dark coloured plastic bags, seal it with the sealing tape and
install it back. Install the cap of the filter cover. Seal all gaps and spacing on the engine
to prevent the volatile oil from leaving the engine.
Measures to Take for Idle Machine up to a Year;
To cleanse the fuel system from water and dirt, disassemble the main fuel filter. After
emptying the fuel inside the filter and the filter body, assemble the filter back. Open the
evacuation valve of the fuel tank and empty the water and dirt in the tank. Isolate the
fuel tank. (Note: All gaps such as air suction, exhaust, flywheel body, engine crankcase
ventilation, engine oil stick should be isolated after the caps have been closed. Make
sure that all the caps are tightly closed and waterproof. The insulation tape should be
water-resistant and weather-resistant. Do not use pipe insulation tapes for this purpose.)
Disassemble the battery, keep it in a battery room where it’s periodical maintenance can
be carried out and it can be charged.
Loosen all straps.
Cover the engine with a waterproof material. The cover blocks air circulation and
prevents condensation. The cover must stay put. Put a tag on the engine indicating the
securing date of the engine.
Check the engine in 2 or 3 months periods. If a sign of corrosion is detected, repeat the
securing process.
Cooling Systems;
Evacuate all liquids in the system by opening all taps if the storage temperature of the
machine may drop below the freezing point. Any remaining liquid in the system may
cause cracks. Take the necessary precautions and make sure all liquids have been
evacuated.
Start-Up of the Engine;
 Remove all covers, bags and protective tapes.

 Change the engine oil and all oil and fuel filters.
 Check the straps, change if necessary.
 Cleanse the engine from dirt, rust, oil and clean the engine.
 Fill up the cooling liquid.
 Fill the fuel system with diesel fuel.
 Clean the air filters. Check the filters and leak-proof elements.
 Change the engine oil and filters.
 Open the rocker lids before starting the engine. Oil the cam shaft and the valves
with engine oil to prevent them from getting damaged.
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 Manually turn the crank shaft and check if there are any hydraulic lockdowns or
friction.
 When the engine is intended to be taken back to work, there will be wearing on
the inside until the engine oil reaches all surfaces of the interior of the engine due
to the friction between the engine parts. To minimize the wearing, cut the fuel and
keep pressing the ignition until the engine oil pressure becomes normal. Start the
engine only after the desired oil pressure is reached.
 Check all the hoses and change if necessary.
 On the first work day of the engine, check the operation of the engine or any oil
leakages.
Pressurized Oiling;
It is very important for the engine to be oiled in the first couple of seconds after start-up.
Operation without oil can cause bearing malfunctions in the engine. Thus the oil must
be pressurized.
Starting the engine After Storing;

Before starting the machine it should be ensured that the right levels of pressure and
temperature are established for oiling, cooling and fuel systems. Check the functionality
of the oil flow control devices to make sure that there is no leakage in any of the systems.
1. Produce oil pressure by pressing ignition without supplying fuel to the engine.
2. Keep the engine working at idle for 10 minutes.
3. Keep the engine working at ¾ rounds at 50 % capacity for 15 minutes
4. Keep the engine working at full rounds, with 100 % capacity for 30 minutes
5. Strictly observe all systems and check for leaks.
The Machine;
Complete all maintenance procedures stated in the manual before securing the machine
in storage.
Never store the machines with electrical parts in open areas. Humidity may cause cable
insulation and contacts deteriorate and fail. Electrical parts become dysfunctional when
they are oxidized. Never leave the batteries under sunlight. The heat empties the battery
and shortens its life.
Storing the Machine (Up to a Year);
 Complete all controls on the operation of the machine. Check the whole hydraulic
system. Complete the required repairs.
 Install all attachments of the machine and operate.
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 Put the attachments down to the ground and check the hydraulic oil levels. Bring
the levels to normal if they are above or below. Do not disassemble any hydraulic
line without decreasing the pressure first.
 Cleanse all the surfaces of the machine from oil, dirt and mud thoroughly.
 Clear out all rust. Re-paint all the surfaces with damaged paint using high-end
paints. Painting and cleaning, when applied right, will provide two years of
protection.
Caution:
Do not paint the surfaces listed below.
 Corrosion proof materials (plastic, machine tags)

 Moving parts and electrical connections
 Command valve systems and shaft surfaces
 Refined montage surfaces
 Surfaces which may counteract the maintenance and operation of the machine
or the hydraulic system
 Park the machine on the storage area. Balance the machine by putting blocks
under it. Any attachments capable of storing water like excavators and dump
trucks must be positioned and stabilized with the intention of evacuating the
water. Disassemble the tires and rims of the machine if there are any. Store the
tires and rims properly.
Caution:
DO NOT USE Titan IS21 Concrete Spraying Machine apart from its production
intentions.
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6. TECHNICAL DATA
The machine consists of treading system, operator cabin, hopper group, compressor,
concrete delivery line, hydraulic parts, the manipulator, hydraulic cylinders and
automation system all assembled on steel constructed chassis. See spare parts for
further information.
The machine is 4-wheel-drive and has 3 steering options. Crab walk, normal and
manoeuvre mode. See Steering Modes for further information.
The machine runs on a diesel engine. The power output of the engine is used both for
hydraulic power and mechanical horizontal movement power. The machine has
electronic transmission. The automatically chosen gear for the tread transfers the
rounding to the transmission output.
The power is distributed to the axles through front and rear shafts and a dropbox after
the transmission. The same time the electric from electrical network of the city is used
to deliver power to various systems through the electric engine.
The electric engine supplies power to the compressor. The compressor produces
pressurized air and enables the concrete to be pumped. The electric engine also
supplies power to the hydraulic pump. The hydraulic pressure output is used to move
the hydraulic arms, brakes, steering system and the boom which holds the pressurized
concrete hose.
The brake system either works on springs or hydraulic oil depending on the axle type
on the machine. The voltage required for the electric engine to function, which is
supplied from the electric network is 380V. There exists an electrical panel on the
machine to ensure the safe usage of this voltage.
A cable roll is present on the chassis of the machine to deliver the current from the
electrical network to the machine. The cable on the roll is supplied to be durable to the
voltage load. The cable winding works hydraulically. The mechanism winds or loosens
the cable depending on the tension.
The additive tank has a capacity of 1000 lt. The additive in the tank is sent to the
concrete mix by a pump. The pump is powered by a 1,1 -2 kW electric engine. Voltage
of this engine is supplied from the electrical panel.
The concrete poured on the grill of the hopper passes the grill and falls down on the
hopper by the help of the vibrator on the grill. Then the concrete is pumped to the
spraying hose by concrete delivery cylinders. The concrete, mixed with the additive is
sprayed with pressurized air.
The movement of the concrete hose carrying boom is produced by hydraulic cylinders
and a winding gear.
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To ensure the efficiency of the work, steering system can pivot 180 degrees in the cabin
to face towards the back of the machine. Safe manoeuvre ability is provided this way
while moving backwards.
The steering system works by the direction of hydraulic power towards steering
cylinders and these cylinders positioning the wheels.
Warning and danger signs concerning the operator are projected on the panel in the
cabin, with or without sound.
6.1. Chassis
It is the main frame that carries the manipulator arm, the engine, the cabin and all other
equipment located on the machine. It has carrier properties and durable to hard working
standards. In other words, it is the main load-bearing structure of the machine.
Fig. 52
The chassis is manufactured as a box profiled. It can work under coarse conditions such
as underground mines and construction tunnels. Placement of the loads are arranged
to reach the optimum weight distribution on the chassis. The system parts and plates
are attached on the chassis either by welding or bolting.
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6.2. Diesel Engine

JCB Dieselmax T2/T3 Diesel Engine, water cooled 85 kW Tier 3 / Stage 3A approved1
Max. Power : 85 kW (114hp) at 2200 rpm

Max. Torque : 440 Nm at 1300 rpm
Diesel Tank : 140 l
The JCB diesel engine is a turbocharged 4 cylinders engine.
JCB Dieselmax Engine Tier 3 is a liquid cooled engine. The liquid cooling system
prevents overheating and any damage to the engine or any of its components
originating from heat. The cooling liquid is half water and half anti-freeze. The cooling
liquid capacity is 20 liters.
Fuel standards are indicated in the JCB engine catalogue.
The exhaust system is equipped with a catalytic convertor. Thus the pollution of the
exhaust gasses are reduced. To decrease the sound from the engine, there is an
exhaust suppressor.
Fig. 53
6.3. Transmission
A hydraulic transmission is used to transfer the engine’s power to the shafts.
Transmission has a torque convertor, gearbox and disk shoe groups.
The gear selection from the gear stick is delivered to the solenoid valves on the
transmission through electrical current.
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The pin inside the electrically activated solenoid valve moves. Transmission oil is
directed as a result of this movement. The oil presses correspondent speed’s disk and
shoes inside the transmission box. Thus, wished rounds are transferred from the
transmission to the shafts.
The torque converter regulates the machine torque without levelling. It compiles of a
propeller, turbine, stator and transmission fluid. Engine transfers its power to the
propeller. Propeller pushes the transmission oil to the turbine. The turbine is connected
to the output shaft. Turbine delivers hydraulic power to the transmission. Stator is
located between the turbine and the propeller and directs the oil from the turbine to the
propeller for circulation.
 Powershift
 Automatic and manual 4-speed forward
 Manual 3-speed reverse
 Four-wheel drive
Fig. 54
6.4. Axles & Shafts

The torque obtained from the transmission is transferred to the axles. A transfer box is
used to deliver the movement to the front and rear axles. Shafts deliver the movement
from the transfer box to the axles.
Axles are the systems that transfer movement to the tires and include differential and
brake groups. Axle group includes both hydraulic oil and spring pressure lowered
braking system
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With operator’s will, when the steering wheel is turned, axles direct the incoming oil with
orbital valve pressure. According to the direction selected, hydraulic oil is sent to the
hydraulic cylinders attached to the axle. Hydraulic cylinders puts pressure on the wheel
chassis and turns it.
Axle Type : Planetary

Make/Model : JCB
Front axle : ±8° oscillating and steerable
Rear axle : Rigid and steerable
Tyres : 12.5-20
Steering : 4 wheel steering, crab steering, 2 (front) wheel steering
Fig. 55
6.5. Braking System

Within the axle equipment, there are oil bath type disk brake packs for both of the drive
shafts in drive seats. Brakes work hydraulically. The output pressures of the brakes are
different from each other. A malfunction on any of the brakes does not affect the function
of other brakes.
The machine also has a parking brake. Parking brake works with spring cylinders. When
the brake is released, oil flows from charge valves to spring cylinders and disable the
brake.
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Service brake : 4 wheel disk brakes in oil bath

Parking brake : Spring applied hydraulic released
Fig.56
Caution: 1
To disable the parking brake;
2
- Unscrew the bolt (1).
- Replace the bolt (1) with a tall bolt (2)
- Screw the tall bolt (2).
Fig. 57
6.6. Operator’s Cabin

The operator cabin is designed for the convenience of the operator with 180° pivoting
ergonomic operator’s seat and wheel, adjustable seat belt, beacon lamp, controllers for
all driving controls, optional air conditioning and wide line of sight. The cabin is FOPS
(Level 2)-ROPS certified. It is equipped with a reverse operation capable seat to provide
extended maneuver and driving capabilities.
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OPERATING MANUALS
The cabin seat’s pivoting ability enables high maneuver and driving capability. The seat
can be rotated by pressing the pedal under the seat console. Steering control is
automatically adjusted according to the reversed seat.
The operator’s cabin contains a dickie seat which allows transporting two persons at
the same time. (Fig. 60) (optional)
Fig. 58 Fig. 59 Fig.60
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6.7. Manipulator Arm (Manipulator Group)

It is the manipulator that consists the vertical arm, the main arm and telescopic
extension. It can rotation 270 degrees. The arms are controlled by the operator.
Direction control valve blocks enable lifting, tilting, rotation, turning and angle adjusting.
Load check valves, located on the hydraulic cylinders are used to block the oil from
leaving the cylinder unintended and ensure safety. Parts of the manipulator are welded
constructions. Telescopic extensions are polyamide bearings.
The main arm that is fixed on the vertical arm by a joint is moved by the cylinder that is
connected from the pipe head to the vertical arm and from the rod end to the main arm.
Manipulator extension data:

 Horizontal reach: 9,2 m
 Vertical reach: 7 m
 Reach data may vary according to the manipulator.
Fig. 61
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OPERATING MANUALS
Fig. 62
Vertical Arm;
It is fixed on the rotation gear and makes the manipulator group rotate 270° around its
axis. The rotation gear is driven by the rack and pinion gear, and the rack and pinion
gear is powered by the hydraulic power, generated from the hydraulic pump.
Extending the Manipulator Arm;
Manipulator arm is operated through the control levers or the remote controller.
 Raise the main manipulator arm by 30° at least, remove from the guiding.
 Rotate the manipulator arm to a full radial turn.
 Make sure that the hoses can move freely.
 Extend the telescopic manipulator arm, adjust the appropriate distance.
 Perform all movements before pumping concrete.
6.8. Hydromotors
Torque power of the electric motor is transferred to the pump. Pump sends oil to the
hydromotor. Oil starts the movement of hydromotor on the concrete input hopper,
located in the back of the machine. Hopper vibration is achieved this way. Nozzle
rotation and nozzle tilt operations are also held by torque motors. These motors ensure
the equal concrete distribution to the spraying area by moving the nozzle head.
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Fig. 63 Fig.64 Fig.65
Hydromotors on the machine;
 Water pump
 Hopper hydromotor
 Vibrator hydromotor
 Cable reel hydromotor
 Robot hydromotor
Fig. 66 Fig.67
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6.10. Technical Data

Concrete Pump:
Abrasion resistant concrete delivery cylinder specifications;

Max. Capacity : 34 m³/hour (Theoretica)
Max. concrete pressure : 60 bar
Max. hydraulic pressure : 240 bar
Power : 55 kW at 400V-50 Hz
Concrete cylinder : 180 x 1.000 mm
Concrete line diameter : 5”-4”-3 ¼”
The concrete pump can pump concrete with slump values up to 8-10 with the self-
provided pressure.
Dosing System;
Hose pump, adjusting the flow rate, driven by the electric engine with frequency
converter;
Power : Electric driven – 1,5 kW
Maximum Pressure : 8 Bars
Maximum Flow Rate : 600 lt/hour
Additive Tank : 1.000 l
Water Hose Reel and Pump;
Manual hose reel;

Hose length : 10 m
Hose diameter : 3/8”
Water Pump : 16 lt/min., 180 bars
Titan Rigid Chassis;
Type : Rigid, high strength steel

Front Stabilisers : 2, extendible
Rear Stabilisers : 2, fixed
Compressor;
Electric driven screw compressor;

Flow rate : 10,3 m³/min.
Normal operating pressure : 6 bars
Electric motor : 55 kW
Cooling fan motor : 1,5 kW
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OPERATING MANUALS
Remote Control;
Following functions may easily be controlled via cable remote control having 15m cable
length.
Performance;
Maximum gradient : 40%

Maximum speed : 24,5 km/h
Inner Turning Radius : 3.300 mm
Outer Turning Radius : 6.600 mm
Electric System;
Alternator : 12V-95 A
Battery : 12V-150 Ah
Protection : IP 65
Driving Lights : 2 x Halogen 55W headlights/ 2 x Halogen 55W taillights
Turn signals and back-up light.
Cable Reel;
Drive : Hydraulic
Power : 400V, 50 Hz,
Cable : 3x70 + 35 mm²
Cable length : 50m
Dimensions & Weight;
Width : 2.000 mm
Length : 7.950 mm
Height : 2.800 mm
Dry Weight : 11.500 kg
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OPERATING MANUALS
7. LAYOUT PLAN AND TECHNICAL DRAWINGS
7.1. Dimensions
Fig. 68
Fig. 69
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OPERATING MANUALS
7.2. Turning Circle Diameters
Fig. 70
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OPERATING MANUALS
7.3. Steering Positions
Fig.71 Fig.72 Fig.73
 Machine is assisted by means of load-sensing power steering with double

displacement on 4 steering wheels and steering selection device for:4 wheel
drive, 2 (front) wheel drive and crab steering mode.
1. 4–wheel drive with the rear wheels in the opposite direction to the front ones.
(Fig.71)
2. 2 (front) wheel drive. (Fig. 72)
3. Crab steering mode the same steering angle on the front and the rear wheels.
(Fig. 73)
 To check the current type of steering, panel should be used given in Fig. 74.
Fig. 74
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OPERATING MANUALS
7.4. Manipulator Arm Spraying Range
Fig. 75
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OPERATING MANUALS
8. USE OF CONTROL PANEL AND STARTING THE MACHINE
8.1. Front Console Panel
1 2 3 4 5 6 7 8
Fig.76
7 8
1
0000 Battery Charging 6 Engine Overheating
2 Engine Oil Pressure 7 Transmission Temperature
3 Transmission Oil Pressure 8 Engine Air Filter
4 Parking Brake
5 Fuel Filter Indicator Lights
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OPERATING MANUALS
9 10 11 12 13 14 15 16
Fig.77
9 Turn Signal (Left) 15 High Beam Indicator
10 Service Brake Pressure 16 Turn Signal (Right)
11 4 - Wheel Drive
12 2 (front)- Wheel Drive
13 Crab Steering Mode
14 Engine Pre-heater
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OPERATING MANUALS
8.2. Control Lever (Left)
17 18
Fig.78
17 Horn Button 18 Gear

17
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OPERATING MANUALS
8.3. Control Lever (Right)
22
19 21 22
20
Fig.79
19 Left-Right Turning 22 Windshield Washer Fluid

Indicator Signal
20 21 Windshield Wiper (On/Off) Controller
Windshield Wiper:
 Used to clean.
 Wiping will not be effective unless wiper blade is clean and in good
condition.
I-position: Windshield wiper is on.
0-position: Windshield wiper is off.
Windshield Washer:
 A dirty windshield can block your view and potentially lead toan
accident.
 When the wiper blade spreads deposits on the windshieldand smearing
occurs, use the washer.
Push the botton for windshield washer fluid.

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OPERATING MANUALS
Fig.80
23
23 Headlight
Move the lever up to turn on the headlights and move it down to turn off.
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OPERATING MANUALS
8.4. Side Console Controllers

30
24
32
25 26 27 28 29 31
Fig. 81
24 Hand Throttle 29 Heater
25 Fuel Tank 30 PTO input-output
26 Engine Tempreture 31 Cabin Headlight
Steering Mode 32 Parking Brake

27
Selection Switch
28 Beacon Lamp
Page 71 / 129
OPERATING MANUALS
8.5. Stabilizers Control
33 Left Front Stabilizer
34 Right Front Stabilizer
35 Right Back Stabilizer
36 Left Back Stabilizer
33 34 35 36
Fig. 82
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OPERATING MANUALS
8.6. Hopper Control Levers
39 39
37 38
Fig. 83
37 Vibrato - Water Pump
38 Hopper Shutter
39 Mixer
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OPERATING MANUALS
8.7. Manipulator Control Levers
40 41 42 43 44
Fig. 84
Manipulator Arm Rotation

40
Manipulator Arm Up/Down
41
Telescopic Extension
42
Nozzle Rotation
43
Nozzle Tilt
44
Page 74 / 129
OPERATING MANUALS
28
8.8. Electrical Panel
45 46 47
24
48 49 50 51
52 53 54 55
56 57 58 56
Fig. 85
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OPERATING MANUALS
45 Compressor ready to running.
46 Compressor: 0 – compressor stop.

I - compressor start.
47 Ready: the system is ready to running.
48 Working Hours: It shows working hours.
49 Panel – Remote Control: To choose panel or remote control.
50 Additive: 0 - additive off.

I – additive on.
51 Temperature Gauge: It shows hydraulics oil temperature.
52 Emergency Stop
53 Concrete Pumping - Reverse
54 Fan: 0 – fan is off.

I – fan is open.
55 Oil Temperature: When hydraulic oil temperatures above 70°C, the
lamp is light.
56 Pump Stop: The light turns on when the pump stops.
57 Pump Start: The light turns on when the pump starts.
58 Working Lights: Manipulator and hopper’s lights.
59 No Oil: When hydraulics oil drops blew the minimum level, the
warning light turns on. The electric motor shuts down.
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OPERATING MANUALS
9. MAINTENANCE INSTRUCTIONS
All maintenance and repair work on the machine including lubrication of machine
components, periodic check-ups and maintenance, replacement of defective parts,
demounting and replacing of machine components during maintenance must be
performed by authorized and qualified personnel.
Daily routine check list for the operator:
Outer: Check the tyres, oil levels, wheels, lamps and wipers.
Inner: Check the hand brake, indicator panel, rear view mirror, brake and throttle pedals.
Please refer to maintenance table for further information.
Warnings for the Controller, Operator and Maintenance Personnel
Working within the Limits;
All personnel concerned with the operation of the machine must observe the rules and
warnings noted in the operating and maintenance manual.
Operating and Maintenance Measures;
Specific operating and maintenance measures stated in this manual should be strictly
observed.
Welding Measures;
Turn off the switch located inside the engine cabin prior to any welding job on the
machine. Make sure that the welding current is applied to this area and other
components are not affected / damaged by the current.
General Measures and Control;
The operator of the machine and other personnel must strictly observe the following
measures in order to prevent any damage to the machine or the personnel.
1- Always perform the daily routine check prior to starting the machine for the first
time during the day.
2- Check for any improper or defective hose and pipe joints, electrical and hydraulic
system, direction control blocks prior to operation. Check the diesel engine if the
operation will be carried out with diesel power.
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OPERATING MANUALS
3- Use the control lever gently, do not switch lever direction before ensuring that it
is in the neutral position.
4- Do not move the manipulator arm without stabilizing the machine using support
legs.
5- Never make sudden movements / turns especially during operation and always
be aware of the surrounding area.
Maintenance and Repair;
Carry out the maintenance regularly and without any delay. Do not alter the pre-set
pressure and flow rate settings of the hydraulic pump and the valves. Do not break the
seals of pressure relief valves. The welding works on devices, hydraulic jacks, chassis
or platform, any part of the pump or pressurized parts may only be performed by
authorized service staff of Titan or by authorized and qualified personnel with the
permission and knowledge of Titan.
Working Area;
The operator is responsible for the entire work area and should be able to see and
control the entire work area. Always take any measure required to avoid possible access
to the machine by unauthorized personnel or unintentional movement of the machine
while leaving the work area.
Close the work area to traffic and pedestrian access as per the rules in effect.
In case of overheating;
1. Stop the pump.

2. Do not stop the engine. The oil cooler must continue running.
3. Replace the hot water inside the water tank with cold water.
4. Run the pump when the red colored warning indicator light becomes off.
Run the pump with low speed.
5. Examine the reasons of overheating after the operation of the pump ends.
 Prior to stopping the machine, cool the system for a while by running the engine
out of gear if the machine has been operated in hard conditions.
Caution:
 Be careful with the low clearances,
 Never forget that the machine you are driving is an earthmoving machine,
 Do not attempt to enter or turn in any bridge if there is not enough span.
 Be careful with the fans and ventilation ducting.
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OPERATING MANUALS
Pumping;
Heat up the hydraulic oil before pumping. This action may only be performed while
various systems (pump and manipulator) are idle running.
Prior to start pumping, place 2 sponge balls into the pipe line, run the hopper mixer and
put concrete and water in order to make sure that the manipulator line is completely wet
with cement grout. Turn on the pump and keep it on until a well mixed concrete comes
from nozzle head. Take the sponge balls. A new and long delivery line creates a big
resistance, therefore use enough of cement mortar. Run the concrete cylinders for a
couple of times and switch on the mixer.
Mix the concrete inside the transmixer truck with highest speed until obtaining a well-
mixed concrete. Pour the concrete into the hopper and continue pumping with the
concrete pump. If the level of concrete is too low (Under shaft of the mixer) the pumps
sucks air into the concrete delivery cylinders.
If the inside of delivery line is rusty to create high resistance, pump a couple of m3 of
concrete slowly, and then increase the pumping rate gradually. In case of a blockage,
take the concrete back into the hopper by suction and remix.
Continue pumping while observing for any irregularities.
Reasons for Concrete Line Blockage;
 The cement grout is too viscous.

 Leakage in the concrete line.
 Leakage in the pipe line.
 Residue concrete in S-tube or delivery line
 Concrete mix is not suitable for pumping.
Cautions on Concrete Pumping;
 While pumping concrete with weak pumping characteristics, the mixer shaft
should be visible. The undesired concrete (such as too coarse mix, mix with lack
of sand, light concrete) can be delivered easier if the level in hopper is up to the
bottom sides of the mixer shaft. By using this method, the concrete pump sucks
air into the concrete in delivery cylinders and thus the concrete delivery carries
out by padding method.
 Release the pressure in the delivery line by suction for a short time during stand
by. From time to time, pump forward and backward for a short time.
 Never make the concrete delivery line idle while pressurized.
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OPERATING MANUALS
 While working with fluidal concrete including high content of coarse aggregate
(subject to segregation), keep the concrete level in hopper as low as possible
while idle.
 On long waiting periods during operation, take the concrete back to the hopper,
remix and pump again.
 In order to prevent segregation of concrete during long waiting periods, turn off
the drive engine, run with intervals of 10-15 minutes and move the concrete
forward and backward. Never pump segregated, hardened (setting) or
coagulated concrete.
 Make sure the air pressure is correct and there are no leaks
 Accumulated air in the line is dangerous. The compressed air exits the line with
a blast and scatters the concrete. These air packets are mainly caused of low
filled hopper, the air sucked while starting to pump or the gaps that occur while
replacing a pipe.
 If the temperature exceeds 65° during continuous pumping or pumping with long
periods, empty the water tank immediately and fill with cold water. Continue
adding water if the temperature cannot be stabilized.
Examine and repair the reasons of overheating. Thermostat and cooling radiator
engages when oil temperature exceeds 55°.
 Never inject / spray water into the oil tank. If water is sprayed into the tank,
the moisture of the air that is condensed in the oil tank turns into water and
damages the pumps. In exceptional cases that require extra cooling, the delivery
cylinders may be cooled by spraying water.
 All pumps are equipped with thermo electrical switches. The pump stops
automatically and the warning indicator on electrical panel lights if the oil
temperature exceeds 70°.
In case of overheating;
6. Stop the pump.

7. Do not stop the engine. The oil cooler must continue running.
8. Replace the hot water inside the water tank with cold water.
9. Run the pump when the red colored warning indicator light becomes off.
Run the pump with low speed.
10. Examine the reasons of overheating after the operation of the pump ends.
 Prior to stopping the machine, cool the system for a while by running the engine
out of gear if the machine has been operated in hard conditions.
 If the manipulator starts to oscillate during pumping, make sure that the machine
is positioned properly (All four support legs must step on the ground securely and
must be stabilized). Readjust the support legs and level the machine again if
necessary.
 Change the pumping speed if the machine has already been positioned properly.
(Usually a decrease is necessary).
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OPERATING MANUALS
Cleaning;
 Mixer and S-Tube does not run if the grid is removed. Place the grid, run the
pump for a few strokes and lift the grid again.
 Open the hopper shutter to remove the residue concrete inside the hopper. S-
Tube, hopper delivery cylinders and water tank must be cleaned with high
pressure water. Clean the machine entirely, then apply oil and kerosene mixture
in order to provide an easy cleaning after the next pumping operation.
 In case of risk of freezing, empty the water tanks, water pump, additive tank and
dosing pump. Empty the water tank also when the machine will not be used for
a specific time interval (throughout the night, in the weekends etc.).
Cleaning with High Pressure Water;
The cleaning of the machine with high pressure water is one of the best proven
methods.
1- Continue pumping until the concrete in the hopper is pumped out. Suck for a few
strokes in order to release the pressure in the line.
2- To remove the residue concrete; open the hopper shutter, open the bend with
lever joint which is located at the output of the S-Tube.
3- Run the concrete pump in suction mode. Wash the inside of S-Tube with high
pressure water. Clean the S-Tube and the delivery cylinders.
4- Place the cleaning ball into the bend with reduction. Make sure that the ball leans
the concrete inside the delivery line.
5- Close the bend with lever joint. Fill the hopper with water. Start pumping wait until
the ball is out of the concrete line.
6- Do not damage the seals of the mixer shaft while cleaning the hopper.
7- Do the cleaning also for the additive line,
- Close the additive valve located on the dosing pump and open the water
valve,
- Close the water valve when clean water comes out from the nozzle.
Preparing to Drive;
Place the manipulator to its supporting guide, release the support legs and take all
safety measures indicated in the manual to drive the machine. Secure the nozzle. Tie
up all loose components. In diesel driven models, separate the PTO from the gearbox
if concrete pumping is performed via diesel drive. Always keep in mind the total height
of the machine and the centre of gravity which is at a high point.
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OPERATING MANUALS
Caution:
 Before driving, check that the valves of the manipulator and the support legs are
closed. All switches must be pointing 0, the fixing apparatus must be locked and
secured.
 Be careful with the low clearance heights,
 Never forget that the machine you are driving is an earthmoving machine,
 Do not attempt to enter any bridge or turn if there is not enough span.
 Be careful with the fans and ventilation ducting.
9.1. General Maintenance

Detailed maintenance instructions are given below. Specific maintenance should be
carried out within the periods stated in the maintenance chart. Keep the concrete
spraying machine free from dirt, mud and oil for operator safety. Soiled equipment
endanger operation security and cause malfunctions.
Conduct the maintenance in accordance with the instructions. Do not attempt to make
any repair on the machine if you lack required knowledge and information. Consult Titan
for questions about the procedures or the maintenance.
We advise you to have your pump checked every 1000 th hour or once a year by Titan
Authorized Service personnel. Use original spare parts for safety. Maintenance
increases machine life and makes the machine work more efficiently.
Instructions below are mandatory to prevent any damage to the operator, workers or
the machine.
Complete daily maintenance before each machine start-up and first start-up off the day.
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OPERATING MANUALS
9.2. Before Maintenance
Any planned modification on the machine should be reported to Titan Makina. The
machine can be modified only after Titan Makina’s approval. Any unapproved
modification on the machine cancels the warranty. Improper modifications put the
workers and the work into danger. Titan Makina holds no responsibility for accidents
that generate from unapproved modifications.
All the safety rules that apply to operation are also effective for maintenance. Do not
disable or bypass any safety equipment during or after maintenance. Serious injuries
may occur if the regulations are not properly observed. Preparations required for
maintenance are listed below.
 Move the machine to a neat and clean area. Carry out the general cleaning.
 Conduct all maintenance procedures stated in this manual.
 Do not alter any settings of the machine without consulting Titan.
 Do not allow untrained or irrelevant persons in the machine operating area.
 Stop the engine prior to maintenance. Do not keep the engine running unless
required. Keep away from moving parts while the engine is running.
 Before maintenance, make sure that the tires are not damaged.
 Tire manometer and tire inflator should be calibrated.
 Hydraulic oils and the cooling liquid heats up while the machine is running. Hot
oil and liquid also heats up the components in contact with them. You may
accidentally contact hot oil and water during maintenance. Be cautious while
working on components with such risks.
 Electrical system works with 12 V. The power is supplied by means of a battery.
Disable all electrical parts before carrying out welding on the machine. The
master switch on the machine disconnects the battery for disabling the electrical
parts. This master switch must be turned off before welding.
 Turn off the master switch before cleaning the machine with water or steam to
protect the electrical parts. Avoid any contact between electrical components and
water.
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OPERATING MANUALS
Fig. 86
 Be cautious while working on components that carry, store or produce oil, water
or air pressure. These components may still be under pressure even when the
engine is not running. Lower down the pressure before handling such parts.
 Do not use over pressurized water or corrosive products while cleaning the parts.
 Use personal protective equipment during maintenance.
 Keep the machine on a flat surface during the maintenance of parts with fuel,
various oils and water.
 Any contaminating waste produced during the maintenance of the machine
should be kept in a waste storage considering the environmental factors.
 Keep the components and indicators clean during maintenance.
 Oil samples from the machine parts may provide an insight on the state of the
product.
 The maintenance instructions on this manual are prepared for machines with
standard working conditions. Shorten maintenance periods for machines under
heavy working conditions.
 Do not approach the fuel system with any flammable or incinerating materials.
Do not work on the fuel system while the engine is running when the fuel system
would be under pressure.
 Wait for at least 5 minutes after the engine is stopped before working on the fuel
system.
 Stop the engine before working on hydraulic oil and oiling system. Decrease the
pressure of pressurized points on the system. Be cautious.
 The engine is water-cooled. The cooling water may reach high temperatures
while the engine is running. Maintenance on the cooling system should be
delayed until the water temperature decreases to a safe value. Cooling system
works under high pressure.
 Do not open the water radiator case while the system is hot. Temperature of the
cooling liquid may cause severe burns.
Page 84 / 129
OPERATING MANUALS
.
Fig.87
 Water, oil and fuel levels should be kept under control at all times. Do not operate
the machine while oil and water levels are not suitable.
 Electrical system has a significant role in proper operation of the machine. Keep
the electrical parts clean and neat. Electric leakages and short circuits impede
normal operation of the machine and cause fires. Make sure to remove any dirt
before working on the electrical system.
 Check the power and voltage values of the components to be used in the
electrical system. The values must not be higher than the values of replaced
original parts.
 Use original equipment and spare parts recommended for the machine by Titan.
Ensure that the fuel is clean and in compliance wih the norms. Products and
spare parts that are not well-manufactured shorten the service life of the
machine.
9.3. Daily Maintenance (Every 10 Hours)
 Tour around the machine for a general check. The general check will provide
information on the general condition of the machine. This general check aims to
avoid major malfunctions on the machine.
 Check for any oil leakages. Gather information on the causes of oil leakages and
over accumulated grease. Prevent such accumulation and dirt and eliminate the
cause of the problem.
 Check the parts in contact with concrete, replace worn parts.
 Check the tightness of visible bolts and nuts. Tighten up the loose ones and the
ones with potential to fall down. It may be understood from the bolts whether the
looseness is due to the operation of the machine or a malfunction.
 Check abrasions on the concrete line with a hose thickness measuring device.
Change worn out hoses and similar parts. Minimum hose thickness must be 2.5
mm.
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OPERATING MANUALS
 Grease both shaft bearings in the hopper.

 Check the space between abrasion plank and S-tube after operating and
cleaning the pump.
 Grease The S-tube bearings and valve pistons.
 Check cracked or broken parts. If the parts pose a risk to health or machine
integrity, do not start the machine until the parts are repaired. If the parts do not
cause any trouble, repair the parts at the next maintenance period.
 Check any damage on the tires. The tires are under high pressure. Damaged or
worn out tires may pose danger. Check the air pressure and set the pressure
back to the normal pressure if required
 Ensure that the warning lights are working properly.
 Check the engine oil level. If it is high or low, bring it back to the normal level.
 The oil level cannot be measured while the engine is running. Wait for a couple
of minutes after the engine has stopped to check the oil levels, giving the time
required for the engine oil to get back to the reserve. The engine oil level
inspection should be carried out on a flat surface after the engine has cooled
down.
 Pull out the oil level stick. Wipe the stick with a clean cloth and put the stick back
to its place. Then pull it out again. Check the oil level over the stick. Oil less than
the minimum level is extremely dangerous. Do not start the machine before
adding up sufficient oil. (Fig. 88)
Fig. 88
 Check the coolant water. Add coolant if needed. The coolant water check
should be done after the engine has cooled down. Otherwise, hot water may
cause burns. Check the radiator panel and the coolant water installation. Make
Page 86 / 129
OPERATING MANUALS
sure there are no leakages. The air flowing through the radiator gaps cools
down the engine. A clean radiator is important for an effective cooling.
 Check the status and tension of the V strap.
 Check the oil level in the transfer box. Fill up if it is not enough.
 Make sure there are no oil leakages in the axles.
 Check the joints on the connection points of the Shafts.
 Check the transmission oil level. This directly affects the machine performance.
(Figure 89)
Fig. 89
 Check the hydraulic oil level.
Checking the Filters;
Check the front dust accumulation reservoir and its air filter. Clean the reservoir with
care and check the outer air filter. The air filter is a significant factor on the service life
of the machine and the engine.
It is not a problem to have accumulated dust in the reservoir, since the reservoir’s duty
is to hold dust. Clean the front dust reservoir if necessary. The reservoir can be cleaned
everyday if the working conditions include significant amounts of dust. The air filters are
delicate components. Air filters must be changed immediately if any damage is
detected. The dust particles, if they manage to get in the engine, will affect its
performance and functionality. Unfiltered air causes damage on pistons, piston rings,
piston shells and injectors.
Page 87 / 129
OPERATING MANUALS
Fig. 90
The chassis filter is a water separator. It enables the cleansing of fuel from water. The
fuel used on the machine must always be clean and suitable to the norms. The state of
fuel determines the performance acquired from the consumed fuel in ignition rooms of
the engine. Evacuate the water in the filter.
Fig.91
Page 88 / 129
OPERATING MANUALS
9.4. Weekly or Every 100 Hours Maintenance

The following should be carried out after the daily maintenance is completed.
 Check the axle oil level.

- Remove fill/level plug A and its sealing washer. Oil should be level with the
bottom of the fill/level hole.
- If necessary, top up with oil (see Liquids and Amounts). Clean and refit
fill/level plug A with a new sealing washer. (Fig. 92)
Fig. 92
 Check Hub Oil Level

- Make sure the OIL LEVEL mark on the hub is horizontal.
- Remove fill/level plug C. Oil should be level with the bottom of the fill/level
hole.
- If necessary, top up with oil. Clean and refit fill/level plug C. (Fig. 93)
Fig. 93
Page 89 / 129
OPERATING MANUALS
 Check the tire bolt torques.

 Check the neutral starting operation of the transmission.
 Check the battery. Keep the battery clean at all times. Measure the acid degree
by an acid battery hydrometer.
 Check the engine bracket seals. It is losing its utility if there are fractions,
deformation or drying. This situation increases the engine noise and oscillation.
Renew the seals.
 Control the return line filter. If it’s necessary replace the new filter.
Fig. 94
Page 90 / 129
OPERATING MANUALS
Fig. 95
 Check the battery. Keep the battery clean at all times. Measre the acid degree
by an acid battery hydrometer.
 Check the engine bracket seals. It is losing its utility if there are fractions,
deformation or drying. This situation increases the engine noise and oscilation.
Renew the seals.
9.5. Every 250 Hours

A The following should be carried out after the daily and weekly maintenances are
completed.
 Change the water-fuel separator filter. Engine performance is directly affected by

this filter. Evacuate the air generated in the system.
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OPERATING MANUALS
Fig. 96
 Change the engine oil. Shut off the engine and change the oil while the engine
is still heated up if possible. Disassemble the tap under the oil pan. Get the
evacuated oil to a suitable plate. Do not let the oil drip on the floor. After
closing the tap, fill the new oil from oil input part. Check the level of the oil by
the oil stick.
Ignition
Charging
engine
Oil Evacuation Dynamo
Fig. 97 Tab
 Change the engine oil filter. Disassemble the filter either by hand or filter strap.
Clean the filter cartridge with a clean cloth. Oil the filter seal and install the new
filter. It is advised to install the new filter empty.
Page 92 / 129
OPERATING MANUALS
Fig. 98
 Chage the fuel filter. Disassemble the filter either by hand or filter strap. Clean
the filter cartridge. Evacuate the air in the system. Change the engine oil. Shut
off the engine and change the oil while the engine is still heated up if possible.
Disassemble the tap under the oil pan. Get the evacuated oil to a suitable plate.
Do not let the oil drip on the floor. After closing the tap, fill the new oil from oil
input part. Check the level of the oil by the oil stick.
Starter Alternator
Motor Oil Drain Plug
Fig. 99
 Change the engine oil filter. Disassemble the filter either by hand or using a
filter strap. Clean the filter cartridge with a clean cloth. Oil the filter seal and
install the new filter. Always replace the filter with a new unused filter.
Page 93 / 129
OPERATING MANUALS
Fig. 100
 Change the fuel filter. Disassemble the filter either by hand or using a filter
strap. Clean the filter cartridge. Evacuate the air in the system.
Fig. 101
 Change the outer air filter. Disassemble the outer air filter gently. Pay attention
not to hit the filter hold or spill the dust. Do not clean the outer air filter. Clean the
cartridge. Do not damage the inner air filter. Change the inner air filter if
necessary. Carefully assemble the new filter.
 1 inner air filter is changed for approximately 2 changes of outer air filter. The
inner air filter change periods may vary according to the working conditions and
the dirt and dust released while changing the outer air filter.
Page 94 / 129
OPERATING MANUALS
Fig. 102
 Change the transmission oil filter. Disassemble the filter either by hand or using
a filter strap. Oil the filter seal and install the new filter. Always replace the filter
with a new unused filter.
 Change the transmission oil filter. Disassemble the filter either by hand or using
a filter strap. Oil the filter seal and install the new filter. Always replace the filter
with a new unused filter.
Fig.103
Page 95 / 129
OPERATING MANUALS
Caution:
Follow this picture for changing filter;
Fig. 104
Control and Change of hydraulic filter element;
The filter element is the component that effectively performs the work of filtering the oil
in hydraulic circuits.
 Daily or once in each shift control of filter element.
Fig. 105
Page 96 / 129
OPERATING MANUALS
 Every 250 hours, change the filter element.
Fig. 106
Changing filter element;
Make sure that oil line to the filter is shutt off to avoid the risk of damage or leakage of
oil. Use the correct tools to uncrew the filter head.
 Unscrew the four bolts.
Fig. 107
Page 97 / 129
OPERATING MANUALS
 Open the filter’s head.
Fig. 108
 Remove the element from the filter housing.
Fig. 109
Page 98 / 129
OPERATING MANUALS
 Replace the new filter element.
Fig. 110
 Close the filter head and screw the four bolts.
Fig. 111
Page 99 / 129
OPERATING MANUALS

The following should be carried out after the daily, weekly and 250 hours maintenances
are completed.
 Check the engine hose connections. Ensure that there are no leakages in fuel or
oil systems. Check the radiator. Repair any visible damage and clean any
accumulated dirt.
Fig. 112
 Replace the inner air filter. The inner air filter is not cleaned but replaced. After
taking the outer air filter out, gently disassemble the inner air filter. Clean the
cartridge and install the new inner air filter. Do not let dust, dirt, etc. enter the
engine air inlet.(Fig. 113)
Fig. 113
Page 100 / 129

OPERATING MANUALS

The following should be carried out after the daily, weekly, 250 hours and 500 hours
maintenances are completed.
 Change the transfer box oil.
Fig. 114
 Evacuate the oil to avoid spills on the floor.
Fig. 115
Page 101 / 129

OPERATING MANUALS
 Fill in the new oil. Be careful with the heat if the filling process is carried out while
the system is still hot.
Fig. 116
 Change the differential and traction oils. Open the oil evacuation tabs(2). Place
the machine on a flat surface. Fill the required oil and re install the tabs (1).
1 Oil filling tab

2 Oil excavation tab
Fig. 117 3 Oil level check tab
 Changing the transmission oil;

- Park the machine on a flat and solid surface.
- Shut off the ignition and stop the machine.
- Loosen and pull out bolts “A".
Page 102 / 129

OPERATING MANUALS
- Disassemble filter “B” and sealing “C”.

- Evacuate the oil in a separate tank. The oil can be hot at this stage, be
careful.
- Add new oil up to the minimum level after the evacuation is done.
- Start the machine and stop after a few seconds. Add oil until the oil level
on the stick reaches normal levels.
- Clean and re-install the filter. Change the seal with a new one during
assembly. Tighten bolts “A” with 10 Nm torque.
Fig.118
 Changing the transmission filter;

- Loosen and pull out the bolts.
- Change the filter with a new one.
- Tighten the bolts back at ¾ tension after installing the new filter.
 Changing the differential oil;

- Remove fill/level plug A and drain plug B, together with their sealing
washers. Allow time for the oil to drain out.
- Clean and refit drain plug B with a new sealing washer. Tighten to 90
Nm (66 lbf ft).
- Fill the axle with oil (see Lubricants and Capacities) through the fill/level
hole A. Oil should be level with the bottom of the fill/level hole.
Page 103 / 129

OPERATING MANUALS
- Clean and refit fill/level plug A with a new sealing washer. Tighten to 90
Nm (66 lbf ft).
Fig.119
 Change Hub Oil;

- Set the machine level, with the tyres just clear of the ground. Manually
rotate the wheels to bring the OIL LEVEL mark on the hubs to the vertical
position, with the fill/level plugs C at the bottom.
Fig.120
Page 104 / 129

OPERATING MANUALS
- Remove fill/level plugs C. Allow the time to pass for the oil to be drained
out.
- Set OIL LEVEL marks to the horizontal.
Fig.121
- Fill the hubs with oil (see Lubricants and Capacities), through the fill/level
holes C. Oil should be level with the bottom of the fill/level hole.
- Clean and refit fill/level plugs C.
9.8. After Maintenance
Re-install the protective and safety equipment disassembled during maintenance and
repair.
If a loading test is required, the test must be conducted at maximum capacity.
9.9. Changing the Wheels

Caution:
Before proceeding, always read the safety regulations for the operations to be carried
out as mentioned on previous pages.
Page 105 / 129

OPERATING MANUALS
Caution:
Wheel maintenance and replacing are crucial and dangerous operations. So Titan
advises these operations to be carried out by an authorized dealer or skilled personnel
if the conditions are suitable.
To change the tire, the following procedure should be observed:
1. Engage the parking brake.

2. Shift the gear selector to neutral.
3. Turn off the engine and then remove the ignition key.
Forward
Neutral
1 2 Reverse 3
Fig. 122 Fig. 123 Fig. 124
Caution:
Changing a tire on a slope or near canals is prohibited to avoid the machine to overturn
and cause serious injuries.
Ensure that the surface where the operation is performed on is solid and flat.
Wedge position under the wheel should be set diametrically opposite to the one that will
be changed.
Page 106 / 129

OPERATING MANUALS
Fig. 125 Fig.126
Equipment listed below are required to change or replace the wheels:

 Trolley
 Axle stand (under the drive axle), (2 x 6tons)
 Jack, 15 tons
 Torque wrench, (630 Nm)
Jack up the machine after ensuring that the drum is empty while parking. Also ensure
that there are always 3 wheels resting on level and solid ground. Place a wedge between
the oscillating axle and the chassis.
Caution:
The front axle oscillates and there is a risk of crushing your limbs between the axle and
the chassis during lifting. Incorrect jacking up may also cause the machine to overturn,
posing a grave risk to anyone working in the vicinity.
Make sure that the area underneath the jack can support the entire weight of the
machine.
Page 107 / 129

OPERATING MANUALS
A
B
Fig. 127
In the figure above, A is the jack and B is the axle stand. In this step first of all the jack
(A) must be fitted under the central body. Then slowly jack up the machine until the arch
rests on the chassis, then continue jacking up slowly until the deflated tire lifts off the
ground and then proceed with repairing it.
Throughout the tire changing or repairing process; weight of the machine should be
supported with axle stand (B).
Page 108 / 129

OPERATING MANUALS
Fig. 128
After fitting or changing the wheel, tighten the nuts. Ensure that the torque value of the
nuts is 630 Nm using the torque wrench.
Fig. 129 Fig. 130
To replace the rear tires, fit jack (A) and axle stand (B) as shown below. Then follow the
same procedure for the front tires.
Page 109 / 129

OPERATING MANUALS
B
Fig. 131
Page 110 / 129

OPERATING MANUALS
9.10. Replacement and Adjustment of Parts
9.9.1 Replacement of Hydraulic Cylinder
Fig. 132
Remove of Hydraulic Cylinder (6); (Fig.132)
1) Discharge the water tank by opening the water discharge valve.

2) Remove the water tank cover bolts (1).
3) Close of the hydraulic cylinder(6).
4) Disassemble the connecting clamps (7) that connect the hydraulic cylinder to
the concrete block.
5) Remove the hoses (8-9) on the hydraulic cylinder.
6) Remove the bolts on the sheet bar that connects the hydraulic cylinders.
Remove the plate (5).
7) Remove the cylinder by removing the bolts (10) around the roller.
Page 111 / 129

OPERATING MANUALS
Installation of Hydraulic Cylinder

1) Screw the bolts (2) by fitting the cylinder in place.
2) Screw the plate (5). Tighten the bolts (4).
3) Install the cylinder's hydraulic hoses (8-9).
4) Install the clamps (7) connecting the hydraulic cylinder (6) to the water
discharge flange.
5) Fill in the water tank with water. It is recommended to add additives (soap,
oil, ...) in order to provide lubricity in the water.
6) Tighten the bolts (1) by closing the water tank cover.
9.9.2 Replacing the Concrete Delivery Cylinders (Chromium Bushing)
Fig. 133
Page 112 / 129

OPERATING MANUALS
Remove of Concrete Hydraulic Cylinder (10); (Fig. 133)

3) Close of the hydraulic cylinder (6).
4) Disassemble the connection clamps (7).
5) Remove the clamps that connect the water tank flange (11) and the delivery
piston adaptor (12).
6) Remove the water tank flange (11).
7) Remove the concrete delivery cylinder by loosening the nuts of the tie rod (15)
that connect the concrete delivery cylinders to the water tank.
Installation of Concrete Hydraulic Cylinder
1) Replace the concrete delivery cylinder (10).

2) Tighten the nuts of the tie rod (15) that connect the concrete delivery cylinder
to the water tank.
3) Substitution the water tank flange (11).
4) Place the concrete piston (13) into the concrete delivery cylinder (10).
5) Install the clamps (7) that connect the water tank flange (11) and the delivery
adaptor (12).
6) Fill the water reservoir with water. It is recommended to add additives (soap,
7) Close the cover of the water tank and screw the bolts (1).
Replacing the Concrete Delivery Piston in Delivery Cylinders (Chromium

Bushing)
Remove of Concrete Piston (10);

3) Pull the hydraulic cylinder (6) to the end of the inner part.
4) Close the hydraulic cylinder, the concrete piston (13), tighten the single clamp
(7) and withdraw the cylinder.
5) Remove the concrete plunger and remove the delivery piston adaptor with a
vice.
Installation of Concrete Piston (10);
1) Install the delivery piston adaptor (12) to the concrete piston (13).
2) Lubricate the concrete piston (13) and the concrete delivery piston (10) with
grease.
Page 113 / 129

OPERATING MANUALS
3) Lower valve 11 located in the big valve block to minimum speed. (NFDD - LGN
valve)
4) Connect the single clamp (7).
5) Replace the new concrete piston (13).
6) Remove the single clamping clamp (7).
7) Install the recess flange (11) and the clamps.
8) Place the concrete delivery cylinder in the first position.
9) Fill the water reservoir with water. It is recommended to add additives (soap,
10) Screw the bolts (1) by closing the cover of the water tank.
11) Set the speed of the concrete conveying cylinder to the recommended speed
for the 11th valve (NFDD-LGN valve) on the large valve block.
Change the Sensor (8);
Fig. 134
Page 114 / 129

OPERATING MANUALS
Remove of Sensors; (Fig. 134)
1) The sensors on the cover are between two nuts. The sensors may change
before you remove the cover.
2) Loosen the upper nut when exchanging sensors between two nuts.
3) Remove the lower sensor nuts (6).
4) Disconnect the electrical connection cables for the sensor.
5) Remove the sensor (8).
Install of Sensors;
1) Replace the new sensor (8).

2) Make the cable connections according to the heading "Conduction - reverse
sensor connections" in the "Electrical Circuit Diagram".
3) Tighten the top and bottom nuts.
4) Secure the sensor (8) in the centre of the cover flange (6).
5) Push the hydraulic cylinder to the end of the water tank (1). Provide the sensor
reads the cylinder.
6) Ensure that the distance between the flange and the sensor is not more than
8 mm.
Liquids and Amounts:
Engine Oil 15lt 15W40

Front Traction 1,9ltx2 80W90
Rear Traction 1,9ltx2 80W90
Differential 18lt Mobil Fluid 426
Gearbox 12lt Mobil Trans HD30
Transfer Box 1,5lt 80W90
Hydraulic System 270lt Castrol Hyspin AWS
Engine Coolant 20lt Water
9.11. Lubrication Points
Caution :
“ “ red circle means lubrication daily.
“ “ blue circle means lubrication weekly or in every 50 hours.
Page 115 / 129

OPERATING MANUALS
3 1
1 2
fd
2 Fig. 135
5
6
Fig. 136 8
Page 116 / 129

OPERATING MANUALS
14
10
9
12 11
15
13
Fig. 137
17
16
18
19
Fig. 138
Page 117 / 129

OPERATING MANUALS
1 2 Axles Greasing Points
Fig. 139
 Grease the axle pivots and shaft joints. Check the oil levels weekly or every 50
hours. There are 6 grease points on the sealing rings and 8 grease points on
the joints.
Fig. 140
Caution:
Page 118 / 129

OPERATING MANUALS
3 Shafts
3
3 3 3
Fig. 141
Fig. 142
 Grease the cross-pieces on the shaft. Check the oil levels weekly or every 50
hours. There are 6 grease points on the cross-pieces.
CAUCATION:
Page 119 / 129

OPERATING MANUALS
4 Operator’s Seat
Fig. 143
Fig. 144
 Grease the operator’s seat weekly or every 50 hours.
Page 120 / 129

OPERATING MANUALS
5 6 Rear Hydraulics Stabilizers
Fig. 145
Fig.146
Daily or once in shift
 Check the greasing points and grease the rear hydraulics stabilizers 5-6.
Page 121 / 129

OPERATING MANUALS
7 Hopper
Fig. 147
Fig. 148
 Check the greasing points and grease the hopper 7.
Page 122 / 129

OPERATING MANUALS
8 Hopper Cylinder
Fig. 149
Fig. 150
 Check the greasing points and grease the rear hydraulics stabilizers 8.
Page 123 / 129

OPERATING MANUALS
9 10 11 Manipulator Lubrication Points
10
11
Fig. 151
Fig. 152
 Check the greasing points and grease the rear hydraulics stabilizers 5-6.
Page 124 / 129

OPERATING MANUALS
12 13 Front Hydraulics Stabilizer
12
13
Fig. 153
Fig. 154
 Check the greasing points and grease the front hydraulics stabilizer 12-13.
Page 125 / 129

OPERATING MANUALS
14 15 Front Hydraulics Stabilizer
14
15
Fig. 155
Fig. 156
 Check the greasing points and grease the front hydraulics stabilizer 14-15.
Page 126 / 129

OPERATING MANUALS
16 17 18 19 Manipulator Arm
19
17 18
16
Fig. 157
Fig. 158
 Check the greasing points and grease the front hydraulics stabilizer 16-17-18-19.
Page 127 / 129

OPERATING MANUALS
10. SCOPE of DELIVERY

Technical Document TT-GMF-02
Contents of Tool Kit
 17ʺ tool box

 18ʺ pipe wrench
 200mm hollow chisel
 12 pcs. set of open-end wrenches
 180mm pliers
 180mm side cutter
 12 pcs. set of Allen keys
 Hammer - 1kg
 63mm flat head screwdriver
 63mm phillips head screwdriver
 Voltage tester
 Rowlock wrench
 Nozzle cleaning drill
 R-clips (10 pieces)
 Hopper outlet o-ring (5 pieces)
 3ʺ lever joint (2 pieces)
 4½ʺ lever joint (1 piece)
 5½ʺ lever joint (1 piece)
 3ʺ gasket (4 pieces)
 4½ʺ gasket (4 pieces)
 5½ʺ gasket (4 pieces)
 4ʺ cleaning ball (1 piece)
 5ʺ cleaning ball (1 piece)
 3ʺ ball throw flange (1 piece)
 2ʺ dovetail (1 piece)
 3ʺ ball throw blind flange (1 piece)
 5½ʺ ball throw flange (1 piece)
 2ʺ dovetail (1 piece)
 Nozzle and nozzle flange (1 piece)
 ¾ʺ dovetail (2 pieces)
 ¾ʺ air hose – 6m
Page 128 / 129

OPERATING MANUALS
11. CE DECLARATION
Page 129 / 129

TROUBLESHOOTING
Electric No Trouble Remedy
1 Check the electric motor's running. If the electric motor isn't running, check the connettion cable.
Check the electric motor 's direction of rotation . (Cooling fan behind the electric motor looks cross when it must
2
rotate clockwise. )
3 Check the P1 main pump oil tank's suction valve. If suction valve is closed, open the suction valve.
4 Check the oil level. If it isn't enough, to add the oil.
5 Check the automatisation panel's pumping-reverse button. The button must be pumping position
Check the number 11 NFDD-LGN reducing valve on the big valve block VB1. Adjust to want stroke. If the reducing valve
6
is malfunction, changed it.
Check the number 9 RDFA-LWN relief valve on the big valve block VB1. Adjust to 250 bars.If the relief valve is
7
malfunction, changed it.
Cylinders move off Check if NG6 valve with single bobbin on the big valve block (VB1) is magnetized enough. If NG6 valve's bobbin isn't
Main Cylinder
8
magnetized, changed the NG6 valve. If the bobbin isn't supplied energy, check the electrical system.
Check the NG6 valve in the core with single bobbin number 12 on the big valve block VB1 is mechanically. The core
1. 9
isn't running, replace NG6 valve.
Check if NG16 valve's pilot valve number 13 on the big valve block (VB1) is magnetized enough. If NG6 valve's bobbin
10
isn't magnetized, changed the NG16 valve. . If the bobbin isn't supplied energy, check the electrical system.
Check the NG16 valve's pilot valve in the core with single bobbin number 13 on the big valve block VB1 is mechanically.
11
The core isn't running, replace NG16 valve.
Check the hopper water tank's sensor. If the sensors are malfunction, replace the sensors. Adjust position both of the
12
sensors.
13 Check the 112 cc pump. Contact the Titan Authorized Service.
14 Read item 1.6.
15 Read item 1.10.
Main cylinders
16 Check whether the oil in the mail cylinder is leaked. If the cylinder is leaking the oil, change the cylinder.
drift off.
17 Check the 112 cc pump's regulator filter. If the regulator filter is clogging, change the new one.
18 Read item 1.13.
Titan Makina Ltd. Şti.

1160. Sok. No: 9 Ostim 06370 Ankara Tel: + 90 312 354 9977 Fax: + 90 312 385 5611
Web: www.titanltd.com.tr E-mail: titan@titanltd.com.tr
No Trouble Remedy
Check the hopper water tank's sensor. If the sensors are malfunction, replace the sensors. Adjust position both of the
Cylinder
19
Main
Main cylinders sensors.
1. 20 change stroke of Check the hopper water tank's sensor position. Adjust the sensors so that the flanges are visible.
21 cylinder setting. Read item 1.16.
22 Check the check valves installed on the main cylinde. If the check valves are malfunction, change the check valves.
1 Read item 1.1.
2 Check the suction valves on the oil tank of P2 pump. If the suction valves are off, turn the valves on.
3 Read item 1.3.
4 Read item 1.4.
Valve Plungers in the Valve Housing
5 Check if the S-tube is compacting in the concrete hopper or if there is a substance blocking the movement.
6 Check the hopper grating's sensor on the left side concrete hopper. If the sensor is malfunction, change the sensor.
Check the QPAB-LCN valve (no:12) on the small valve block (VB2). Adjust 130 bars. If the valve is malfunction, change
7
the valve.
Check the RVCA-LWN valve (no:6) on the small valve block (VB2). Adjust 150 bars. If the valve is malfunction, change
8
the valve
S-Tube's piston Check the RDDA-LWN pressure relief valve (no:3) on the small valve block (VB2). Adjust 240 bars. If the valve is
2. 9 doesn't operate. malfunction, change the valve.
Check the NG10 directional control valve(no:10) always magnetized on the small valve block(VB2). The NG10
10
directional valve is necessary magnetized with boom's movement.
Check if the gate of NG10 directional control valve sticked to on the small valve block(VB2), hung up. The valve's gate is
11
off.
Check the RDDA - LWN pressure relief valve (no:6) on the big valve block(VB1). Adjust 250 bars. If the valve is
12
malfunction, change the valve.
Check if NG6 plate connected NG6 valve's bobbin on the small valve block is energized enough. The bobbin must be
13
energized when the electrical system is running.
Check if the gate of NG6 valve sticked to the NG6 plate, on the small valve block (VB2), hung up. If it is malfunction,
14 replace it.

No Trouble Remedy
15 Check the bobbin of the NG6 pilot valve above the NG16 directional control valve (no:7) on the big valve block are
energized reversely at each stroke change. If the bobbin isn't energized, check electrical system.
S-Tube's piston Check if the bobbin of NG6 pilot valve above the NG16 valve(no:7) on the big valve block (VB1) is energized enough. If
16 moves off . the bobbin is malfunction, replace the new bobbin.
17 Check the s-tube's piston. If the s - tue's piston is malfunction, change it.
S-Tube's Piton
18 Check the P2 pump. Contact the Titan Authorized Service.

19 Check the accumulator . If the accumulator is malfunction, replace the new accumulator.
2. Check the FDCB-LAN reducing valve (no:4) on the small valve block (VB2). If the reducing valve is malfunction, replace
20 S-Tube's piston
the new reducing valve.
moves off slowly.
21 Check whether the oil in the mail cylinder is leaked. If the cylinder is leaking the oil, change the cylinder.
22 Check the P2 pump. Contact the Titan Authorized Service.
23 Read item 2.20.
24 S-Tube's piston Read item 2.21.
25 slow down in Read item 2.22.
26 time. Read item 1.20.
27 Read item 1.21.
1 Check the DPC130 manipulator control valve's pressure relief valve. Adjust 240 bars.
Check the RPCC-LWN pressure relief valve(no:11) on the small block (VB2). Adjust 230 bars. If the pressure relief valve
2
is malfunction, replace it.
Manipulator Check the RDDA-LWN pressure relief valve(no:3) on the small block (VB2). Adjust 230 bars. If the pressure relief valve
Manipulator
3
doesn't move up. is malfunction, replace it.
3. 4
Check if NG10 valve's bobbin on the small valve block (VB2) is energized enough. The NG10 valve's bobbin is necessary
energized to manipulator movement.
5 Read item 2.20.
6 Check the adjustment flow underlain by the control levers of the DPC130 manipulator control valve.
7 manipulator is up Check the FDEA-LAN reducing valve (no:5) on the small valve block (VB2). Turn on to the end.
8 slowly. Read item 3.4.
9 Read item 2.20.

No Trouble Remedy
1
Check if the water pump or vibrator is running. While water pump or vibrator is running, the stabilizers don't run.
2 Hydraulic Check the pressure adjustment of SD5/4 directional control valve. Adjust 130 bars.
Stabilizers
3 stabilizers aren't Check the SD5/4 directional control valve. If it is maldfunction, replace it.
4. 4 running. Check the hydraulic stabilizer's locks on the hydraulic stabilizer.
5 Check the hyrdraulic stabilizers' cylinder.
6 Check the gear pump (P3).
7 Hydraulic Read item 4.5.
8 stabilizers are Check the SD5/4 directional control valve's tank line.
9 running slowly. Read item 4.6.
1 Check if the control lever of hopper shutter's cylinder position on or off.
2 Adjust the SD5/2 valve's pressure relief valve 160 bars.
3 The vibrator isn't Check the SD5/2 valve's internal linkage of control lever.
4 running. Check the vibrator.
5 Check the vıbrator's hydromotor.
Vibrator
6 Check the P3 pump.

5. 7 Check the hopper grating's bearing support, welding of hopper gratin, rubber buffer.
8 Check the vıbrator is stuck to hopper grating.
9 Check if the conrete clean up on the vibrator.
The vibrator is
10 Read item 5.2.
running slowly.
11 Read item 5.3.
12 Check the SD5/2 valve.
13 Read item 5.6.
1 Read item 5.1.
Water Pump
2 Check the washing gun of water pump.

3 Water pump isn't Check whether water is coming to hose reel.
6. 4 running. Check the water pump.
5 Check the water pump's hydromotor.
6 Check whether the oil is coming to hydromotor of water pump.

TITAN IS21 CONCRETE SPRAYING MACHINE MAINTENANCE TABLE
100 250 500 750 1000 1250 1500 1750 2000
CODE PROCESS DAILY WEEKLY YEARLY
HOURS HOURS HOURS HOURS HOURS HOURS HOURS HOURS HOURS
Machine And Manipulator Control X X
Machine And Manipulator by Expert Control X
Overall Control
Screw The Bolts And Nuts Adjust X
Dosing Pump Line Control X

Oil Level Control X
Engine Coolant Control X X
Water-fuel separator filter Control X
Water-fuel separator filter T126-07-008 Change X X X X X X X X
Oil and Water Leakage Control X
Oil (14lt) 15W40 Change X X X X X X X X
Oil Filter T126-07-009 Change X X X X X X X X
Fuel Filter T126-07-010 Change X X X X X X X X
Connecting Pipes Control X X X X
Engine Radiator Cleaning Control X X X X
Belts Control X
Air Filter External Component T126-07-007 Change X X X X X X X X
Air Filter Internal Component T126-07-006 Change X X X X
Valve Adjustment Adjust X
Air Absorbing Jar Control X
Oil Shutter O-ring Change X X X X
Oil Level Gauge O-ring Change X
Engine Coolant Change
Hydraulic Pipes Control X X
Oil Leakage Control X
Transfer Box Oil Level Control X
Oil (1,5 lt) 80W-90 Change X
Emergency Stop Functions Control X
Electric Connections Control X
Electric System
Cabled - Radio Controller Functions Control X
Cable Reel Control X
Water Box Water Level Control X
Water Box
Water Pump Intake Filter Control X
Greasing The Shaft Bearing Control X
Hopper And Mixer Mixer Functions Control X
Mixer Connections Control X
Oil Level Control X
Oil (16lt) Mobil HD30 Change X X
Transmission Oil Filter T126-07-011 Change X X X X X X X X
Transmission Strainer Cleaning X X
Drive Shafts Greasing X
TITAN IS21 CONCRETE SPRAYING MACHINE MAINTENANCE TABLE
100 250 500 750 1000 1250 1500 1750 2000
CODE PROCESS DAILY WEEKLY YEARLY
HOURS HOURS HOURS HOURS HOURS HOURS HOURS HOURS HOURS
Oil Level Control X X X X X X X X
Traction Gear Oil (1,9lt x 2) 80W90 Change X X
Differential Oil (18 lt) Mobil 426 Change X X
Axle and Axle Shaft Shafts Control X
Steer Rod Control X X X X X X X X X
Axle Pivot And Turn Connection Greasing X
Hydraulic Cylinders Control X X X X X X X X X
Oil (Electric + Diesel Working Hour) HYSPIN AWS Mobil 46 Change X X
Hydraulic Oil Level (270 lt) Control X
Concrete Pipes Pressure Line Control X
Hydraulic System Return Filter Control X
Return Filter T126-07-161 Change X X X X X
High Pressure Filter Control X
High Pressure Filter Change X X X X X
Mineral Oil AIRMAX 2000 Change X X
Air filter element Change X X
Oil filter element Change X X
Panel filter Change X X
Separator Filter Change X X
Kit, inlet valve MER 122 Change X
Kit, inlet valve MER 145 Change X
Kit, inlet valve HDKG 85-120-160 Change X
AIR COMPRESSOR Kit, minimum pressure valve Change X
Thermostatic valve element Change X
Check oil level Control X
Check / Clean air filter element Cleaning X X X
Check load / unload working modes Control X X X
Check air and oil leakages Control X X X
Clean separator moisture Cleaning X X
Check screws for electrical connections Control X X
Air end seal leakage checking Control X X
ELECTRICAL CIRCUIT
DIAGRAM
• 1 1 1 2 1 ] 1 ' 1 ; 1 6 1 7
• •
ı- ı-
• •
ı- ı-
IS21 CONCRETE (
SPRAYING MACHINE ı-
• •
ı-
ELECTRICAL DIAGRAM
ı-
' '
- -
' '
Titan"
?1'::ıjıı::h ;......r.ıg l'IO
r' ·-· ,,_,
"
Drawing : Sebahattin DEMIRCI 1.00U29 IS26
Check : Hakan DUZEL ilıı.te- fwd,0 ıtııı:chOl"e' Tıılol sh!ıts,- Nıı:ıd �-uıt•
Approve : Mehmet KILIC 270t..Xl'l6 2
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Drawing : Sebahattin DEMIRCI
Check : Hakan DUZEL
Approve : Mehmet KILIC
1001129 IS2r>
fınctlmn:
27.04.2011>
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stett,
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1Qot129 ısı� 3
Remote Control Approve : Mehmet KILIC
2'7.04.2011>
fınct�n: t.ıxottın: nıtol ,ııats:
24
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Check : Hakan DUZEL
PrııJtct,
10011251 IS2tt
c.ıte
Cra�� na.,
fın:IIOn: ı.a:on:ın:
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Approve : Mehmet KILIC tl,0"201b 2't 5
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Drawing : Sebahattin DEMIRCI 1ooı12'il ısa 5
Emergency Stop and Control
Voltage
Check : Hakan DUZEL
Approve : Mehmet KILIC t7,04.2D1D
fın:Uın: ıı.a:ottın: nıtot ,ııeets: IE<tftet:
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1001129 IS2t>
Lighting and PTC Curcuit Check : Hakan DUZEL
fınctıoıı: 1ı.ıxottın: nıtol ,ııeet&: IE<tsteetı
2'7.04.2011> ,;
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1001129 IS2't.
Curcuit Check : Hakan DUZEL
Approve : Mehmet KILIC fınctlıın: 1ı.ıxottın: nıtol &ha?ts: IE<tftet:
2'7.04.2011> 24
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tııt.: 112\'.=
Drawing : Sebahattin DEMIRCI 1Qotl2'il ısıt> 8
M1 Control Curcuit Check : Hakan DUZEL
Approve : Mehmet KILIC ti'.0"'2011>
Fınct�n: ıı.ıxonxı:
,.
nıtol &lıll!ts: IEttftet:
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Drawing : Sebahattin DEMIRCI O:O�rg no.,
Pump Start Control Curcuit Check : Hakan DUZEL
1001129 IS2� 9
Approve : Mehmet KILIC fın:l�n: 1ı.ıxottın: nıtol ,ııııets: IEttftet:
27.04.2011> ı; 10
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Check : Hakan DUZEL
PrııJtct:
1Qot12!I IS2r>
ini�� no.,
I ""·· 10
Curcuit Approve : Mehmet KILIC ı:.ıte: fın:tııın: ıı.a:on:ııı: nıtol ,ııeets: ıet net:
l?'i'.0"-2016, 24 11
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Titan" Concrete Pumping- PııoJect, o:o�rg no., tılt.,

1001129 IS2� 11
Reverse Sensor Check : Hakan DUZEL
lklte fın:l�n: ı.ıxottın: nıtol ,ııııets: IE<t net:
Diagram 27.04.2011> Vt 12
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Concrete Pumping- Reverse Drawing : Sebahattin DEMIRCI
12
Concrete Control Diagram Check : Hakan DUZEL
1ooı12'il ısa
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Titan·
PrDJtct: lnl�rg ııo.: tııt.:
Remote Control Check : Hakan DUZEL
1001129 IS26- 13
curcuit Approve : Mehmet KILIC
ı:ute fınctlıln: ı.ıxonın: nıtol &hB!1&: tE<t net:
27,0"'2D1ô 24 1t
' 5 6
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1
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increase
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decrease
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valve
PrııJtct: ini�� no., tııt.:

Remote Drawing : Sebahattin DEMIRCI
10ot12!I IS2r> 14
Check : Hakan DUZEL
Control Approve : Mehmet KILIC ı:.ıte: fın:tııın: ı.a:on:ııı: nıtol ,ııeets: ıet net:
l?'i'.0"-2016, 24 15
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Titan·
Pl'ııJect, 112\'.= Sl'ett:
.....
Contrete Pumping-Reverse Drawing : Sebahattin DEMIRCI D'G�rg no.,
Valve Control Curcuit Diagram Check : Hakan DUZEL
1Qot1251 ISZt.
t7.04.201b
FınclNn: ıı.a:oıtın: "
nıtot ,ııı!l!ts: ıett neı:
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""··
Titan·
PrııJtct: ııraııııg ııo.,
Concrete Pumping-Reverse
Valve Control Diaagram
Check : Hakan DUZEL
1Qot125I IS2t>
ı:.ıte fınctıon: ıı.ıxon:ın:
I nıtol &lı2'1S: ıeıt net:
16
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rotation
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up-down up-down forward- up-down right-left Rotation euraıu
reverse
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working
button
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1'.7 �1135 PlOT 'iAlF Rli ALOT 'iJ.lF
-
' Pilot Valve
ı t ı t . ,
Titan· Drawing : Sebahattin DEMIRCI PııoJect, ını�ıg na.,
17
Manipulator Valve
Curcuit
Check : Hakan DUZEL
1Qot129 IS26,
ı:ute
2'7.04.2011>
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2'7.04.2011> ,;
PRESSURE
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10.5=ADDITTIVE SINGAL
PLC UNIT Drawing : Sebahattin DEMIRCI

Check : Hakan DUZEL
IS21 CONCRETE SPRAYING MACHINE AUTOMOTIVE
ELECTRICS DRAWING
1160. Sokak No: 9 Ostim/ANKARA

Tel: +90 312 354 9977
Faks: +90 312 385 5611
MOTOR
HEATING
BATTERY CHARGE
LAMP
STARTER ALTERNATOR
MOTOR
ENGINE WORKING HOUR
HEATING
Çi ze n (Dra wn b y): P ro j e ct: Rev.: S a y f a ( Page) : 1

IS21 CONCRETE SPRAYING Em re KİBAR ti ta n p ro j e _ r2
MACHINE AUTOMOTIVE ELECTRICS K o n t r o l E d e n ( C o n t r o l l e d b y: ) T ari h (Date ): T o p l a m S . ( T o t a l P . )S: o n r a k i ( N e x t page ) :
DRAWING T ayfun KOÇAK 10.12.2016 21 2
+TOP
IGNITION
HEATING HEATING
AUTOMATIC LAMP
AUTOMATIC HEATING TIME

STARTER RELAY
+TOP +TOP
+BOTTOM
MAIN FEEDING
RELAY
HEAT
SENSOR
STARTER
RELAY

CHARGE LEFT SIGNAL
LAMP
E. OIL LAMP BRAKE
DISPLAY PANEL 2
CHARGE FOUR
DISPLAY PANEL 1
PRESSURE WHEEL
LAMP
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BRAKE
E. FİLTER CRABBING
LAMP
HEATING MAIN BEAM

LAMP
ENGINE ENGINE
TEMPERATURE TEMPERATURE
T. TEMPERATURE RIGHT
SIGNAL
AIR FILTER
Çi ze n (Dra wn b y): P ro j e ct: Rev.: S a y f a ( Page ) : 3

TOP
NEXT PAGE
GEAR STICK BOTTOM BOTTOM

18
BOTTOM BOTTOM
2
BOTTOM BOTTOM
27
BOTTOM BOTTOM
BOTTOM
17 ECU
BOTTOM BOTTOM A. PORT
38
BOTTOM BOTTOM
7
BOTTOM BOTTOM
28
BOTTOM
BOTTOM
BACK-UP
BACK-UP LIGHT
HORN
HORN

MACHINE AUTOMOTIVE ELECTRICS K o n t r o l E d e n ( C o n t r o l l e d b y: ) T ari h (Date ): T o p l a m S . ( T o t a l P . )S: o n r a k i ( N e x t Page ) :

BOTTOM BOTTOM
TRANSMISSSION
READER SENSOR
ECU B TERMINAL BOTTOM BOTTOM
BOTTOM BOTTOM
BOTTOM BOTTOM BOTTOM

BOTTOM BOTTOM BOTTOM
PREVIOUS
PAGE
BOTTOM BOTTOM
BOTTOM
BOTTOM
BOTTOM


+BOTTOM
RADIATOR
BUTTON
+BOTTOM
+BOTTOM
+BOTTOM
+BOTTOM
+BOTTOM
+BOTTOM
RADIATOR

FEEDING FEEDING
+BOTTOM
+BOTTOM
PARKING
BRAKE
BUTTON
+BOTTOM
+BOTTOM
+BOTTOM
DOOR
SENSOR
+BOTTOM
PARKING
BRAKE
LAMP

MACHINE AUTOMOTIVE ELECTRICS K o n t r o l E d e n ( C o n t r o l l e d b y: ) T ari h (Date ): T o p l a m S . ( T o t a l P. )S: o n r a k i ( N e x t page ) :
+BOTTOM
+BOTTOM
LIGHTING
BUTTON
+BOTTOM +BOTTOM
+BOTTOM +BOTTOM
LIGTHING
+BOTTOM
BRAKE ENGINE ENGINE
ACCUMULATOR TEMPERATURE TEMPERATURE
BRAKE LAMP
SENSOR SENSOR BATTERY
LAMP
TEMPERATURE
AND BATTERY
ALARM

+CABİN HEADLIGH
BUTTON
+BOTTOM
+BEACON
LAMP
+BOTTOM
+TOP
+BOTTOM +BOTTOM
+TOP +TOP
BEACON LEFT STOP

CABIN LAMP RIGHT
HEADLIGHT STOP

+BOTTOM +BOTTOM +BOTTOM
SPRING -
LOADED SIGNAL
BUTTON SIGNAL SWICH
SWICH
+BOTTOM
+BOTTOM
+BOTTOM
+BOTTOM +BOTTOM
ENGINE
ENGINE
Çi ze n (Dra wn b y): P ro j e ct: Rev.: S a y f a ( Page ) :

IS21 CONCRETE SPRAYING Em re KİBAR ti ta n p ro j e _ r2 10

HEALIGHT +BOTTOM
BUTTON
+BOTTOM
+TOP
+BOTTOM +BOTTOM +BOTTOM +TOP
SIGNAL
SWICH
+BOTTOM +BOTTOM +BOTTOM

+BOTTOM
+BOTTOM
+BOTTOM +TOP
15 30B 49 30 49A C +
QUART BUTTON FLASHER
R L
SIGNAL SIGNAL
+UP
+BOTTOM +BOTTOM
+UP

+TOP
1
2 +TOP
CRABBING SWICH 3
1
5 +TOP WHEEL POSITIONER
6
+BOTTOM 2
+BOTTOM
1 2 3 4 5 6
+TOP +TOP
+TOP +TOP
+NEXT PAGE
+NEXT PAGE
+NEXT PAGE
+NEXT PAGE
Çi ze n (Dra wn b y): P ro j e ct: Rev.: S a y f a ( Page) :

+PREVIOUS PAGE
+PREVIOUS PAGE
+PREVIOUS PAGE
+PREVIOUS PAGE
+TOP +TOP +TOP +TOP +TOP +TOP +TOP


ECU UNIT
ECU B PORT ECU A PORT
13 19 1 2 3 4 5 26 36
+TOP

17.0
+TOP
RELAY IGNITION
SWICH -HEATING BUTTON
TIME RELAY BOBBIN
- MIRROR HEATING 1 - MIRROR HEATING 2
17.0


18.0
ENGINE TRANSMISSION EURO DISEL TRANSMISSION ENGINE AIR

OIL PRESSURE OIL FİLTER TEMPERATURE FILTER
LAMP
+TOP +TOP +TOP +TOP +TOP
+TOP +TOP +TOP +TOP +TOP
-SENSOR -SENSOR -SENSOR -SENSOR -SENSOR
18.0


19.0
+TOP
-FUEL HOUR -TEMPERATURE

HOUR
+TOP
+TOP
-FLOAT
VALVE
19.0


20.0
+BOTTOM +TOP
+TOP
+TOP
-STOP SELENOİD ACCELERATION

JET
-HEATING SENSOR
20.0

MACHINE AUTOMOTIVE ELECTRICS K o n t r o l E d e n ( C o n t r o l l e d b y: ) T ari h (Date ): T o p l a m S . ( T o t a l P . )S: o n r a k i ( N e x t page) :
+TOP
+TOP +BOTTOM

DRAWING T ayfun KOÇAK 12.01.2017 21
HYDRAULIC CIRCUIT
DIAGRAM
O.M. (see chapter 10)
S.P. (see chapter 20)
O.M.(see chapter 10)

S.P.(see chapter 21)


15.02.2015 DATE NAME SIGN MATERIAL -

DRAWING WEIGHT -
NOTE: CONTROL TURGAY KARGIN
APP
QUANTITY
SCALE
-
-
OPERATING MANUAL: O.M. SYSTEM NO
IS21 STEERING AND BRAKE DIAGRAM
SPARE PART: S.P. DRAWING NO -
AIR COMPRESSOR
OPERATING MANUAL
INDUSTRIAL
AIR
COMPRESSOR
EKO SERIES
(15-315 kW)
PLEASE READ THIS MANUAL CAREFULLY PRIOR TO

COMPRESSOR START-UP.
INSTALLATION AND MAINTENANCE
EKO
EKO D
EKO GD
EKO VST
EKO DVST
EKO GDVST
USER MANUAL
1
EKO-BA-2011-A
Article No: 909001-E-A
TABLE OF CONTENTS
SECTION 1 SAFETY
1.1 GENERAL....................................................................................................................................................................... 2
1.2 PERSONAL PROTECTIVE EQUIPMENT................................................................................................................... 2
1.3 PRESSURE RELEASE................................................................................................................................................... 2
1.4 FIRE AND EXPLOSION................................................................................................................................................ 2
1.5 MOVING PARTS .......................................................................................................................................................... 2
1.6 HOT SURFACES, SHARP EDGES AND SHARP CORNER...................................................................................... 2
1.7 TOXIC AND IRRITATING SUBSTANCE................................................................................................................... 3
1.8 ELECTRICAL SHOCK.................................................................................................................................................. 3
1.9 LIFTING AND HANDLING.......................................................................................................................................... 3
1.10 OTHER IMPORTANT MATTERS ............................................................................................................................... 3
SECTION 2 INSTALLATION
2.1 LOCATION OF COMPRESSOR................................................................................................................................... 4
2.2 VENTILATION AND COOLING.................................................................................................................................. 4
2.3 SERVICE AIR PIPING................................................................................................................................................... 4
2.4 OIL LEVEL CHECK...................................................................................................................................................... 4
2.5 ELECTRICAL PREPARATION.................................................................................................................................... 4
2.6 MOTOR ROTATION DIRECTION CHECK................................................................................................................. 5
SECTION 3 SPECIFICATIONS
3.1 TECHNICAL SPECIFICATIONS.................................................................................................................................. 6
SECTION 4 COMPRESSOR SYSTEMS
4.1 INTRODUCTION........................................................................................................................................................... 7
4.2 DESCRIPTION OF COMPONENTS ............................................................................................................................ 7
4.3 COMPRESSOR UNIT, FUNCTIONAL DESCRIPTION….......................................................................................... 7
4.4 COMPRESSOR DISHARGE SYSTEM, FUNCTIONAL DESCRIPTION................................................................... 7
4.4 COMPRESSOR COOLING AND LUBRICATION SYSTEM, FUNCTIONAL DESCRIPTION................................7
4.6 AIR INLET SYSTEM, FUNCTIONAL DESCRIPTION............................................................................................... 7
4.7 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION............................................................................................... 7
SECTION 5 MAINTENANCE
5.1 GENERAL....................................................................................................................................................................... 8
5.2 DAILY OPERATION..................................................................................................................................................... 8
5.3 PERIODIC MAINTENANCE …………………………………………....................................................................... 8
5.4 OIL MAINTENANCE.................................................................................................................................................... 8
5.5 OIL FILTER MAINTENANCE...................................................................................................................................... 8
5.6 SEPARATOR MAINTENANCE.................................................................................................................................... 8
5.7 PART REPLACEMENT AND ADJUSTMENT PROCEDURES............................................................................... 8
A OIL FILTER ELEMENT CHANGE .............................................................................................................................. 9
B AIR INTAKE FILTER ELEMENT CHANGE .............................................................................................................. 9
C AIR INTAKE FILTER ELEMENT INSPECTION ........................................................................................................9
D SEPARATOR ELEMENT CHANGE ............................................................................................................................ 9
E CONTROL SYSTEM ADJUSTMENT …...................................................................................................................... 10
F POLY-V BELT REPLACEMENT AND TENSIONING .............................................................................................. 10
G OIL RETURN (SCAVENGE) LINE MAINTENANCE ............................................................................................... 11
H MOISTURE SEPARATOR MAINTENANCE AND DRAIN TIME SETTINS ...........................................................11
5.8.A SERVICE INSTRUCTIONS FOR THREE-PHASE MOTORS ................................................................................... 12
5.8.B ANAEROBIC SEALANT (LOCTITE) USAGE ……………………………………………………………………... 12
5.8.C PIPING AND INSTRUMENTATION DIAGRAM ...................................................................................................... 13
5.9 INVERTER MAINTENANCE AND INSPECTION FOR ALL VST COMPRESSORS ........................................... 14
SECTION 6 TROUBLESHOOTING
6.1 INTRODUCTION........................................................................................................................................................... 15
6.2 TROUBLESHOOTING.................................................................................................................................................. 15
SECTION 7 ANNEX – TABLES AND ILLUSTRATIONS
7.1 COOLING AIR EXHAUST DUCTS ………………..................................................................................................... 21
7.2 CABLE SIZES, FUSES, CIRCUIT BREAKERS .......................................................................................................... 22
7.3 RECOMMENDED SPARE PARTS AND SERVICE OPERATIONS ………………………….…………………… 23
SECTION 8 PROCEDURE FOR ORDERING PARTS ......................................................................................................24
ADDENDUM MAINTENANCE RECORDS ..........................................................................................................................................25
PLEASE READ THE PARTS LIST BOOK FOR SPARE PARTS LIST WITH EXPLODED VIEW ILLUSTRATIONS.
DATE OF INITIAL COMMISIONING PROJECT MANAGER:

OPERATION: ENGINEER:
INTRODUCTION
Dear EKOMAK Compressor User

Your compressor has been produced using advanced technology, with the latest engineering standards and with years of tested
knowledge. It is virtually problem-free, efficient and reliable if operated properly. Security and safety must be the main consideration.
EKO air screw compressors have been made to produce compressed air which is used for air tools, machines and processes.
The manufacturer is not liable for applications outside the scope of this machine and its intended use; this will void the warranty if this
seems to be the case. However, any machine could be a potential source of danger if improperly handled or used, tampered with by
unqualified, untrained or careless personnel or if not used within the scope of its intended use. Therefore, be sure to observe all
instructions supplied in this and other supplied manuals and strictly comply with all local safety and accident prevention rules and
regulations.
DO NOT attempt to handle, locate, mount, maintain and/or carry out any reparation process unless you have read and understand this
manual carefully & had contact with the responsible Ekomak contact.
Your compressor may deviate slightly from the illustrations shown in this manual. This is of no importance for the operation of the
machine.
Should any questions arise in spite of the instructions in this manual or if you have any inquiries concerning this manual or wish to
obtain additional copies, please do not hesitate to contact our Technical Service Department they will glad to help you. Make sure the
manual is kept near the compressor and thus always at hand for operating personnel.
This compressor should be operated and used only by trained and qualified persons. No person is allowed to operate the compressor-
even for a short time-without adequate-training.
The owner should clearly establish who is responsible for assembling, disassembling and reassembling the compressor for putting it into
operation, set up, operating and servicing the compressor.
The owner is obliged to operate the compressor only if it is in a safe condition. Major repairs must only be carried out by the
manufacturer or by specially authorised, qualified personnel.
Product safety signs or decals should be periodically inspected and cleaned or replaced when they no longer meet the legibility
requirements for safe viewing at a reasonable distance.
Make sure that enclosures removed for maintenance or repairs are refitted before restarting the compressor.
DO NOT remove, alter or deactivate any machine parts such as safety valve, belt guard, fan guard, safety pressure switch, temperature
switch, fuses, sensors etc.
DO NOT begin any maintenance or adjustment work before the compressor has been switched off, P1 (internal/system) and P2
(line) pressures are –0- and make sure to secure the compressor against accidental restart.
DO NOT use any flammable or explosive material for cleaning purposes.

DO NOT allow any flammable gas use which may cause explosion or burning in the inlet air.
Keep the working area clean and tidy.
Only qualified electricians are allowed to perform any work on the electrical system.
Only use original specified spare parts for your compressor. We assume you keep needed spares in your stock. DO NOT allow any
unauthorized companies for part replacement.
Only use EKOMAK specified parts for servce or repair work. Ensure that enough stock is available to carry out service work. It is not
permitted to have unauthorised personnel working on EKOMAK Compressors. Local rules and regulatons must be adhered to when
working on EKOMAK Compressors.
Any local safety regulations must be strictly observed and when these regulations conflict with what is written within these Manuals, the
local regulations take effect. These regulations must be observed even when they have not been documented.
Compressors must be seated on a suitable foundation.
DO NOT attempt to operate the compressor out of stated operating pressures. (operating pressure is indicated on the serial number
plate)
READ THIS MANUAL CAREFULLY
Each authorized machine operator must have fully read the manual before working on the compressor. The person who is
responsible for plant safety should request all operators to confirm this by signing off.
I HAVE READ AND UNDERSTOOD THIS OPERATOR’S MANUAL
Signature Date
Owner ...................................... .............................................
Operators ...................................... ............................................
1
1. SAFETY
1.1 GENERAL residue off using water based industrial cleaner or steam-clean
EKOMAK Corporation and its subsidiaries design and manufacture as required. If necessary remove acoustical material, clean all
all of their products so they can be operated safely. However, the surfaces and replace acoustical material. Any acoustic material
responsibility for safe operation rests with those who use and with a protective covering that has been torn or punctured
maintain these products. The following safety precautions are should be replaced immediatelly to prevent accumulation of
offered as a guide who, if conscientiously followed, will minimize liquid or oil film inside the material. Do not use flammable
the possibility of accidents throughout the life of this equipment. solvents for cleaning purposes.
The compressor should be operated only by those who have been D. Disconnect and isolate power at source prior to attempting any
trained and delegated to do so, and who have read and understood repairs or cleaning the inside of the enclosure.
this manual. Failure to follow the instructions, procedures and E. Keep electrical wiring, including all terminals and presssure
safety precautions in this manual can result in accidents and connectors in a good condition. Replace any wiring where the
injuries. Read this manual prior to installation, start up and insulation has cracked, cut, or otherwise degraded. Also
maintenance. replace terminals that are worn, discoloured or corroded. Keep
NEVER start the compressor unless it is safe to do so. DO NOT all terminals and pressure connectors’ clean, dust free and
attempt to operate the compressor when safety is in doubt. Tag the tightened.
compressor and render it inoperative by physically disconnecting F. Keep grounded and/or conductive objects such as tools away
and locking out all power at source, ensure that a visible sign from exposed live electrical connects such as terminals to
illustrates the need to keep the machine isolated from the supply so avoid arching which might serve as a source of ignition.
others who may not be aware of the unsafe condition, cannot G. Remove any acoustic material or other material that may be
attempt to operate it until such time as the condition is corrected. damaged by heat or that may support combustion and is in
Install, use and operate the compressor only in full compliance with close proximity, prior to attempting welding repairs.
all applicable Federal, State and Local codes, standards and H. Keep a suitable fully charged fire extinguisher or extinguishers
regulations. DO NOT modify the compressor and/or controls in nearby when servicing and operating the compressor.
any way except with written Ekomak factory approval. I. Keep oily rags, refuse, general litter or other combustibles out
1.2 PERSONAL PROTECTIVE EQUIPMENT of and away from the compressor.
Prior to installing or operating the compressor, owners, employers J. Do not run the compressor without proper and adequate
and users should become familiar with, and comply with, all cooling air flow.
applicable regulations and any applicable Federal, State and Local K. Do not attempt to operate the compressor in any classification
codes, standards and regulations relative to personal safety and of hazardous environment unless the compressor has been
protection equipment. specially designed and manufactured for that duty.
1.3 PRESSURE RELEASE 1.5 MOVING PARTS
A. Install an appropriate shut-off (ball) valve between the A. Keep hands, arms or other parts of the body also clothing away
compressed air outlet of the compressor and compressed air from (pulleys and belts, fans and other) moving/rotating parts.
receiver/tank inlet of the user’s compressed air system. The B. Do not attempt to run the compressor while the fan, belts or
shut-off valve will ensure (quick) pressure isolation between other guards are removed. Keep a safe distance from moving
compressor and compressed air system/pipework, during any parts while protective barriers are removed.
maintenance and repair works. C. Wear snug-fitting clothing and tie back long hair when
B. Select/Use appropriate devices, air hoses, pipe and filters for working around the compressor, especially when exposed to
more effective running/service of the compressor. Ensure all hot or moving parts.
equipment is adequate for working pressure and capacity. D. Keep access doors, if any, closed except when making repairs
C. Check that all compressed air connections are tight/secure and and adjustments.
there are no leakages. Loose and/or poor connections can result E. Make sure all personal are out of and/or clear of the
in accident. compressor prior to attempting to start or operate it.
D. Before removing any fittings, hoses and valves etc. Release the F. Disconnect and isolate all power at source and verify internally
compressors internal air pressure. Stop the compressor then that all circuits are de-energized to minimize the possibility of
ensure that air pressure in the separator tank is released and the accidential start up or operation, prior to attempting repairs or
internal pressure gauge (or the display) shows 0 (zero) internal adjustments. This is especially important when compressors
air pressure. Open the oil filter cap of the separator tank only are remotely controlled, the remote control must be made
when compressor is not running and there is no air pressure in visible by means of signs that can be clearly seen from each
the separator tank. In order to prevent burns and injury, wait point of compressor.
until oil foaming in the separator tank has subsided post G. Keep hands, feet, floors, controls and walking surfaces clean
compressor shut down. and free of oil, water or other liquids to minimize the
E. Keep persons and aminals away from the compressed air possibility of a fall or slip.
discharge points. Do not direct compressed air towards persons H. Provide adequate illumination where the compressor is
or animals. Do not inhale/breathe (industrial) compressed air. installed.
F. Do not play with compressed air hoses such activities can lead 1.6 HOT SURFACES, SHARP EDGES AND SHARP
to injury. CORNERS
G. Do not change factory pressure settings of safety pressure A. Avoid body contact with hot oil, hot surfaces and sharp edges
switch and/or pressure safety/relief valve. and corners.
1.4 FIRE AND EXPLOSION B. Keep all parts of the body away from all points of air
A. Clean up lubricant spills or other combustible substances discharge.
immmediately, when such spills occur inside or around the C. Wear personal protective equipment including gloves and head
compressor. covering when working in, on or around the compressor.
B. Shut down the compressor and allow a cool down period. Keep D. Keep a first aid kit handy. Seek medical assistance promptly in
sparks, flames or other sources of ignition at a safe distance case of injury. Do not ignore small cuts and burns as they can
and do not permit smoking in the vicinity when checking or lead to infection.
adding lubricants.
C. Do not allow oils or oil film to accumulate on, under or around
acoustic material, or on any external surfaces of the air
compressor or on internal surfaces of the enclosure. Wipe
2
1. SAFETY
1.7 TOXIC AND IRRITATING SUBSTANCES

A. Do not use air from this compressor for respiration purposes F. Make sure forklift truck forks are fully engaged and tipped
(breathing). back prior to lifting or transporting the compressor.
G. Carefully lift the compressor, observing the whole area from
DANGER! a safety perspective.
Death or serious injury can result from inhaling compressed H Ensure that a lift operator in constant attendence whenever
air without adequate safety equipment. compressor is suspended.
B. Do not use compressed air in air lines supplying respirators or I Forklift no higher than necessary to clear obstacles at floor
other breathing equipment and do not discharge air from these level and maneouver at minimum practical speeds.
systems in unventilated or other confined areas. J Prevent personel from walking under the compressor when it is
C. Operate the compressor only adequately ventilated areas. suspended . Lift the compressor no higher than necessary
D. Locate the compressor or provide a remote inlet so that it is not
likely to ingest exhaust fumes or other toxic, noxious or
corrosive fumes or substances.
E. Coolants and lubricants used in this compressor are typical to
the industry. Care should be taken to avoid accidental ingestion
and/or skin contact. In the event of ingestion, seek medical
prompt medical assistance. Wash with soap and water in the
event of skin contact. Consult the lubrication section of this
manual for information related to oil replenishment.
1.8 ELECTRIC SHOCK

A. In addition to this manual, the compressor must be installed
and maintained in full compliance with all applicable Federal, Figure 1.1 : LIFTING and HANDLING
State and Local codes, standards and regulations, including
those of the National Electrical Code and also including those
relative to equipment grounding conductors and only by 1.10 OTHER IMPORTANT MATTERS
personell that are trained, qualified and delegated to do so. A. If the compressor enclosure is large enough to hold a person
B. Keep limbs, tools and conductive objects away from exposed and if it is necessary to enter it to perform service adjustments,
live electrical connections. Work in a dry environment, stand inform other personel before doing so, or else secure and tag
on insulatiing surfaces and avoid contact with the compressor the access door in the open position to avoid the possibility of
when making adjustments or repair to exposed live parts of the others closing and possibly latching the door with personel
electrical circuitry. Make all adjustments and repairs with one inside.
hand only-if possible with the right hand-, so as to minimize
B. Do not leave electrical cable ends exposed in accessable
the possibility of creating a current path through the heart.
areas without insulating or covering them adequately (to
C. Repairs must be carried out in a clean, dry, well lit and
ventilated area only. prevent an electrical shock or short-circuit).
D. Do not leave the compressor unattended with exposed C. Make sure that the 3-phase power cables and grounding cable
electrical connections. When unavoidable disconnect, lock and are connected to correct input terminals.
tag all power at source so others cannot inadvertendly restore D. Make sure all personel are out of compressor before closing
power. and latching enclosure doors.
E. Disconnect, lock and tag all power at source prior to E. Do not leave any spare parts, cleaning equipment, tools and
attempting repairs or adjustments to rotating machinery and measuring/control equipments in or on the compressor after
prior to handling any ungrounded conductors. any kind of adjustments and/or repairs.
F. At the VST compressors please wait (after you have turned off the F. Ensure that the safety guards are reconnected after any kind
compressor) 5 minutes before engaging the current circuit. of repair and adjustment.
G. Test all circuits prior to starting the compressor after G. Ensure that moving parts are free to move and not rubbing
installation. against other components or housing.
H. We recommend installation of a fault relay in the main
switchboard of the work
1.9 LIFTING AND HANDLING

A. Set compressor down only on a level surface capable of safely
supporting at least its weight and its physical size.
B. Make sure entire lifting rigging and supporting structure has
been inspected, is in good condition and has a rated capacity
of at least the weight of the compressor. If you are unsure of
the weight, then weigh the compressor before lifting.
C. Inspect lifting attachments for cracked welds and for cracked,
bent, corroded or otherwise degraded areas, also check for
loose bolts or nuts prior to lifting.
D If the compressor includes lifting eyes, then lift using the eyes
provided. When no eyes are provided, lift using a sling as
shown in figure 1.1. In any event, lift and/or handle only full
compliance with Federal, State and Local codes.
E. Make sure pallet mounted compressors are firmly bolted or
otherwise secured to the pallet prior to attempting to forklift or
transport them. Never attempt to forklift a compressor that is
not secured to its pallet, as uneven floors or sudden stops may
cause the compressor to tumble, possibly causing serious
injury or damage to property in the process.
3
2. INSTALLATION
2.1 LOCATION OF COMPRESSOR 2.5 ELECTRICAL PREPARATION
An EKO Series compressor must be placed on a level surface Electrical wiring must be selected and connected according to the
capable of supporting its weight and rigid enough to maintain a rated current values of the compressor as documented within the
level compressor frame. A level, compressor alignment is required. manuals. Connections must be performed by the qualified
The floor must be protected against humidity build up and oil electricians.
leakage which may burn and/or lead to corrosion. The piping NOTE!
weight load should not be transferred to the connections, supports Electrical connections must be checked for conformity, ensure
must be used.. An example area and location is shown in Figure that connections are tight and correctly connected before
2.1. Where external, satelite locations are concerned please consult energising the compressor.
Ekomak or an authorized Ekomak service company which is
WARNING !
nearest to you.
Lethal shock hazard exists inside. Disconnect all power at
source and isolate before opening and servicing
A: COMPRESSOR
1- FLEXIBLE HOSE B: AIR RECEIVER
2- AIR PIPING C: DRYER
3- SHUT OFF VALVE D: FILTER
4- DRAIN LINE E: SHUT OFF VALVE
Figure 2.1: INSTALLATION
2.2 VENTILATION AND COOLING
Select a location to ensure sufficient unobstructed air flow
in/around and out of the compressor to keep the operating
temperature stable. The minimum distance around the compressor
must be observed for maintenance and adequate cooling.
Compressors must be installed according to certified technical .
drawings, dimensions and in addition an ‘Ekomak Screw
Compressors Installation Principles’ document. In order to prevent
a rising ambient temperature in excess of the norm, it is imperative
that adequate ventilation is provided. Do not install the compressor
where it will be exposed to temperatures less than 0 °C’ heat the
compressor room if required. The compressor cooler must not be
exposed to direct sun light; also the compressor cooling air exhaust
system must not be subjected to opposing winds, drafts. These
points can impact the stable operation of the compressor, Pay
particular attention to this subject in addition to other important
factors for compressor room selection and location.
2.3 SERVICE AIR PIPING

Service air piping should be installed as shown in Figure 2.1. A
shut off valve (E) should be installed to isolate the compressor
from servicing the line.
2.4 OIL LEVEL CHECK

A transparent oil level tube line is installed next to the oil filler
plug on the separator tank; two crimps are in place to highlight the
oil level; the Oil level must be between the two crimps highlighted
also, by a sticker which is visible behind the transparent tube. In
order to check oil level accurately, the compressor must be run
until the oil temperature rises to 90ºC, stop the machine and wait
15 minutes, then observe the oil level.
If the running temperature remains below 90ºC, obstruct the
cooling air flow briefly to assist with a temp’ increase. Checking
the oil level below 90ºC can be misleading. If oil level is low, add
oil to the correct level, do not fill above max’ oil level. (Please
read Maintenance section for details…)
4
2. INSTALLATION
2.6 MOTOR ROTATION DIRECTION CHECK 2.6 MOTOR ROTATION DIRECTION CHECK FOR
FOR EKO COMPRESSORS WITHOUT PHASE EKO COMPRESSORS WITH PHASE SEQUENCE
SEQUENCE RELAY RELAY
WARNING! WARNING!
A Motor rotation check must be carried out at compressor start Motor rotation check must be made at compressor start up. As
up. Open the access door to view motor/Air end rotation. needed, open the access door to view motor rotation.
Some Ekomak rotary screw air compressors contain a phase
It is a definite requirement to check the direction of rotation
sequence relay, it is not possible to run the compressor in wrong
during the initial start up.
(motor & air-end) rotation direction.
Please read and follow the instructions below:
1. For EKO machines with a Frequency Inverter (VST);
CHECKING ROTATION DIRECTION FOR COMPRESSORS
• Open the outer panels of the Compressor so that the moving parts
are visible.
EQUIPPED WITH ELECTROMECHANIC CONTROL
Press “READY” button and see the light is on. After you release this
• Initially switch on the machine and immediately select the
button, if the light remains on, you can run the compressor. If the
emergency stop button. Check the rotation of the main fan
light is off, that means, the phases (R,S,T) are connected wrong.
against the arrow illustrated on the tin panel.
Disconnect the power and change the position of any two phases. To
• If the main fan is turning in the opposite direction swap (Phase check it again, please look at the motor protection relay in the
L1, L2) . electrical cabinet. If the light of this relay is on, that means the
• Add the outer panels back onto the Compressor. compressor is ready to start. Then switch the Start-Stop button to
Any tampering of main Electrical feed necessitates this rotation Start position and run the compressor only for a few seconds. The
check. air-end must be rotating on counter clockwise when looking at its
pulley or coupling side. (See Figure 2.2.)
• For EKO machines without a Frequency Inverter
• Open the outer panels of the Compressor so that the moving parts
are visible.
• Initially switch on the machine and immediately select the
emergency stop button. Incorrect Airend rotation can lead to
sever damage if left for longer than approx’ 2 seconds.
• The rotation of the Airend is illustrated on red on the pulley belt
protective plate. For each particular airend type a chart has been
created below (Table 1).
• By incorrect airend rotation direction, swap (Phases L1, L2).
• Add the outer panels back onto the Compressor.
Any tampering of main Electrical feed necessitates this rotation
check. (See Figure 2.2.)
Figure 2.2: DIRECTION OF ROTATION
CHECKING ROTATION DIRECTION FOR COMPRESSORS

EQUIPPED WITH ELECTRONIC CONTROL
Energize the compressor. If the control panel is energized and if there
is no alarm (Er:0020) on the screen that means you can run the
compressor. But if the panel is not energized or if you face Er:0020
fault, that means the phases (R,S,T) are connected wrong. Disconnect
the power and change the position of 2 phases. Then press START
button and run the compressor only for a few
seconds. The air-end must be rotating on counter clockwise when
looking at its pulley or coupling side. (See Figure 2.2.)
5
3. SPECIFICATIONS
3.1. TECHNICAL SPECIFICATIONS
COMPRESSOR TYPE : ………………………………………..

SERIAL NUMBER : ………………………………………..
WORKING PRESSURE : 7 bar 8 bar 10 bar 13 bar
3
CAPACITY : ..................... m /min
DRIVE TYPE : Belt Drive Direct (Gear) Drive
START SYSTEM : Star-Delta Inverter Driven
AIR END TYPE : ...............................................................
COOLING SYSTEM : Air Cooled
AMBIENT TEMPERATURE : 0-45 ºC
AVERAGE WORKING TEMP. : 82-96 ºC
DELIVERY AIR TEMPERATURE : 8-12 ºC above ambient
MAIN MOTOR : 380/400 V, 50/60 Hz, ……… RPM, ……… kW, ……….. A
FAN MOTOR : 380/400 V, 50/60 Hz, ……… RPM, ……… kW, ……….. A
RECOMMENDED OIL : ………………………………………… (The first filling type of oil.)
EQUIVALENT OILS : …………………………………………
OIL CAPACITY : .................... L ……………...…….……
(*) INVERTER : ……………………………………………….….
(*) MOTOR SPEED (MAX-MIN) : ………...... - …..……… RPM …….… - .…..… Hz
(**) BELT TENSION FREQUENCY : ……..… Hz (Natural Frequency of Beltspan)
(*) Only for VST, DVST, GDVST type variable speed EKO compressors.
(*) Only for belt driven EKO compressors.
.
The specifications above are for information only, EKOMAK reserves design modification rights without prior notification. Please read
troubleshooting section and the last section of this manual, for troubleshooting and spare part ordering procedure. Please state the model name
and the serial number when you will order spare parts for your compressor; it will be helpful for your company and EKOMAK to supply and get
spare parts in an efficient correct manner.
6
4. COMPRESSOR SYSTEMS
4.1 INTRODUCTION A pressure relief (safety) valve is set to open if the separator tank
Ekomak oil injected rotary screw air compressors are heavy-duty pressure exceeds the separator tank rating. Also, the control system
air compressors with proven quality, durability and reliability. will trip the compressor if the discharge (Air-End delivery)
4.2 DESCRIPTION OF COMPONENTS temperature reaches 115°C (trip limit) as a high temp’ protection.
EKO, EKO D, EKO GD, EKO VST, EKO DVST, EKO GDVST WARNING !
series rotary screw air compressors consist of a screw compressor Do not remove caps, plugs or other parts when compressor is
unit (air-end), electric motor, starter, drive system with belt-pulley running or pressurized. Stop compressor and release all
or direct coupling, air inlet system, compressed air discharge internal pressure before doing so.
system, compressor lubrication and cooling system, control panel 4.5 COMPRESSOR COOLING AND LUBRICATION
HMI (and controller unit), oil/air separation system, all mounted in
a steel cabinet/enclosure. In addition to above mentioned
SYSTEM, FUNCTIONAL DESCRIPTION
The cooling system consists of a fan, fan motor, an oil/air cooler,
components, for VST, DVST and GDVST models of EKO
oil filter, interconnecting pipes and tubing and a separator tank.
compressors only, an inverter drive is used to manage main motor
Pressure in the separator tank creates oil flow by forcing the oil
speed as a variable speed drive application, this is for continuous
from the high pressure area of the sump to the oil cooler then
and sensitive variable capacity regulation.
through the oil filter to the low pressure area in the compressor
The main motor rotates and drives the screw compressor unit (air-
unit.
end) using a belt-pulley system for EKO and EKO VST models, or
direct coupling for EKO D, GD, DVST, GDVST models. The Oil is seperated from harmful dirt particles and deposits by the oil
compressor unit (the air-end) compresses air by help of oil film and filter. It is then injected into the compressor unit in large quantities
delivers it to the separator tank (the oil/air receiver). The separator and mixes with the air as the rotors turn compressing it.
element in the tank separates oil from the air as it is passed through Oil is added to the separator tank using the oil filling hole and plug.
the seperator element. Oil is collected at the bottom of the tank and
is forced to pass through an oil cooler (> 71°C) where it is cooled The oil flow has three basic functions:
then passed through the oil filter and finally it is injected into the 1. As coolant, it deters rising air temperature normally
Air-end at the injection port/orifice, when a given pressure is associated with the heat of compression.
reached compressed air passes through minimum pressure valve 2. Seals leakage paths between the rotors, stator and also
towards the cooler and eventually to the air receiver of the service between the rotors themselves.
line. A fan blows cooling air on to the oil/air combined cooler 3. Lubricates the rotor bearings.
section to cool oil before returning it into the compressor unit (> The air/oil mixture exits the compressor unit, into the separator
71°C) and also, to cool the compressed air in the aftercooler tank where the oil is firstly coarsely separated from the air; a fine
section of the combined cooler. separation is then performed by the separator element. After that,
the air flows through the aftercooler to the service line while the oil
4.3 COMPRESSOR UNIT, FUNCTIONAL is cooled in preparation for reinjection.
DESCRIPTION
Ekomak rotary screw air compressors (all of EKO series) feature The separator tank (receiver) performs three basic functions:
an oil-injected type compressor unit (Air-End) which consists of 1. Acts as a primary oil separator by structural feature.
two rotors and a housing it provides positive displacement type air 2. Serves as the compressor oil sump.
compression, a continuous and pulse free flow of air. 3. Houses the oil separator element.
NOTE ! (Please look at Figure 5.7 at the end of “Maintenance” section.)
Any interferance with internal parts of the Air-End (Ekomak
compressors) is not permitted and will void the warranty. 4.6 AIR INLET SYSTEM, FUNCTIONAL
DESCRIPTION
4.4 COMPRESSOR DISCHARGE SYSTEM, The compressor inlet system consists of a dry type air filter and an
FUNCTIONAL DESCRIPTION air inlet valve (suction regulator) as shown in Figure 4.1.
While compressed air/oil mixture (delivered by the Air-End) enters The air inlet valve directly controls the amount of air intake to the
the separator tank, the velocity of the mixture is reduced and compressor in response to the operation of the control solenoid
changes direction. Thus, this allows oil to gather (be collected) at valve (by the controller). The inlet valve also acts as a check valve,
the bottom of the separator tank. The air/oil mixture with reduced thus preventing reverse rotation when the compressor is shut down.
oil rate is then directed to the separator element, which, due to its
special design, captures the oil particles moving with the flowing
air and separates oil from the air. Meanwhile, some of oil leaks into
the separator element. This amount of oil will be returned to the
compressor unit (Air-End) through a scavenge/return line which
starts at the bottom of the separator element, by pressure
differential between the separator tank and the compressor inlet.
The life of the separator element can be assessed with periodical
inspections by checking the pressure difference between the line
pressure and internal pressure (P2 and P1). When the compressor is
on load and above 5 bar, the differential must be less than 1.5 bar.
If the pressure difference is over 1.5 bar the separator element must
be changed. If the safety pressure switch stops the compressor
frequently, pressure loss in the separator element must be checked.
The minimum pressure (and non-return/check) valve which is
located downstream of the separator assures a min. tank/ internal Figure 4.1: AIR INLET SYSTEM
pressure of 4 (to 4.5) bar while the compressed air is passed
through the separator element. This (minimum) pressure is
necessary for sufficient air/oil separation and also for sufficient oil
circulation.
The minimum pressure valve has also a check valve feature to 4.7 CONTROL SYSTEM, FUNCTIONAL DESCRIPTION
prevent reverse compressed air flow from the service line to the Functional description of the control system is explained on related
separator tank on shut down and during operation of the pages of the ‘Operation’ instructions fascicle with details. (Please
compressor in an unloaded condition. The minimum pressure valve read ‘Operation’ instructions, in the 2’nd fascicle of this user manual.)
prevents air flow to the compressor outlet when the internal
pressure (P1) is under 4 (or 4 to 4.5) bar.
7
5. MAINTENANCE
5.1 GENERAL AFTER EVERY 1000 HOURS OF OPERATION

WARNING! 1. CHECK CONTROL AIR LINE TUBING, CHANGE IF IT IS
Before performing compressor maintenance, disconnect, REQUIRED.
physically isolate the compressor from its power source and 2. CHECK CONTACTS OF MOTOR CONTACTORS,
isolate the compressor from system pressure by closing the CHANGE IF IT IS REQUIRED.
shut-off valve and ensure internal pressure has completely 3. CHANGE THE PANEL FILTER(s). (Clean if applicable.)
dropped to zero. 4. CLEAN THE COOLER’S (Honeycomb) OUTSIDE
As you proceed with this section, it will be plain to see that the SURFACES VIA NON-FLAMMABLE LIQUID CLEANER.
Maintenance program for this air compressor is quite minimal. 5. CHECK THE DIFFERENTIAL PRESSURE BEFORE AND
Periodical checks and the sevice indicators will alert you when AFTER THE SEPARATOR ELEMENT. CHANGE
service maintenance is required. Read this carefully prior to any SEPARATOR ELEMENT IF IT IS BLOCKED.
maintenance and ensure that the maintenance is performed by an 6. CLEAN THE AIR INLET FILTER. CHANGE THE FILTER
authorized person. This will increase the lifetime of your ELEMENT IF IT IS REQUIRED.
compressor. MAINTENANCE BY UNAUTHORIZED, NON- 7. CHECK OIL HOSE CONNECTIONS (for leakage).
TRAINED PERSONS AND/OR WORKSHOPS WITHOUT AFTER THE FIRST 2000 HOURS OF OPERATION
ADEQUATE FACILITIES WILL VOID THE WARRANTY AND 1. CHANGE OIL AND OIL FILTER.
MAY CAUSE INJURY AND ACCIDENTS. 2. CHANGE THE O-RING OF THE OIL FILLING PLUG.
WARNING ! 3. CHECK ALL OIL HOSE UNIONS/COUPLINGS.
The Compressor must be run for at least 1-2 hours in one week. If a 4. CHECK ALL OF ELECTRICAL POWER CONNECTIONS.
stand still period is > 6 months, oil filter and separator element 5. ADD GREASE TO THE MOTOR BEARINGS. SEE MOTOR
must be changed at the end of the 6 months period (if the LUBRICATION TABLE at the end of this manual (Table 2).
components are used). Also a thermostatic valve repair kit and AFTER EVERY 4000 HOURS OF OPERATION
minimum pressure valve repair kit must be used to service if (In addition to the 2000 hour service)
compressor is out-of-use (not operated) for 6 months. If running 1. CHANGE SEPARATOR ELEMENT.
the unit for 1-2 hours a week is not guaranteed, a corrosion 2. CHECK ALL ENCLOSURE/FRAME BOLTS.
protection agent/oil must be filled into the compressor unit (air-
end) and also into the sepaerator tank. This must be drained prior to 5.4. OIL MAINTENANCE
an initial run. Please consult Ekomak for details about corrosion 1. Shut down the compressor and release internal pressure.
protection agent/oil & procedure if necessary. 2. Remove the oil drain plug and connect the drain
Hose to the drain valve. Put the open end of the hose in a
NOTE: Please conform to all national and local laws and container for used oil .
regulations for effluent oil & condensate removal procedures. 3. Remove the oil filter element.
4. Drain oil completely.
5.2 DAILY OPERATION 5. Close the drain valve and screw the plug of the drain valve .
Prior to starting the compressor, it is necessary to check the oil 6. Fit the new oil filter element after filling with new oil.
level in the sump (separator tank). If the oil level is low, simply 7. Remove the oi,l plug and fill the new oil up to signed/specified
add the necessary amount. If the addition of the oil becomes too normal oil level into the separator tank.
frequent, a simple problem has developed which is causing this 8. Fit and tighten all related parts/connections/fittings then start
excessive loss. Read the TROUBLESHOOTING section for a the compressor by observing running status, carefully check
possible cause and remedy. for leaks (and other possible problems).
After a routine start has been made, observe the control panel 9. The oil may be hot , do not touch.
display and be sure it monitors correctly for this particular phase of
operation. After the compressor has warmed up, a general check is 5.5. OIL FILTER MAINTENANCE
recommended on the overall compressor and control panel, in Replace the oil filter element and the gasket under any of the
order to ensure that the compressor is running properly. following conditions, whichever occurs first:
WARNING ! 1. Every 2000 hours.
DO NOT remove caps, plugs or other components when the (This may be reduced to 1000 hours for dusty environments.)
compressor is running or pressurized. Stop the compressor and 2. Every 6 months.
relieve all internal pressure before doing so. 3. Every oil replacement.
5.3. PERIODIC MAINTENANCE 5.6 SEPARATOR MAINTENANCE

1. As 1st priority, using the control button (or P1 and P2 pressure
AFTER INITIAL 50 HOURS OF OPERATION gauges), check differential pressure value before or after the
1. CHECK THE BELT FREQUENCY. separator element. Replace the separator element when the
(The first belt tensioning procedure must be performed by the differential pressure is higher than 1.5 bar even if service hours
authorized service company personnel. If belt tension is as less than 4000 hours. If pressures are only shown on the
required, new tensioning procesure is not necessary.) controller display, and not gauges, check differential pressure
displayed on the controller display or calculate it by using
AFTER EVERY 50 HOURS OF OPERATION (WEEKLY) displayed P1 (internal) and P2 (delivery/working) pressure
1. CHECK OIL LEVEL.
values. When the separator element is blocked (pressure
2. DRAIN CONDENSED WATER FROM THE BOTTOM OF
differential is very high) the control system displays an error
THE SEPARATOR TANK.
message, if this feature is live.
3. CLEAN THE OIL/AIR COOLER’S (Honeycomb Section)
OUTSIDE SURFACES BY USING COMPRESSED AIR. 2. Replace the separator element at the end of every 4000 hours, if
4. CLEAN THE PANEL FILTER(s). the compressor runs more than 4000 hours in one year. If the
5. CLEAN THE AIR INLET FILTER. operating environment is very dusty or ambient temperature is
6. CHECK THE INTERNAL ARRANGEMENT OF THE higher than 35ºC, separator element must be changed at the end
COMPRESSOR (for leaks). of 3000 service hours.
7. CHECK WORKING OF THE BELT . IF YOU SEE 3. Replace the separator element regulary after one year. Because
VIBRATION OR LOOSENING , CALL THE SERVICE. of it’s design and attributes, separator elements can not be
(*)You can clean the air filter inside maintenance interval, with cleaned instead of replaced.
compressed air (max. 2 bar and dry air) . You must blow the air from
inside to the outside and not damage the filter element. Distance for
blowing is 10 -30 cm
8
5. MAINTENANCE
5.7 PARTS REPLACEMENT AND ADJUSTMENT C- AIR INTAKE FILTER ELEMENT INSPECTION
PROCEDURES 1. Place a bright light inside the element to inspect for damage or
holes.
A- OIL FILTER ELEMENT REPLACEMENT (Figure 5.1) 2. Inspect all gaskets and gasket contact surfaces of the housing.
1. Stop the compressor and wait until all internal pressure has been Replace the gasket if a fault is observed.
released. 3. If the clean element is to be stored for later use, it must be
2. Using a strap wrench, remove the old element. stored in a clean container.
3. Clean gasket sealing surface. 4. After the air filter element has been installed, inspect and
4. Apply a light film of oil to the new gasket. Fill oil into the filter tighten all air inlet connections prior to resuming operation.
element.
5. Tighten the new element by hand. Avoid cross threading. D- SEPARATOR ELEMENT REPLACEMENT
6. Restart compressor and check for leaks. (refer to Figure 5.3)
CAUTION ! The separator elements must be changed every year. Follow the
To minimize the possibility of filter element rupture, it is important procedure explained below for separator element replacement:
that ONLY original replacement elements identified with the 1. Stop the compressor. Close the outlet (shut-off) valve.
Ekomak name, and appropriate part number be used and that 2. Ensure all pressure in the receiver/separator tank is released.
substituted elements are not be used, as such filters may have 3. Disconnect all piping connected to the separator tank’s cover
inadequate or questionable working pressure ratings. plate to allow removal.
4. Loosen and remove the the cover plate bolts.
5. Lift the cover plate from the separator tank. Remove the
FILTER HEAD separator element.
6. Inspect the separator tank for rust or dirt. Clean if necessary.
7. Fit the new separator element into the separator tank, by using
GASKET
new gaskets.
8. Replace the separator-cover gasket and place cover plate,
washers and bolts.
ELEMENT
9. Tighen bolts (in across/opposite order with required torque).
10. Reconnect all piping making sure that they are correct and
tight.
11. Clean the scavenge strainer (and/or orifice) before restarting
the compressor. (If scavenge filter exists on the scavenge line.)
Figure 5.1: OIL FILTER
B- AIR INTAKE FILTER REPLACEMENT

(refer to Figure 5.2)
Air filter replacement time depends on environment conditions, but
SEPARATOR
as average or expected service time, it should be performed every 6
ELEMENT
months. The air filter element replacement procedure is as below:
1. Stop the compressor.
2. Clean exterior of air filter housing.
3. Release tension on cover clamp assembly. SEPARATOR
4. Remove element and clean interior of housing using a damp TANK
cloth. DO NOT blow dirt out with compressed air.
5. Replace the element.
6. Reassemble in the reverse order of the disassembly.
Figure 5.3: SEPARATOR ELEMENT & TANK

Figure 5.2: AIR INLET FILTER
9
5. MAINTENANCE
E- CONTROL SYSTEM ADJUSTMENT

(refer to Figure 5.4)
The compressor is delivered with a control system assigne with
factory standard settings, according to the data plate of the
compressdor. If a new adjustment is requested or required, prior to
adjusting the control system, it is necessary to determine the
desired operational pressure range and also the maximum working
pressure at which the compressor is to operate. The pressure must
not exceed the maximum working pressure which is stamped on
the compressor data (serial number) plate.
Start the compressor with the shut-off valve closed (or slightly
open). Compressor will pass between load and unload running Figure 5.4: PRESSURE SWITCH
modes. Observe the line pressure (on the control panel display or
P2 pressure gauge). If the control sysytem does not unload or it F- POLY-V BELT REPLACEMENT AND TENSIONING
unloads the compressors prior to the desired pressure, adjust the (Only for EKO and EKO VST series belt-drive compressors)
working pressure switch (or working pressure setpoint of the 1. Stop the compressor and disconnect and lock all power at
controller if the compressor is equipped with electronic control source. (Then unscrew/remove the belt guard.)
panel) as required. 2. Release the tension on the belt by loosening bolts/nuts which
are fixing the motor plate to the frame.
REMEMBER THE WORKING PRESSURE SWITCH IS 3. Slowly turn the belt and remove it be carefull to not squeeze
SENSITIVE AND INCORRECT PRESSURE SETTINGS MAY your fingers among belt and pulley.
CAUSE DAMAGE TO THE COMPRESSOR. 4. Put in place a new belt of the same type and size with the
original. Both the belt and the pulley have grooves equally. Put
FOR PRESSURE RANGE (MAX. WORKING PRESSURE) these grooves in correspondance.
ADJUSTMENT 5. Ensure the belt tension is correct. The measured belt tension
1. There are two adjustment screws on the pressure switch for frequency must be same with which is specified on the
high and differential values of the working pressure ranges. ‘Technical Specifications’ page of this manual, 3’rd section.
The screw on the right hand side-when looking from the front Tighten (or slacken) tensioning bolt/nuts of motor plate as
of the switch- is the high pressure setting screw. Turn the required, to get correct belt tension.
screws gently during adjustment. 6. Check pulley alignment by using apropriate template. Check if
2. If the compressor runs unloaded under required pressure, turn front faces of pulleys are coincident in same plane, (it is OK).
screw counterclockwise slightly up to reach desired pressure. 7. Tighten the counter nuts of the tensioning bolts to fix the motor
NOTE: IF YOUR COMPRESSOR IS EQUIPPED WITH AN position after ensuring or confirming the alignment is correct.
ELECTRONIC CONTROL PANEL, THE WORKING 8. Check all bolts and nuts are secured.
9. Re-energize the compressor and start it. Check the belt-pulley
PRESSURE SENSOR IS USED INSTEAD OF THE
arrangement while running and readjust if it is necessary. If the
SWITCH AND WORKING PRESSURE SETTINGS ARE belt is vibrating, the cause may be inadequate belt tension
CONTROLLED USING THE CONTROL PANEL. (slack belt) or mistaken pulley alignment.
Please read and perform electronic control panel (controller
Belt tension checking (and adjusting if it is necessary) is important
unit) adjustment instructions and explanations (in the 2nd
to prevent early wear and break out of the belt.
edition manual, “Operation”) for VST, DVST, GDVST series
and other type Ekomak compressors with electronic control The belt should be re-tensioned after the first 50 running hours
system. and the tension should be checked for every 500 hours.
FOR DIFFERENTIAL ADJUSTMENT USING OF BELT TENSIONING FREQUENCY MEASURING
Differential is the difference between the high and low pressure DEVICE:
settings. Here, ‘high’ means unload or maximum working pressure By using Contitech VSM-1 or another device with same
value while ‘low’ means load or minimum working pressure value. functionality,
Differential is set to run compressor on-load at desired pressure. 1- While the compressor is not running, hit the top middle of the
After setting the maximum working (unloading) pressure of the installed belt by hand or by a wrench without damaging the belt, to
compressor, using the ‘Range’ adjustment screw, the diffential vibrate it. Or pull the belt from the middle to up hardly by finger.
pressure is set by using ‘Differential’ adjustment screw. If the 2. While the belt is vibrated by hitting locate the probe of the
compressor loads before desired pressure, the differential device at about 2 cm distance from middle top surface of the belt.
adjustment screw should be turned clockwise gently to widen the 3. The device will display the tensioning frequency as Hertz (Hz)
differential. The screw should be turned counter clockwise to unit. That is “Natural Frequency of Beltspan” value and it must be
reduce the differential value. equal to the reference value. If the measured frequency value is
Please adjust the pressure range and differential as described above higher than the reference value, the belt tension is more than
(and as shown on Figure 5.4). Observe the delivery pressure (P2) required, if the measured frequency value is lower than the
while adjusting. (Use the outlet delivery pressure of the compressor reference value, it is less than required (slack).
as a benchmark.) Finally, check the compressor performs unload
Warning! If pulley diameters or belt length will be changed later,
and load functions correctly, as expected and specified in normal
then, belt tensioning frequency reference value will changed. The
conditions.
given reference value on “Technical Specification” page of the this
DANGER manual (in Section 3) is for original factory belt-pulley
PREVENT contact with electrical contacts, terminals or leads configuration. It is required to refer to an authorized local
Severe electrical shock may occur. DO NOT leave the pressure compressor service company for a new belt tensioning frequency
switch cover open. value for a new pulley-belt configuration.
10
5. MAINTENANCE
G- OIL RETURN (SCAVENGE) LINE MAINTENANCE

During oil/air separation, small quantities of oil pass through the
separator. The oil is re-circulated to the system through the return The quantity of moisture/condensation build up in the moisture
(scavenge) line. When the compressor is running at full load, oil separator vessel (in conjunction with vessel spec’), depends on the
flow should be visible in the transparent retun line. Sluggish flow installation environment (ambient) conditions, moisture content,
at full load indicates a need to clean the return line strainer or temperature, and also loading condition/rate of the compressor.
scavenge orifice. When the little hole of the scavenge orifice is
blocked by fragments or due to corrossion the oil level in the
separator tank reduces quickly. When decreasing oil level is
experienced, the reason could be a blocked orifice. In this case,
remove the scavenge assembly (strainer, orifice etc) and clean
it/them using compressed air or a thin wire, prevent damage whilst
cleaning the assembly. DO NOT increase the diameter of the
scavenge orifice. This may reduce the capacity of the compressor.
Figure 5.6: MOISTURE SEPARATOR (Optional)
DANGER !
Stop the compressor and wait for all internal pressure to
release (“0” bar must be shown on P1 pressure gauge or the
display for P1 internal pressure) before any maintenance or
repairs are carried out.
In order to service the moisture separator, open the vessel by

removing the fixing bolts between the housing and the cap.
Clean the vessel and the internal parts before reassembling. Use
a new o-ring, lubricate it with grease, then reassemble the
moisture separator vessel.
Figure 5.5: SCAVENGE ASSEMBLY
Check the drain soleonid valve, clean (with compressed air) or
H - MOISTURE SEPARATOR MAINTENANCE replace if neccessary.
As an option, a moisture separator is located downstream of the
For float type drain device, there is no drain timer function, this
Compressors air cooler (after-cooler) just before the compressor
outlet/delivery flange or pipe, which removes condensed water
operates according to the water/condensation fill level. To
which builds up in the oil/air cooler. This moisture separator prelong the servive life of this floater ensure that it is cleaned
(Figure 5.6) drains condensation which is collected in the vessel, on a regular basis. Where this is the case, no timer or Solenoid
automatically (controlled by a timer, solenoid valve or float exists.
device).
If a drain line is needed for the compressor, it must be
If the compressor is equipped with a moisture separator option constructed as such that pressure back flow to the moisture
(customer request), the drain (‘start’ and ‘on/open’) time is set in seperator is prevented.
the factory.
(Generally, it is adjusted to open for 3 seconds at one minute
intervalls. It can be set at 1 to 5 minute intervals to open for 3 to 6
seconds. Note: The condensation drain will close after the open
period has expired until the next interval starts.
Authorized service personnel should set this drain according to the
principles above.
• To determine the correct discharge intervals ensure that prior to
drain closure only air and no moisture is being discharged from
the drain, this is to prevent moisture build up in the vessel which
can lead to pressure loss and blockages. (A mechanical balance
must be found to reduce moisture build up).
11
5. MAINTENANCE
5.8.A SERVICE INSTRUCTIONS FOR THREE- PHASE MOTORS

1) The electric motor has left the factory assembled and physiaclly connected to a compressor unit. It has been electrically connection and
dynamically balanced, and is ready for operation. For a trouble-free functionality care must be taken that the motor is not subjected to
possible damaging scenarios during transport and in the event of any damage, it must be properly documented and escalated.
2) When the motor has not been used for a prolonged period of time, inspect the bearings and re-grease if necessary.
3) When operating the motor at rated voltage and rated output, the motor temperature rises to an approx’ maximum ambient temperature of 40
ºC but must not exceed 80 ºC for class F insulation.
4) Check the data on the rating plate. The voltage marked on the rating plate must compare with the networks main voltages within tolerance.
5) In all of our compressors, electric motors have WYE-DELTA starter (except EKO – VST series compressors).
6) VDE 0580 and VDE 0100 norms require that all motors be correctly earthed.
MOTOR BEARING LUBRICATION CHART.

Table 2
GREASE GREASE REPLACEMENT

SPEED GREASE
POWER (kW) LUBRICATION AMOUNT REPLACEMENT GREASE QTY
(rpm) TYPE
HOURS (gram) HOURS (gram)
75-90 1500 2000 25 16000 145 SKF LGWA 2

75-90 3000 2000 25 16000 145 SKF LGWA 2
110-132-160 1500 2000 40 16000 260 SKF LGWA 2
110-132-160 3000 2000 30 16000 170 SKF LGWA 2
200-250 1500 2000 50 16000 325 SKF LGWA 2
250-250 3000 2000 35 16000 210 SKF LGWA 2
315 1500 2000 60 16000 390 SKF LGWA 2
315 3000 2000 45 16000 250 SKF LGWA 2
* For 75 kw motors and above use the Lubricantion table above for a bearing lurication reference.
* For motors smaller than 75 kw reference must be made to the motor type plate regarding bearing lubrication. .
* The required amount of grease must be applied to the bearings and their casing only after thoroughly cleaning the entire assembly. The front
casing must be completely empty and clean before lubrication.
* SKF LGWA 2 Must be used for lubrication purposes or its equivalents which are named below. No other grease type should be used.
SHELL ALVANIA R3
ESSO UNIREX N3
* A detailed lubrication instruction chart can be found on the machine.
5.8.B FLUID SEALANT (LOCTITE) USE
NO COLOUR
243 BLUE : For securing removable fastenings/connections (bolt-nut fixing).

270 GREEN : For securing non-removable/fixed connections (fasterners and/or fittings).
542 RED : For sealing of fitting connections up to 3/4”.
577 YELLOW : For sealing of fitting connections 3/4” and above.
(*) In Ekomak compressors used Loctite sealing liquids . During maintenance you may use equivalent products with the same quality .
12
5. MAINTENANCE
Figure 5.7: PIPING and INSTRUMENTATION DIAGRAM
13
5. MAINTENANCE
5.9 INVERTER MAINTENANCE AND INSPECTION FOR ALL VST COMPRESSORS
Daily inspection:
Check the following items with the system fully operational.
1. The motor should not be vibrating or making unusual noises.

2. There should be no abnormal heat generation.
3. The ambient temperature should not be too high.
4. The output current value shown on the monitor display should not be higher than normal.
5. The cooling fans on the inverter should be operating normally.
Periodic inspection:
Check the following items during periodic maintenance.
1. Always ISOLATE the power supply before beginning the inspection.

2. Confirm that the LED indicators on the front cover have all EXTINGUISHED, and then wait until the time stated
on the yellow label has elapsed before beginning the inspection. Be sure not to touch terminals directly after
the power has been turned off. Doing so can result in electric shock, due to capacitive charge.
Parts Checks Remedies

External terminals, Are all screws, nuts and bolts tight? Tigthen loose fittings firmly.
mounting bolts/screws, Are connectors tight? Reconnect/tighten the loose connectors.
connectors
Cooling fins Are the cooling fins dirty or dusty? Clean off any dirt or dust using an air
gun with dry air, max. 6 bar.
PCB’s Is there any conductive dirt or oil residue on the the PCB’s? Clean off any dirt or dust using an air
Prevent ESD (Electro Static Discharge) when working with gun with dry air, max. 6 bar.
Electronic equipment.
Cooling fans Is there any abnormal noise or vibration? Or, has the total Replace the cooling fans.
operating time exceeded 20000 hours?
Power elements Is there any conductive dirt or oil residue on the the PCB’s? Clean off any dirt or dust with an air
Prevent ESD (Electro Static Discharge) when working with gun using dry air, max. 6 bar.
Electronic equipment.
DC Capacitors Are there any irregularities, such as discoloration or odor? Replace the DC capacitors of the
inverter.
Periodic maintenance of parts:
For the inverter to optimally perform its function all of its associated components must be fully functional.
Apart from electrical/electronic components, there are components which also require maintenance depending on
conditions. To sustain normal inverter operation, it is necessary to perform periodical inspections and when necessary
replace parts according to their service life.
Periodic inspection requirements vary depending the inverter’s installation, environment and use. The inverter’s
maintenance periods are listed below. Keep them as reference
Part Replacement Interval Replacement Method

Cooling fans 3 years Replace with new parts.
DC capacitors 5 years Replace with new parts.
Fuse (charging resistor) - Check during maintenance.
Aluminium capacitor on PCB 5 years Replace with new board. Decide during inspection.
NOTE:
• Inverter maintenance is valid only for EKO VST, EKO DVST and EKO GDVST series screw air compressors. Inverters (Frequency
converters) are not used in other type EKO compressors .
• Please check terminals of the components, which are located on the circuit. (Frequency, main engine, choke, HF-Filter)
14
6. TROUBLESHOOTING
6.1 INTRODUCTION 1. Check for loose wiring.
2. Check for damage piping.
The information contained in this troubleshooting chart is based 3. Check for parts damaged by heat or an electrical short circuit,
upon both the reports coming from actual field applications and usually apparent by discoloration or a burnt odor.
extensive testing performed at the factory. It contains symptoms Should your problem persist after making the recommended check,
and usual causes for the described problems. All available data consult your nearest Ekomak representative or the Ekomak's
concerning the trouble should be systematically analysed before factory.
undertaking any repairs or component replacement procedures. A WARNING!
detailed visual inspection is worth performing for almost all Take care of the performing any repairs or maintenance or
problems. troubleshooting process by trained and those who know what
to do persons or by our company. Before the compressor
6.2 TROUBLESHOOTING repairs or servicing, disconnect the machine from electric
Doing so can prevent unneccessary damages always remember to: power and air network.
SYMPTOM POSSIBLE CAUSE REMEDY

A No Electrical supply. Energise the compressor.
B Line Circuit breaker tripped. Reset and try again.
For compressors with electronic control system, phase sequence fault prevents
Phase sequence is wrong. ONLY
C compressor to start, and “0020” error message is diplayed. The solution is to check
WHERE PHASE RELAYS ARE USED.
the phase rotation and change sequence/position of any two phases.
Motor protection relay cuts the energy. Please check if the light on this relay. Most
Low incoming voltage or phase fault or common route cause is a phase fault while compressor is running but has a low
D unbalanced phases. ONLY WHERE voltage problem, the fault then disappears after the compressor is stopped. Look at
PHASE RELAYS ARE USED. the light of the relay during start-up, if the light is “ON” at the beginning of motor
1 Compressor does start-up but “EXTINGUISHES” this is a low voltage problem.
not start. If the control system displays a trip/shutdown or alarm message which indicates an
Inverter (in VST, DVST, GDVST error which inhibits a compressor start or run, resolve by referring to the control
E compressors) or electronic control panel (Operation) manual. Check the starter/inverter and controller wiring and
panel/system fault. connections with the electrical wiring diagram of the compressor. Call the nearest
authorized Ekomak local service company.
Check the failure lights on the control panel. If your compressor is equipped with
The compressor stopped due to a
F electronic panel, please read to the electronic control panel (Operation) manual to
failure.
understand the fault signal.
The earth and neutral line connection is Carry out resistant checks. Connect the point ‘Mp’ on the electrical control/starter
G
non existent or incorrect. board, to neutral line and also connect the Earth point to the earth/ground line.
Check your cable size against the cable size table. If the cable size is not enough, the
The cross section of the incoming cable is
A incoming voltage can drop due to a high resistance. Use appropriate cable with
too small.
recommended size and recommended length.
To understand, measure incoming voltage lines/phases while the compressor is
inoperative and start the compressor whilst the measurement continues. If the
B Low incoming voltage.
voltage reduces to 360 volts or lower, the problem is the main power network or
installed power capacity of your factory/workshop.
If ambient temperature is too low (under +5ºC or lower), the oil viscosity can lead to
C The ambient temperature is too low. an increased resistance/load. Ensure the ambient temperature (in installation area) is
kept above +5ºC.
When the compressor has been stopped, an air blow down or releasing sound should
The compresor has been re-started before
be heard. Wait for this air to release and verify that the internal pressure is
D the internal pressure has been fully
released, by pressing the control button and checking the display or by looking
released since the last stop.
at the internal pressure gauge (must display ZERO).
* 11-45 kW models: The air inlet valve is open at the beginning of the start-up
phase, then closes (in WYE stage of start). If it does not close at this stage, there is a
Compressor runs
2 mechanical problem (the control air can not move the valve/head).
with difficultly.
Verify the valve/head moves easily forwards and backward by hand when the
E The Air inlet valve is defective.
compressor is stopped and internal pressure is ZERO. If the valve/head moves
with difficulty, call the authorized local service company. * 55 kW and above
models: Verify the valve/head is full closed; if it is not, the valve/head is defective,
call the authorized local service company.
If the minimum pressure valve (MPV) leaks due to inssufficient valve closure the
network compressed air can return, leading to a difficult compressor start due to
opposing air thus internal pressure build up. To understand this, start the compressor
when the system (outside) air pressure is zero, then observe a normal pressure
F Minimum pressure valve defective.
increase. If pressure does not rise, the MPV does not hold internal pressure and leaks
the air through. Stop the compressor, wait for internal pressure to release then
remove the MPV. Check the gasket and o-rings, replace/renew which one needs to be
replaced.
Stop the compressor and isolate the power out, check the belt or coupling rotates easily
Motor or compressor unit (Air-End) has a
G by hand. If you sense an abnormal high rotation resistance, the cause may be an air-end
mechanical problem.
or motor (bearing) damage; call the service company.
15
6. TROUBLESHOOTING

If the compressor is equipped with a standard (electromechanic) control panel,
The compressor does not switch from the STAR/DELTA time relay (ZR1) may be defective or incorrectly adjusted.
A STAR to DELTA. (STAR/DELTA Check the time adjustment (approx. 6 seconds) light/LED indicators. If the 2nd
motor starter failure.) light/indicator is not illuminated or the colour does not change when STAR
ends, the relay is defective and must be changed.
* 11-45 kW : Inlet valve/head may be stuck in closed position.
B Inlet valve defective. * 55+ kW : The control air from the solenoid valve can not move the actuator
piston (servo cyclinder diaphragm is damaged), call the service company.
C Minimum pressure valve defective. Read 2F.
*11-45 kW: Check power supply to the solenoid valve, when the solenoid is
energised, by listening carefully a mechanical problem with the valve
diaphragm might be audible. If a power switching sound cannot be heard, the
Compressor is not solenoid (the coil) is probably defective. Change the solenoid (coil) or the
3 producing air (does complete solenoid valve if it is required.
not run on load). *55+ kW: Check power supply to 2 solenoid valves. If power is not supplied to
D Solenoid valve defective/unplugged.
solenoids, check “K” relays whether the contacts or coil is damaged. Change
the relay if damaged is determined. Another possible cause is a failure of the
by-pass solenoid valve to close (with 2 way NO solenoid valve). Check the
solenoid valve for blockage dirt, or a damaged solenoid or diaphragm. Change
the solenoid or complete valve if it is required. Check the control/unloading
solenoid valve (with 3 way), change if it is required.
Pressure switch or wiring is defective. If the compressor is not running on load and the ‘on-load’ lamp is not ON there
(for compressors with electromechanic is a pressure switch or wiring problem. Check wiring and pressure switch,
control panel) change if it is defective. Check between the normally open (auxilary) contacts
E
of Contactor K2.
Electronic control panel (the controller By looking on the electrical wiring diagram, check the relay out which
unit) or wiring is defective. energizes the control (loading/unloading) solenoid valve (SV1).
Close the shut-off valve on the delivery line, slowly, to ensure the compressor
Air demand is too high (above the reaches maximum working pressure. If the delivery pressure rises and the
A
compressors capacity). compressor unloads at the max’ working pressure setpoint, it means the
compsumption/demand is higher than the capacity.
If you are sure that the compsumption is not more than the capacity, check for
Air leaks on the delivery or
B air leaks along the compressors pipework (delivery and comsumption line
consumption line.
assembly).
Compressor can Restrictions in the inlet air filter leads to higher running temperatures (also
not reach to the C Air filter is dirty/blocked. capacity loss). Stop the compressor, inspect air filter element and change
4
maximum working (clean) if it is dirty/blocked.
pressure. When the inlet valve does not open enough (valve/head is stuck). While
compressor is inoperative and internal pressure is zero, check that the
D Inlet valve defective.
valve/head is full closed and moves forward and backwards easily. Call the
service company if the valve/head is restricted in any way.
If an abnormal noise is heard whilst the compressor is running, mechanical
Air end mechanical failure (compressor failure could be the issue. If condensed water in the separator tank is not
E
unit). drained periodically, water might have mixed with oil and circulated into the air
end and caused air-end damage. Call the service company.
Check the range adjustment of working pressure switch; when the pressure
Pressure switch is defective. (for reaches the max’ working pressure setpoint, the contacts of the switch must be
compressors with electromechanic switch to the open position. If the device is not switching, it is defective and
Compressor does control panel) must be replaced. (You can have the switch operate more easily by adjusting the
A
not unload at range screw to minimum pressure.)
maximum working Maximum working (Unload) pressure
pressure (over the setpoint has been changed or is wrong. If your compressor has an electronic control panel, check the max. (unload)
5 max. working working pressure setpoint on the menu page of the controller unit (display).
pressure setpoint). This fault can occur when the inlet valve cannot close (valve/head stays open
and jams). While compressor is inoperative and internal pressure is zero,
B Inlet valve defective.
(please read also check that the valve/head is full closed and moves forward and backwards
symptom 9) easily. Call the service company if the valve/head is restricted in any way.
C Solenoid valve defective. Read 3-D.
Air leaking on the control air Check the control air circuit fitttings and connections, tighen when loose.
D
line/circuit. replace hose or tube if it is defective/damaged.
16
6. TROUBLESHOOTING

When the compressor is ruınning on load, observe oil return through the transparent
tube or sightglass. If there is no oil flow/return in the scavenge line, stop the
compressor. Clean the scavenge orifice with a thin wire and compressed air (also
The orifice or strainer on the scavenge (oil clean the strainer when used) then re-fit after checking that the orifice is open by
A
Significant excessive return) line is blocked. blowing air through it. If you have cleaned the orifice (and strainer) properly, you
oil consumption. see oil flow through the scavenge line (transparent tube or sightglass) 10-15 seconds
6 (Oil leaks or oil is after running the compressor, then a foamy oil flow. Check the scavenge oil flow
being carried to the after 15-20 minutes, again.
delivery line) If scavenge (oil return) line is working properly, most possible cause is a damaged
separator element. You can see oil mixed with compressed air at the delivery point,
B The separator element defective.
as liquid oil or oil residue is visible in the pipe (or significant oil content can be seen
in drain condensate). Change the separator element in such circumstance.
Check the oil circulation line/circuit fitttings and connections, tighen when loose. If
C Oil leaks from oil system.
the leak cannot be prevented call the service line.
Read fault (error code) on the controller display (E.OC or E.OL etc.) of the
electronic control panel. Wrong pressure setting or worn/damaged motor bearings
Motor or power supply fault or wrong (mechanical rotation resistance) or power supply voltage fault may cause an
A
maximum working pressure setting. overload (trip, shutdown). Please read the electronic control panel manual
(“Operation” manual) for details. Correct the malfunction by performing fault
finding steps.
Verify that the main motor thermal overload relay is adjusted correctly according to
the main motor’s nominal power and current limit. By using a clamp Current muli
Main motor overload meter (while compressor is running on full load), observe values of currents
protection shut downs through the thermic overload relay are in normal limit and balanced (on each
compressor. Overload relay is defective or overload
B phases). If overload relay cuts the current/circuit while setpoint is correct but
setting is wrong.
7 measured current is below (than setpoint), the relay is defective and must be
(Read symptom 2 if it changed.
occurs during start- If the compressor has electronic control panel (or it is VST) please read the
up) electronic control panel manual (“Operation” manual/fascicle).
C Low incoming voltage. Read 2-B.
Compressor running with pressure above
D Read symptom 5.
max. working pressure setpoint.
When the compressor running on (near to) full load, check the pressure differences
between P1 and P2 gauge pressures. If internal (P1) and delivery (P2) pressure
E Separator element is blocked.
differential has reached to 1-1.5 bar level, that means, the separator element is
blocked and it needs to be changed.
F Mechanic failure in the air-end. Read 4-E.
Verify the fan motor thermic overload relay is adjusted correctly according to the
fan motor’s nominal power and current limit. By using a clamp ammeter (while the
Overload relay is defective or overload fan is running), observe values of currents through the thermic overload relay are in
A
setting is wrong. normal limit and balanced (on each phases). If overload relay cuts the current/circuit
while setpoint is correct but measured current is below (than setpoint), the relay is
defective and must be changed.
Fan motor overload
Panel filter, the cooler honeycomb/battery Ensure that the compressor room (installation area) ventilation is adequate. Change
8 relay
outer surfaces are blocked or (warm) dirty and or blocked filter elements. Clean the cooler surfaces with compressed air.
shut downs B
cooling air exhaust is obtructed. Do not allow obstructions or restrictions (narrow sections) on (cooling air
compressor.
(Ventilation problem). suction/inlet and) exhaust ducting.
If motor currents are higher than normal (nameplate values), it means an overload
of the fan motor. When all enclosure/access doors of the compressor are open, run
C Fan motor defective. the compressor for a short time and listen to the fan motor sound (to understand if it
is abnormal or normal) and inspect the body/stator/housing temperature, if the
motor overheats due to an overload or a bearing problem. Call the service company.
For compressors with electromechanic
control panel, defective working pressure
switch or incorrect settings.
A Read 5-A.
For compressors with electronic control
panel, max’ working pressure setting is
incorrect.
Compressor shuts Check the safety pressure switch setting, it must switch when the set high pressure
down due to high Safety pressure switch (P1) setpoint is
is reached. (To understand if the switch contact is operative or defective, you can
9 pressure fault. incorrect or (P1) pressure sensor (for some
B set the pressure to minimum by turning the adjustment screw.) If the presure switch
electronic control panel models with two
does not switch its contact position between open and close according to safety
(Please read symptom pressure sensors) fault.
pressure setpoint, the switch is defective and must be replaced.
5 together) Minimum pressure valve defective (does
C Inspect gasket and o-rings of the MPV, change if it is required.
not open).
D Separator element is blocked. Read 7-E.
The shut off valve (at the delivery line
E of the compressor, outside the Open the shut-off valve and restart the compressor. (After reset.)
compressor) is left closed.
17
6. TROUBLESHOOTING

Check the temperature gauge (combistat, electromechanic control panel) for
The temperature gauge (combistat) or
A defects or wrong adjustment. Check the temperature sensor (electronic control
sensor setting is wrong.
panel) setting on the controller menu (diplay) page.
B Ambient temperature too high. Check if there is enough ventilation, adjust when required.
The cause may be a narrower air inlet suction area than the compressor’s inlet
Ventilation opening and cooling air air flow section. Or, insufficient hot air exhaust. The temperature may have
C
flow is not adequate. increased and cooling capacity may have reduced, if the cooler is exposed to
direct sunlight or obstructed by opposing wind. Take preventative measures.
D Oil level too low. Check and add oil if necessary.
E Oil filter blocked. Check and replace if necessary.
This can be assessed by looking at the colour of the oil. (The oil color becomes
Oil viscosity decreased and other oil darker and oil viscosity decreases, oil becomes thinner.) If an oil change
High temperature
F features deteriorated. (Oil service life is becomes necessary in a shorter time than the specified oil change time, please,
10 fault shut downs
expired.) check the running conditions of the compressor (worsens, as high ambient and
compressor.
running temperature, gases in the area/environment, moisture rate etc.)
G Air filter is dirty blocked. Check the filter element, clean and replace when required.
H Panel filter is dirty or blocked. Check the filter element, clean or replace when required
Outer (Honeycomb) surface of the
Check and clean if required. (Call service to understand if inside cleaning of
cooler is dirty/blocked. Fan blades are
I the cooler is necessary or not, when outside cleaning can not solve the
dirty. (Or internal oil flow sections of
problem.)
the cooler are blocked.)
Check the exhaust duct, section and resistance (pressure loss) level. The
Cooling air exhaust duct is too long or it
exhaust duct section area must not be narrower than the cooler’s air flow
J has narrower section than
section area and it must not restrict the cooling air flow. Improve the cooling
recommended.
air flow rate by performing modifications.
K Thermostatic valve defective. Call the authorized local service company.
Compressors with electromechanic
control panels, the pressure setpoints of
the working pressure and safety
pressure switch are incorrect (or one of
A these switches is defective and or Read 5-A and 9-B.
incorrectly adjusted).
For compressors with electronic control
11 Safety valve opens.
panel, pressure settings are incorrect.
B Separator element is blocked. Read 7-E.
C Air inlet valve defective. Read 5-B.
D Solenoid valve defective. Read 3-D.
If the safety valve opens under/below it’s pressure setting, replace it with new
Safey (Pressure relief) valve setting is
E one.
wrong/defective.
*55 kw and above: The shut-off valve may be closed.
Main motor overload relay setting is
A Check the setting of the thermic overload relay.
below than the required/normal.
Measure the motor current and sperator pressure loss/difference at full load. If
Compressor shut main motor currents are higher than normal/nominal limits, check voltages.
B Compresor current over-load.
downs itself when Check for mechanical problems on motor or air-end as described 2-G. Change
working pressure is the separator element if pressure difference in the element is high.
12
reaching to the The temperature gauge (combistat)
maximum working setting or max’ (air-end) delivery Check the max’ (air-end) delivery temperature setting.
C
pressure. temperature setting of the electronic
control panel is too low.
Check the (air-end) delivery temperature while runing on full load, also,
D Compressor is overheating.
perform checks as described symptom 10.
For compressors with electromechanic Run on time relay (ZR2) is faulty or incorrect setting. Check the setting
control panel, run on time relay (ZR2) (approx 4 minutes). When the compressor is running off-load, select the
defective or time adjustment is automatic mode by switching the continuous/automatic selection button,
incorrect. observe lights on te relays. If the second light is off, at the end of adjusted
A time, then the relay is defective and it must be replaced.
Compressor For compressor with electronic control Check the setting and functionality, replace the defective part of the controller
13 does not stop panel, the controller unit has a fault (or unit, if it is required. (Call the authorized local service company for checking
in auto mode. incorrect setting). and repairing the controller unit.)
If off-load running time of the compressor is shorter than the setpoint of the
The compressor switches running mode run on time (waiting duration for off-load running, before stop), while the
B from off-load to on-load before the run compressor starts to run on load again, the control system disables and resets
on (wait while idle) time is expired. the run on time countdown (ZR2 relay or timer) and the compressor does not
stop even if it runs in auto mode.
18
6. TROUBLESHOOTING

A Low oil level (quantity). Check the oil level, add oil into separator tank if oil level is low.
Check the ambient temperature. (Prevent high temperature in the intallation
B High ambient temperature.
area if it is possible.)
C Inadequate ventilation. Read 10-C.
D Blocked/Dirty cooling system. Clean the plugged/dirty sections (surfaces) if it is required.
E Blocked/Dirty air filter. Clean and replace if it is required.
* For belt-driven compressors:
Compresor runs at Check the belt tension. Adjust alignment if necessary to prevent vibration.
14 Tighten the belt if it is required using a frequency meter, refer to belt
(high) temperature. * For belt-driven compressors:
tensioning and replacement in the maintenance section or call the service
F Inadequate belt tension (Slack belt)
company. (if the ribs of the belt are contaminated with oil, belt slipping,
resulting in slipping
smoke and a very high screaching noise might be experienced. Prevent this
using chalk. Apply the chalk to the oil contaminated area of the belt then clean
the powder off the belt surface.)
Mechanic problem in the air-end High (abnormal) running noise from the air-end might be experienced. Call the
G
(compressor unit). authorized local service company for repair.
H Thermostatic valve failure. Call the authorized local service company for repair.
If cloth etc has found its way into the separator tank, it can lead to restrictions
When compressor in the oil circulation system. Care must be taken whilst using cleaning
switches between Restriction in oil circulation system materials to clean inside of the compressor and it’s components.
running mode to (pipes, hoses, fitttings, orifices etc.) or If the oil filter is not an original oil filter, resistance to oil flow may be higher.
15 A
off-load, (air-end) blocked oil filter. If the outside air is contamined (around the compressor) fine dust and abrasive
delivery gases/fumes (as in sand blasting workshops, chemical installations/plants), this
temperature rises. contaminated air reduces the service life of the oil, oil filter and separator
element.
Some components are not seated Please check and tighten the connections carefully. (Motor, air-end and fan
A
securely. assemblies must be securely fixed to prevent hazardous situations.)
* For belt-driven compressors:
Compressor runs
Read 14-F. Also, stop the compressor and check alignment of belt pulleys by
with abnormal * For belt-driven compressors:
using a laser test tool and template. If pulleys are misaligned, correct the
16 noise B Belt tension and/or aligment is not
aligment by following described belt tensioning and alignment procedure in
(above the normal correct.
the maintenance section. (Usually, the motor plate & pulley position is correct
db level).
after shipment.)
C Motor bearing problem. Check motor bearings and replace if required.
D Mechanical problem in the air-end. Read 2-G.
Compressor runs * For belt-driven compressors: * For belt-driven compressors:
A
with abnormal Slack or worn belt. Read 14-F. Also, inspect belt ribs, replace the belt if ribs are worn.
noise B Start of motor bearing problem. Check motor bearings and replace if required.
(above the normal
17
level) while the
working pressure C Mechanical problem with the air-end. Read 2-G.
approaches max’
value.
Abnormal noise A possible cause is the air inlet valve does not perform by-pass function while
Air inlet valve defective.
(above the normal A running off-load. (Another possible cause is blocked scavenge line.) Call the
18 level) while service company.
compressor runs Oil filter or oil circulation system is
B Read symptom 15.
off-load. restricted.
Off-Load running Compressed air leaks backward from delivery line to the separator tank,
A Minimum pressure valve defective.
pressure does not through the MPV. Replace MPV gasket and o-rings.
19 reduce to normal B Air inlet valve defective. The air inlet valve does/can not close exactly. Read 5-B.
level (high off-load C Solenoid valve defective or blocked. Clean if the diaphragm control air line is blocked.
running pressure). D Solenoid valve arrangement blocked. Clean the by-pass/bleed air ways.
A Running/Operating temperature is high. Read sysmptom 10.
Check the last oil added. If wrong type oil has been used, drain the oil, replace
Different oil has been used at the last oil
20 Early oil B oil filter (and separator element) then add correct type oil. Call the service
change.
deterioration. company if the problem continues.
The compressor is only used for short Extend running time (duration and frequency) of the compressor or call the
C
periods. service company.
19
6. TROUBLESHOOTING

Recommended oil has not been used,
A Please use original spare parts and the recommended oil.
or, the separator element is not original.
Take precaution against high moisture ratio. Decrease the air moisture content
B High moisture content in ambient air.
if it is possible.
Installation area (Compressor room) is When locating the compressor in sand blasting, casting and chemical process
Separator element not in an appropriate/clean workshops or factories, select the area for the compressor room/installation
C
21 is blocks early environment. Dusty or contaminated which is as clean as possible. Please read “Location of Compressor” subject in
air, gases and fumes etc. the installation section, for details.
If the compressor installed next/near to boiler room, generator room or if the
Continuous running with high (air-end ventilation is not adequate in the compressor room; high working temperatures
D
delivery) temperature. as result of high ambient/room temperatures can shorten the service/operating
life of the separator element.
Running/Starting time (duration and
Extend running time (duration and frequency) of the compressor or call the
E frequency) of the compressor is very
service company.
short (seldom).
A Low voltage problem. Read 2-B.

If STAR-DELTA switching time for main motor is shorter than recommended,
the load the motor draws before reaching full speed is higher than normal and
Early contact wear could be higher that the current capacity of the contactor contacts; this could
B STAR-DELTA switching time is short.
(welding of lead to contact welding or even motor winding damage. STAR-DELTA
22 contacts together) switching time is 6 seconds, do not reduce this. Replace worn contactor
in contactor(s). contacts.
The suggested start count per hour is 6. More frequent start-stop detrimentally
C Frequent start-stop. affects mechanic life, also causes higher operating cost due to very high
starting current. Consult the service company, if it is required.
Contacts are not original contactor Non-original contacts might have very short operating life. Please request
D
parts. original spare parts from the authorized local service company.
A Pulley alignment mistake/defect. Call the service company.

* For belt-driven
compressors: B Belt tension is not according to spec’. Read 14-F and 17. Call the service company.
23
Early belt damage
wear. Continuous running with high
C temperature and abrasive environmental Call the service company.
conditions.
20
7. ANNEX – TABLES AND ILLUSTRATIONS
COOLING AIR EXHAUST DUCTS
HOT AIR OUTLET FROM TOP (COOLER AT TOP)
HOT AIR OUTLET FROM SIDE (COOLER AT SIDE)
21
Table 3
CABLE SIZES, CIRCUIT BREAKER SETTINGS (TMS)
* MODEL KW / HP CABLE SIZE CIRCUIT BREAKER

EKO 15 15 / 20 4 x 6 mm2 40 A
EKO 18 18 / 25 4 x 10 mm2 40 A
EKO 22 22 / 30 4 x 10 mm2 50 A
EKO 30 30 / 40 4 x 16 mm2 63 A
EKO 37 37 / 50 4 x 16 mm2 80 A
EKO 45 45 / 60 4 x 25 mm2 100 A
EKO 45S 45 / 60 4 x 25 mm2 100 A
EKO 55 55 / 75 4 x 35 mm2 125 A
EKO 75 75 / 100 4 x 50 mm2 160 A
EKO 75S 75 / 100 4 x 50 mm2 160 A
EKO 90 90 / 125 4 x 70 mm2 200 A
EKO 110 110 / 150 4 x 95 mm2 250 A
EKO 110S 110 / 150 4 x 95 mm2 250 A
EKO 132 132 / 180 4 x 120 mm2 250 A
EKO 160 160 / 220 4 x 120 mm2 300 A
EKO 200 200 / 270 4 x 185 mm2 400 A
EKO 250 250 / 340 4 x 300 mm2 630 A
EKO 315 315/430 4 x 400 mm ² 800 A
(*) Specified models include all of EKO, EKO D, EKO VST, EKO DVST, EKO GDVST series compressors.
TMS : thermal magnetic circuit breaker
For EKO GD series compressors, one size bigger than the table values may be necessary.
(You can request information from EKOMAK, about required cable size and circuit breaker before beginning to the installation…)
N= Neutral
E= Earth/Ground
NOTES:
1 – A POWER SUPPLY VOLTAGE OF 380V AC IS ASSUMED.
2 – IF THE CABLE LENGTH IS LONGER THAN 50 M, PLEASE USE ONE STAGE BIGGER CABLE SIZE.
3 – DO NOT USE REPAIRED; EXTENDED/AFFIXED CABLES.
4 – DO NOT EXTEND POWER SUPPLY FROM COMPRESSOR’S STARTER BOX TO ANOTHER DEVICE.
22
Table 4
RECOMMENDED SPARE PARTS AND SERVICE OPERATIONS
12000 or 18 months
20000 or 30 months
28000 or 42 months
2000 or 6 months
250 or 500 hours
16000 or 2 years
24000 or 3 years
32000 or 4 years
8000 or 1 year
110000
10000
13000
14000
15000
17000
18000
19000
21000
22000
23000
25000
26000
27000
29000
30000
31000
RECOMMENDED SPARE PARTS
1000
3000
4000
5000
6000
7000
9000
AND SERVICE OPERATIONS
Syntetic Oil (AIRMAX 46) X X X X

Mineral Oil (AIRMAX 2000) X X X X X X X X X X X X X X X X
Air filter element X X X X X X X X X X X X X X X X
Oil filter element X X X X X X X X X X X X X X X X
Panel filter X X X X X X X X X X X X X X X X
Separator element X X X X X X X X
Hydraulic hoses X X
Pneumatic hoses/tubes X X
Kit, inlet valve (MER 122) X X X X
Kit, inlet valve (MER 145) X X X X
Kit, inlet valve (HDKG 85-120-160) X X X X
Solenoid valve X X
Kit, contactor X X
Kit, minimum pressure valve X X X X
Thermostatic valve element X X X X
O-ring, oil filling plug X X X X X X X X X X X X X X X X
Belt (for belt-driven compressors only) X X
Coupling (for direct coupled compressors only) X X X
Main motor bearings X X
Fan motor bearings X
Air end revision X
Pressure sensor X X
Temperature sensor X X
Temperature gauge X
Working pressure switch X X
Safety pressure switch X
SERVICE OPERATIONS
Check oil level EVERY START-UP
Check / Clean air filter element Every 1000 hours
Check load / unload working modes Every 1000 hours
Check air and oil leakages Every 1000 hours
Check scavenge line Every 1000 hours
Clean separator moisture Every 2000 hours
Clean strainer Every 2000 hours
Check screws for electrical connections Every 2000 hours
Clean cooler Every 4000 hours
Check screws for connections Every 4000 hours
Air end seal leakage checking Every 8000 hours
Bearing grease ACCORDING TO INTRUCTION ON MOTOR PLATE. Refer Table 2
ADVISED SPARE STOCK

Solenoid valve
Temperature gauge (*)
Temperature sensor
Pressure sensor Service intervals can vary depending on the
ambient and working conditions ..
Working pressure switch (*)
Kit, inlet valve
Kit, contactor
Kit, minimum pressure valve
Belt (for belt-driven compressors only)
Coupling (for direct coupled compressors only)
(*)The parts that are used only at the machines with an electro-mechanical control systems.( Instead of pressure and temperature sensor.)
Compressor’s Life Time: Compressor life is declared 10 years according to Industrial Goods’s Aftersales Service Legislation. “Ekomak supplies
spare parts of compressors for 10 years from the sales date.”
23
8. PROCEDURE FOR ORDERING PARTS
Parts should be ordered from the nearest Ekomak representative or the representative from whom the compressor was purchased. If for
any reason parts cannot be obtained in this manner, contact the factory directly at the address, fax or phone numbers below.
When ordering parts always indicate THE SERIAL NUMBER of the compressor. This can be obtained from the Bill of lading for the compressor or
from the Serial number plate located on the compressor.
The genuine Ekomak service parts listed meet or exceed the demands of this compressor. Use of replacement parts other than those approved by
Ekomak may lead to hazardous conditions over which Ekomak has no control. Such conditions include, but are not limited to,bodily injury and
compressor failure.
PLEASE READ THE PART LIST BOOK FOR ILLUSTRATIONS AND SPARE PART LIST OF YOUR EKO COMPRESSOR.
TURKEY
EKOMAK A.Ş.
MECLİS MAHALLESİ ATATÜRK CADDESİ MANYAS SOKAK NO:5
SARIGAZİ
34785
İSTANBUL/TÜRKİYE
TEL : +90 216 540 11 33 (10 Hat)
Fax: +90 216 415 41 39
E-Mail: pazarlama@ekomak.com.tr
Web Sitesi : www.ekomak.com.tr
GERMANY
EKOMAK Kompressoren GmbH

Eurotec-Ring 15
D-47445 – MOERS - GERMANY
TEL : +49 (0) 2841 16954 25
: +49 (0) 2841 16954 26
Fax : +49 (0) 2841 16954 30
E-Mail : rtappen@ekomak.com.tr
Web Sitesi : www.ekomak.eu
RUSSIA
EKOMAK Moskow
OOO “EKOMAK”
РОССИЯ, Москва 115114
Дербеневская набережная, д.11, пом.88 (А211)
Тел/факс : +7 495 913 6714
E-Mail : info@ekomak.su
Web Sitesi : www.ekomak.su
24
MAINTENANCE RECORDS
DATE HOURS MAINTENANCE PERFORMED WORK PERFORMED BY AUTHORIZED BY
25
DOSAGE PUMP
OPERATING MANUAL
AND DOSING TABLE
Dosing Table
IS21 Concrete Spraying Machine

3
Concrete Cement Dosage 400 Kg/m
Accelerator Density 1,45 Kg/lt
Effective Concrete Yield % of

Cylinder Volume 95%
Concrete Pump Stroke per Minute (1/min)

1/min 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3
Effektive Concrete Yield (m /hour)
3
m /hour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
Dosing Pump (lt/min)
1% 0,33 0,40 0,47 0,53 0,60 0,67 0,73 0,80 0,87 0,93 1,00 1,07 1,13 1,20 1,27 1,33 1,40 1,47 1,53 1,60 1,67 1,73 1,80 1,87 1,93 2,00
2% 0,67 0,80 0,93 1,07 1,20 1,33 1,47 1,60 1,73 1,87 2,00 2,13 2,27 2,40 2,53 2,67 2,80 2,93 3,07 3,20 3,33 3,47 3,60 3,73 3,87 4,00
% Accelerator
3% 1,00 1,20 1,40 1,60 1,80 2,00 2,20 2,40 2,60 2,80 3,00 3,20 3,40 3,60 3,80 4,00 4,20 4,40 4,60 4,80 5,00 5,20 5,40 5,60 5,80 6,00
4% 1,33 1,60 1,87 2,13 2,40 2,67 2,93 3,20 3,47 3,73 4,00 4,27 4,53 4,80 5,07 5,34 5,60 5,87 6,14 6,40 6,67 6,94 7,20 7,47 7,74 8,00
5% 1,67 2,00 2,33 2,67 3,00 3,33 3,67 4,00 4,33 4,67 5,00 5,34 5,67 6,00 6,34 6,67 7,00 7,34 7,67 8,00 8,34 8,67 9,00 9,34 9,67 10,00
6% 2,00 2,40 2,80 3,20 3,60 4,00 4,40 4,80 5,20 5,60 6,00 6,40 6,80 7,20 7,60 8,00 8,40 8,80 9,20 9,60 10,00 10,40 10,80 11,20 11,60 12,00
7% 2,33 2,80 3,27 3,73 4,20 4,67 5,14 5,60 6,07 6,54 7,00 7,47 7,94 8,40 8,87 9,34 9,80 10,27 10,74 11,20 11,67 12,14 12,60 13,07 13,54 14,00
8% 2,67 3,20 3,73 4,27 4,80 5,34 5,87 6,40 6,94 7,47 8,00 8,54 9,07 9,60 10,14 10,67 11,20 11,74 12,27 12,80 13,34 13,87 14,40 14,94 15,47 16,01
9% 3,00 3,60 4,20 4,80 5,40 6,00 6,60 7,20 7,80 8,40 9,00 9,60 10,20 10,80 11,40 12,00 12,60 13,20 13,80 14,40 15,00 15,61 16,21 16,81 17,41 18,01
10% 3,33 4,00 4,67 5,34 6,00 6,67 7,34 8,00 8,67 9,34 10,00 10,67 11,34 12,00 12,67 13,34 14,00 14,67 15,34 16,01 16,67 17,34 18,01 18,67 19,34 20,01

1160. sokak no:9 Ostim Ankara Tel: + 90 312 354 99 77 Fax: + 90 312 385 56 11
Web: www.titanltd.com.tr E-mail: titan@titanltd.com.tr 1/3
Dosing Table

Concrete Cement Dosage
3
400 Kg/m

Cylinder Volume 95%

1/min 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3
m3/hour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
Dosing Pump (rpm)
1% 1,33 1,60 1,87 2,13 2,40 2,67 2,93 3,20 3,47 3,73 4,00 4,27 4,53 4,80 5,07 5,34 5,60 5,87 6,14 6,40 6,67 6,94 7,20 7,47 7,74 8,00
% Accelerator
2% 2,67 3,20 3,73 4,27 4,80 5,34 5,87 6,40 6,94 7,47 8,00 8,54 9,07 9,60 10,14 10,67 11,20 11,74 12,27 12,80 13,34 13,87 14,40 14,94 15,47 16,01
3% 4,00 4,80 5,60 6,40 7,20 8,00 8,80 9,60 10,40 11,20 12,00 12,80 13,60 14,40 15,20 16,01 16,81 17,61 18,41 19,21 20,01 20,81 21,61 22,41 23,21 24,01
4% 5,34 6,40 7,47 8,54 9,60 10,67 11,74 12,80 13,87 14,94 16,01 17,07 18,14 19,21 20,27 21,34 22,41 23,47 24,54 25,61 26,68 27,74 28,81 29,88 30,94 32,01
5% 6,67 8,00 9,34 10,67 12,00 13,34 14,67 16,01 17,34 18,67 20,01 21,34 22,67 24,01 25,34 26,68 28,01 29,34 30,68 32,01 33,34 34,68 36,01 37,35 38,68 40,01
6% 8,00 9,60 11,20 12,80 14,40 16,01 17,61 19,21 20,81 22,41 24,01 25,61 27,21 28,81 30,41 32,01 33,61 35,21 36,81 38,41 40,01 41,61 43,21 44,81 46,42 48,02
7% 9,34 11,20 13,07 14,94 16,81 18,67 20,54 22,41 24,27 26,14 28,01 29,88 31,74 33,61 35,48 37,35 39,21 41,08 42,95 44,81 46,68 48,55 50,42 52,28 54,15 56,02
8% 10,67 12,80 14,94 17,07 19,21 21,34 23,47 25,61 27,74 29,88 32,01 34,14 36,28 38,41 40,55 42,68 44,81 46,95 49,08 51,22 53,35 55,48 57,62 59,75 61,89 64,02
9% 12,00 14,40 16,81 19,21 21,61 24,01 26,41 28,81 31,21 33,61 36,01 38,41 40,81 43,21 45,61 48,02 50,42 52,82 55,22 57,62 60,02 62,42 64,82 67,22 69,62 72,02
10% 13,34 16,01 18,67 21,34 24,01 26,68 29,34 32,01 34,68 37,35 40,01 42,68 45,35 48,02 50,68 53,35 56,02 58,69 61,35 64,02 66,69 69,36 72,02 74,69 77,36 80,03

Dosing Table

3
400 Kg/m

95%
Cylinder Volume

1/min 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3
3
m /hour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
Dosing Pump (Hz)
1% 1,67 2,00 2,33 2,67 3,00 3,33 3,67 4,00 4,33 4,67 5,00 5,34 5,67 6,00 6,34 6,67 7,00 7,34 7,67 8,00 8,34 8,67 9,00 9,34 9,67 10,00
% Accelerator
2% 3,33 4,00 4,67 5,34 6,00 6,67 7,34 8,00 8,67 9,34 10,00 10,67 11,34 12,00 12,67 13,34 14,00 14,67 15,34 16,01 16,67 17,34 18,01 18,67 19,34 20,01
3% 5,00 6,00 7,00 8,00 9,00 10,00 11,00 12,00 13,00 14,00 15,00 16,01 17,01 18,01 19,01 20,01 21,01 22,01 23,01 24,01 25,01 26,01 27,01 28,01 29,01 30,01
4% 6,67 8,00 9,34 10,67 12,00 13,34 14,67 16,01 17,34 18,67 20,01 21,34 22,67 24,01 25,34 26,68 28,01 29,34 30,68 32,01 33,34 34,68 36,01 37,35 38,68 40,01
5% 8,34 10,00 11,67 13,34 15,00 16,67 18,34 20,01 21,67 23,34 25,01 26,68 28,34 30,01 31,68 33,34 35,01 36,68 38,35 40,01 41,68 43,35 45,01 46,68 48,35 50,02
6% 10,00 12,00 14,00 16,01 18,01 20,01 22,01 24,01 26,01 28,01 30,01 32,01 34,01 36,01 38,01 40,01 42,01 44,01 46,02 48,02 50,02 52,02 54,02 56,02 58,02 60,02
7% 11,67 14,00 16,34 18,67 21,01 23,34 25,68 28,01 30,34 32,68 35,01 37,35 39,68 42,01 44,35 46,68 49,02 51,35 53,68 56,02 58,35 60,69 63,02 65,35 67,69 70,02
8% 13,34 16,01 18,67 21,34 24,01 26,68 29,34 32,01 34,68 37,35 40,01 42,68 45,35 48,02 50,68 53,35 56,02 58,69 61,35 64,02 66,69 69,36 72,02 74,69 77,36 80,03
9% 15,00 18,01 21,01 24,01 27,01 30,01 33,01 36,01 39,01 42,01 45,01 48,02 51,02 54,02 57,02 60,02 63,02 66,02 69,02 72,02 75,02 78,03 81,03 84,03 87,03 90,03
10% 16,67 20,01 23,34 26,68 30,01 33,34 36,68 40,01 43,35 46,68 50,02 53,35 56,69 60,02 63,35 66,69 70,02 73,36 76,69 80,03 83,36 86,69 90,03 93,36 96,70 100,03

ŽƐŝŶŐdĂďůĞ

3
425 Kg/m

ϵϱй
Cylinder Volume
Concrete Pump Stroke per Minute 1/min

ϭͬmin 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
ϯ
Ĩfective Concrete Yield;ŵ ͬhourͿ
ϯ
ŵ ͬhour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
Dosing Pump ;ůƚͬminͿ
ϭй 0,35 0,43 0,50 0,57 0,64 0,71 0,78 0,85 0,92 0,99 1,06 1,13 1,20 1,28 1,35 1,42 1,49 1,56 1,63 1,70 1,77 1,84 1,91 1,98 2,05 2,13
Ϯй
йAccelerator
0,71 0,85 0,99 1,13 1,28 1,42 1,56 1,70 1,84 1,98 2,13 2,27 2,41 2,55 2,69 2,83 2,98 3,12 3,26 3,40 3,54 3,68 3,83 3,97 4,11 4,25
ϯй 1,06 1,28 1,49 1,70 1,91 2,13 2,34 2,55 2,76 2,98 3,19 3,40 3,61 3,83 4,04 4,25 4,46 4,68 4,89 5,10 5,31 5,53 5,74 5,95 6,16 6,38
ϰй 1,42 1,70 1,98 2,27 2,55 2,83 3,12 3,40 3,68 3,97 4,25 4,53 4,82 5,10 5,39 5,67 5,95 6,24 6,52 6,80 7,09 7,37 7,65 7,94 8,22 8,50
ϱй 1,77 2,13 2,48 2,83 3,19 3,54 3,90 4,25 4,61 4,96 5,31 5,67 6,02 6,38 6,73 7,09 7,44 7,79 8,15 8,50 8,86 9,21 9,57 9,92 10,27 10,63
ϲй 2,13 2,55 2,98 3,40 3,83 4,25 4,68 5,10 5,53 5,95 6,38 6,80 7,23 7,65 8,08 8,50 8,93 9,35 9,78 10,20 10,63 11,05 11,48 11,90 12,33 12,75
ϳй 2,48 2,98 3,47 3,97 4,46 4,96 5,46 5,95 6,45 6,94 7,44 7,94 8,43 8,93 9,42 9,92 10,42 10,91 11,41 11,90 12,40 12,90 13,39 13,89 14,38 14,88
ϴй 2,83 3,40 3,97 4,53 5,10 5,67 6,24 6,80 7,37 7,94 8,50 9,07 9,64 10,20 10,77 11,34 11,90 12,47 13,04 13,60 14,17 14,74 15,30 15,87 16,44 17,01
ϵй 3,19 3,83 4,46 5,10 5,74 6,38 7,01 7,65 8,29 8,93 9,57 10,20 10,84 11,48 12,12 12,75 13,39 14,03 14,67 15,30 15,94 16,58 17,22 17,86 18,49 19,13
ϭϬй 3,54 4,25 4,96 5,67 6,38 7,09 7,79 8,50 9,21 9,92 10,63 11,34 12,05 12,75 13,46 14,17 14,88 15,59 16,30 17,01 17,71 18,42 19,13 19,84 20,55 21,26

Dosing Table

3
425 Kg/m

95%
Cylinder Volume

1/min 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Effective Concrete Yield (m /hour)
3
3
m /hour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
Dosing Pump (rpm)
1% 1,42 1,70 1,98 2,27 2,55 2,83 3,12 3,40 3,68 3,97 4,25 4,53 4,82 5,10 5,39 5,67 5,95 6,24 6,52 6,80 7,09 7,37 7,65 7,94 8,22 8,50
% Accelerator
2% 2,83 3,40 3,97 4,53 5,10 5,67 6,24 6,80 7,37 7,94 8,50 9,07 9,64 10,20 10,77 11,34 11,90 12,47 13,04 13,60 14,17 14,74 15,30 15,87 16,44 17,01
3% 4,25 5,10 5,95 6,80 7,65 8,50 9,35 10,20 11,05 11,90 12,75 13,60 14,45 15,30 16,16 17,01 17,86 18,71 19,56 20,41 21,26 22,11 22,96 23,81 24,66 25,51
4% 5,67 6,80 7,94 9,07 10,20 11,34 12,47 13,60 14,74 15,87 17,01 18,14 19,27 20,41 21,54 22,67 23,81 24,94 26,08 27,21 28,34 29,48 30,61 31,74 32,88 34,01
5% 7,09 8,50 9,92 11,34 12,75 14,17 15,59 17,01 18,42 19,84 21,26 22,67 24,09 25,51 26,93 28,34 29,76 31,18 32,59 34,01 35,43 36,85 38,26 39,68 41,10 42,51
6% 8,50 10,20 11,90 13,60 15,30 17,01 18,71 20,41 22,11 23,81 25,51 27,21 28,91 30,61 32,31 34,01 35,71 37,41 39,11 40,81 42,51 44,21 45,91 47,62 49,32 51,02
7% 9,92 11,90 13,89 15,87 17,86 19,84 21,82 23,81 25,79 27,78 29,76 31,74 33,73 35,71 37,70 39,68 41,66 43,65 45,63 47,62 49,60 51,58 53,57 55,55 57,54 59,52
8% 11,34 13,60 15,87 18,14 20,41 22,67 24,94 27,21 29,48 31,74 34,01 36,28 38,55 40,81 43,08 45,35 47,62 49,88 52,15 54,42 56,69 58,95 61,22 63,49 65,75 68,02
9% 12,75 15,30 17,86 20,41 22,96 25,51 28,06 30,61 33,16 35,71 38,26 40,81 43,36 45,91 48,47 51,02 53,57 56,12 58,67 61,22 63,77 66,32 68,87 71,42 73,97 76,52
10% 14,17 17,01 19,84 22,67 25,51 28,34 31,18 34,01 36,85 39,68 42,51 45,35 48,18 51,02 53,85 56,69 59,52 62,35 65,19 68,02 70,86 73,69 76,52 79,36 82,19 85,03

Dosing Table

3
425 Kg/m

Cylinder Volume 95%

1/min 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3
3
m /hour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
Dosing Pump (Hz)
1% 1,77 2,13 2,48 2,83 3,19 3,54 3,90 4,25 4,61 4,96 5,31 5,67 6,02 6,38 6,73 7,09 7,44 7,79 8,15 8,50 8,86 9,21 9,57 9,92 10,27 10,63
2% 3,54 4,25 4,96 5,67 6,38 7,09 7,79 8,50 9,21 9,92 10,63 11,34 12,05 12,75 13,46 14,17 14,88 15,59 16,30 17,01 17,71 18,42 19,13 19,84 20,55 21,26
% Accelerator
3% 5,31 6,38 7,44 8,50 9,57 10,63 11,69 12,75 13,82 14,88 15,94 17,01 18,07 19,13 20,19 21,26 22,32 23,38 24,45 25,51 26,57 27,63 28,70 29,76 30,82 31,89
4% 7,09 8,50 9,92 11,34 12,75 14,17 15,59 17,01 18,42 19,84 21,26 22,67 24,09 25,51 26,93 28,34 29,76 31,18 32,59 34,01 35,43 36,85 38,26 39,68 41,10 42,51
5% 8,86 10,63 12,40 14,17 15,94 17,71 19,49 21,26 23,03 24,80 26,57 28,34 30,11 31,89 33,66 35,43 37,20 38,97 40,74 42,51 44,29 46,06 47,83 49,60 51,37 53,14
6% 10,63 12,75 14,88 17,01 19,13 21,26 23,38 25,51 27,63 29,76 31,89 34,01 36,14 38,26 40,39 42,51 44,64 46,77 48,89 51,02 53,14 55,27 57,39 59,52 61,65 63,77
7% 12,40 14,88 17,36 19,84 22,32 24,80 27,28 29,76 32,24 34,72 37,20 39,68 42,16 44,64 47,12 49,60 52,08 54,56 57,04 59,52 62,00 64,48 66,96 69,44 71,92 74,40
8% 14,17 17,01 19,84 22,67 25,51 28,34 31,18 34,01 36,85 39,68 42,51 45,35 48,18 51,02 53,85 56,69 59,52 62,35 65,19 68,02 70,86 73,69 76,52 79,36 82,19 85,03
9% 15,94 19,13 22,32 25,51 28,70 31,89 35,07 38,26 41,45 44,64 47,83 51,02 54,21 57,39 60,58 63,77 66,96 70,15 73,34 76,52 79,71 82,90 86,09 89,28 92,47 95,66
10% 17,71 21,26 24,80 28,34 31,89 35,43 38,97 42,51 46,06 49,60 53,14 56,69 60,23 63,77 67,31 70,86 74,40 77,94 81,48 85,03 88,57 92,11 95,66 99,20 102,74 106,28

Dosing Table

3

95%
Cylinder Volume
Concrete Pump Stroke Per Minute(1/min)

1/min 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3
3
m /hour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
1% 0,38 0,45 0,53 0,60 0,68 0,75 0,83 0,90 0,98 1,05 1,13 1,20 1,28 1,35 1,43 1,50 1,58 1,65 1,73 1,80 1,88 1,95 2,03 2,10 2,18 2,25
% Accelerator
2% 0,75 0,90 1,05 1,20 1,35 1,50 1,65 1,80 1,95 2,10 2,25 2,40 2,55 2,70 2,85 3,00 3,15 3,30 3,45 3,60 3,75 3,90 4,05 4,20 4,35 4,50
3% 1,13 1,35 1,58 1,80 2,03 2,25 2,48 2,70 2,93 3,15 3,38 3,60 3,83 4,05 4,28 4,50 4,73 4,95 5,18 5,40 5,63 5,85 6,08 6,30 6,53 6,75
4% 1,50 1,80 2,10 2,40 2,70 3,00 3,30 3,60 3,90 4,20 4,50 4,80 5,10 5,40 5,70 6,00 6,30 6,60 6,90 7,20 7,50 7,80 8,10 8,40 8,70 9,00
5% 1,88 2,25 2,63 3,00 3,38 3,75 4,13 4,50 4,88 5,25 5,63 6,00 6,38 6,75 7,13 7,50 7,88 8,25 8,63 9,00 9,38 9,75 10,13 10,50 10,88 11,25
6% 2,25 2,70 3,15 3,60 4,05 4,50 4,95 5,40 5,85 6,30 6,75 7,20 7,65 8,10 8,55 9,00 9,45 9,90 10,35 10,80 11,25 11,70 12,15 12,60 13,05 13,50
7% 2,63 3,15 3,68 4,20 4,73 5,25 5,78 6,30 6,83 7,35 7,88 8,40 8,93 9,45 9,98 10,50 11,03 11,55 12,08 12,60 13,13 13,65 14,18 14,70 15,23 15,76
8% 3,00 3,60 4,20 4,80 5,40 6,00 6,60 7,20 7,80 8,40 9,00 9,60 10,20 10,80 11,40 12,00 12,60 13,20 13,80 14,40 15,00 15,61 16,21 16,81 17,41 18,01
9% 3,38 4,05 4,73 5,40 6,08 6,75 7,43 8,10 8,78 9,45 10,13 10,80 11,48 12,15 12,83 13,50 14,18 14,85 15,53 16,21 16,88 17,56 18,23 18,91 19,58 20,26
10% 3,75 4,50 5,25 6,00 6,75 7,50 8,25 9,00 9,75 10,50 11,25 12,00 12,75 13,50 14,25 15,00 15,76 16,51 17,26 18,01 18,76 19,51 20,26 21,01 21,76 22,51

Dosing Table

3
Effective Concrete Yield % of 95%

Cylinder Volume

1/min 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3
3
m /hour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
Dosing Pump (rpm)
1% 1,50 1,80 2,10 2,40 2,70 3,00 3,30 3,60 3,90 4,20 4,50 4,80 5,10 5,40 5,70 6,00 6,30 6,60 6,90 7,20 7,50 7,80 8,10 8,40 8,70 9,00
2%
% Accelerator
3,00 3,60 4,20 4,80 5,40 6,00 6,60 7,20 7,80 8,40 9,00 9,60 10,20 10,80 11,40 12,00 12,60 13,20 13,80 14,40 15,00 15,61 16,21 16,81 17,41 18,01
3% 4,50 5,40 6,30 7,20 8,10 9,00 9,90 10,80 11,70 12,60 13,50 14,40 15,30 16,21 17,11 18,01 18,91 19,81 20,71 21,61 22,51 23,41 24,31 25,21 26,11 27,01
4% 6,00 7,20 8,40 9,60 10,80 12,00 13,20 14,40 15,61 16,81 18,01 19,21 20,41 21,61 22,81 24,01 25,21 26,41 27,61 28,81 30,01 31,21 32,41 33,61 34,81 36,01
5% 7,50 9,00 10,50 12,00 13,50 15,00 16,51 18,01 19,51 21,01 22,51 24,01 25,51 27,01 28,51 30,01 31,51 33,01 34,51 36,01 37,51 39,01 40,51 42,01 43,51 45,01
6% 9,00 10,80 12,60 14,40 16,21 18,01 19,81 21,61 23,41 25,21 27,01 28,81 30,61 32,41 34,21 36,01 37,81 39,61 41,41 43,21 45,01 46,82 48,62 50,42 52,22 54,02
7% 10,50 12,60 14,70 16,81 18,91 21,01 23,11 25,21 27,31 29,41 31,51 33,61 35,71 37,81 39,91 42,01 44,11 46,22 48,32 50,42 52,52 54,62 56,72 58,82 60,92 63,02
8% 12,00 14,40 16,81 19,21 21,61 24,01 26,41 28,81 31,21 33,61 36,01 38,41 40,81 43,21 45,61 48,02 50,42 52,82 55,22 57,62 60,02 62,42 64,82 67,22 69,62 72,02
9% 13,50 16,21 18,91 21,61 24,31 27,01 29,71 32,41 35,11 37,81 40,51 43,21 45,91 48,62 51,32 54,02 56,72 59,42 62,12 64,82 67,52 70,22 72,92 75,62 78,33 81,03
10% 15,00 18,01 21,01 24,01 27,01 30,01 33,01 36,01 39,01 42,01 45,01 48,02 51,02 54,02 57,02 60,02 63,02 66,02 69,02 72,02 75,02 78,03 81,03 84,03 87,03 90,03

Dosing Table

3

95%
Cylinder Volume

1/min 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3
3
m /hour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
Dosing Pump Hz)
1% 1,88 2,25 2,63 3,00 3,38 3,75 4,13 4,50 4,88 5,25 5,63 6,00 6,38 6,75 7,13 7,50 7,88 8,25 8,63 9,00 9,38 9,75 10,13 10,50 10,88 11,25
2% 3,75 4,50 5,25 6,00 6,75 7,50 8,25 9,00 9,75 10,50 11,25 12,00 12,75 13,50 14,25 15,00 15,76 16,51 17,26 18,01 18,76 19,51 20,26 21,01 21,76 22,51
% Accelerator
3% 5,63 6,75 7,88 9,00 10,13 11,25 12,38 13,50 14,63 15,76 16,88 18,01 19,13 20,26 21,38 22,51 23,63 24,76 25,88 27,01 28,13 29,26 30,38 31,51 32,64 33,76
4% 7,50 9,00 10,50 12,00 13,50 15,00 16,51 18,01 19,51 21,01 22,51 24,01 25,51 27,01 28,51 30,01 31,51 33,01 34,51 36,01 37,51 39,01 40,51 42,01 43,51 45,01
5% 9,38 11,25 13,13 15,00 16,88 18,76 20,63 22,51 24,38 26,26 28,13 30,01 31,89 33,76 35,64 37,51 39,39 41,26 43,14 45,01 46,89 48,77 50,64 52,52 54,39 56,27
6% 11,25 13,50 15,76 18,01 20,26 22,51 24,76 27,01 29,26 31,51 33,76 36,01 38,26 40,51 42,76 45,01 47,27 49,52 51,77 54,02 56,27 58,52 60,77 63,02 65,27 67,52
7% 13,13 15,76 18,38 21,01 23,63 26,26 28,88 31,51 34,14 36,76 39,39 42,01 44,64 47,27 49,89 52,52 55,14 57,77 60,39 63,02 65,65 68,27 70,90 73,52 76,15 78,78
8% 15,00 18,01 21,01 24,01 27,01 30,01 33,01 36,01 39,01 42,01 45,01 48,02 51,02 54,02 57,02 60,02 63,02 66,02 69,02 72,02 75,02 78,03 81,03 84,03 87,03 90,03
9% 16,88 20,26 23,63 27,01 30,38 33,76 37,14 40,51 43,89 47,27 50,64 54,02 57,39 60,77 64,15 67,52 70,90 74,27 77,65 81,03 84,40 87,78 91,15 94,53 97,91 101,28
10% 18,76 22,51 26,26 30,01 33,76 37,51 41,26 45,01 48,77 52,52 56,27 60,02 63,77 67,52 71,27 75,02 78,78 82,53 86,28 90,03 93,78 97,53 101,28 105,03 108,79 112,54

Dosing Table

3
475 Kg/m

95%
Cylinder Volume

1/min 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3
3
m /hour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
1% 0,40 0,48 0,55 0,63 0,71 0,79 0,87 0,95 1,03 1,11 1,19 1,27 1,35 1,43 1,50 1,58 1,66 1,74 1,82 1,90 1,98 2,06 2,14 2,22 2,30 2,38
%Accelerator
2% 0,79 0,95 1,11 1,27 1,43 1,58 1,74 1,90 2,06 2,22 2,38 2,53 2,69 2,85 3,01 3,17 3,33 3,48 3,64 3,80 3,96 4,12 4,28 4,43 4,59 4,75
3% 1,19 1,43 1,66 1,90 2,14 2,38 2,61 2,85 3,09 3,33 3,56 3,80 4,04 4,28 4,51 4,75 4,99 5,23 5,46 5,70 5,94 6,18 6,41 6,65 6,89 7,13
4% 1,58 1,90 2,22 2,53 2,85 3,17 3,48 3,80 4,12 4,43 4,75 5,07 5,39 5,70 6,02 6,34 6,65 6,97 7,29 7,60 7,92 8,24 8,55 8,87 9,19 9,50
5% 1,98 2,38 2,77 3,17 3,56 3,96 4,36 4,75 5,15 5,54 5,94 6,34 6,73 7,13 7,52 7,92 8,32 8,71 9,11 9,50 9,90 10,30 10,69 11,09 11,48 11,88
6% 2,38 2,85 3,33 3,80 4,28 4,75 5,23 5,70 6,18 6,65 7,13 7,60 8,08 8,55 9,03 9,50 9,98 10,45 10,93 11,40 11,88 12,35 12,83 13,30 13,78 14,25
7% 2,77 3,33 3,88 4,43 4,99 5,54 6,10 6,65 7,21 7,76 8,32 8,87 9,42 9,98 10,53 11,09 11,64 12,20 12,75 13,30 13,86 14,41 14,97 15,52 16,08 16,63
8% 3,17 3,80 4,43 5,07 5,70 6,34 6,97 7,60 8,24 8,87 9,50 10,14 10,77 11,40 12,04 12,67 13,30 13,94 14,57 15,20 15,84 16,47 17,11 17,74 18,37 19,01
9% 3,56 4,28 4,99 5,70 6,41 7,13 7,84 8,55 9,27 9,98 10,69 11,40 12,12 12,83 13,54 14,25 14,97 15,68 16,39 17,11 17,82 18,53 19,24 19,96 20,67 21,38
10% 3,96 4,75 5,54 6,34 7,13 7,92 8,71 9,50 10,30 11,09 11,88 12,67 13,46 14,25 15,05 15,84 16,63 17,42 18,21 19,01 19,80 20,59 21,38 22,17 22,97 23,76

Dosing Table

475 Kg/m
3

Cylinder Volume

1/min 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3
3
m /hour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
Dosing Pump (rpm)
1% 1,58 1,90 2,22 2,53 2,85 3,17 3,48 3,80 4,12 4,43 4,75 5,07 5,39 5,70 6,02 6,34 6,65 6,97 7,29 7,60 7,92 8,24 8,55 8,87 9,19 9,50
%Accelerator
2% 3,17 3,80 4,43 5,07 5,70 6,34 6,97 7,60 8,24 8,87 9,50 10,14 10,77 11,40 12,04 12,67 13,30 13,94 14,57 15,20 15,84 16,47 17,11 17,74 18,37 19,01
3% 4,75 5,70 6,65 7,60 8,55 9,50 10,45 11,40 12,35 13,30 14,25 15,20 16,16 17,11 18,06 19,01 19,96 20,91 21,86 22,81 23,76 24,71 25,66 26,61 27,56 28,51
4% 6,34 7,60 8,87 10,14 11,40 12,67 13,94 15,20 16,47 17,74 19,01 20,27 21,54 22,81 24,07 25,34 26,61 27,88 29,14 30,41 31,68 32,94 34,21 35,48 36,75 38,01
5% 7,92 9,50 11,09 12,67 14,25 15,84 17,42 19,01 20,59 22,17 23,76 25,34 26,93 28,51 30,09 31,68 33,26 34,84 36,43 38,01 39,60 41,18 42,76 44,35 45,93 47,52
6% 9,50 11,40 13,30 15,20 17,11 19,01 20,91 22,81 24,71 26,61 28,51 30,41 32,31 34,21 36,11 38,01 39,91 41,81 43,71 45,61 47,52 49,42 51,32 53,22 55,12 57,02
7% 11,09 13,30 15,52 17,74 19,96 22,17 24,39 26,61 28,83 31,04 33,26 35,48 37,70 39,91 42,13 44,35 46,57 48,78 51,00 53,22 55,43 57,65 59,87 62,09 64,30 66,52
8% 12,67 15,20 17,74 20,27 22,81 25,34 27,88 30,41 32,94 35,48 38,01 40,55 43,08 45,61 48,15 50,68 53,22 55,75 58,29 60,82 63,35 65,89 68,42 70,96 73,49 76,02
9% 14,25 17,11 19,96 22,81 25,66 28,51 31,36 34,21 37,06 39,91 42,76 45,61 48,47 51,32 54,17 57,02 59,87 62,72 65,57 68,42 71,27 74,12 76,98 79,83 82,68 85,53
10% 15,84 19,01 22,17 25,34 28,51 31,68 34,84 38,01 41,18 44,35 47,52 50,68 53,85 57,02 60,19 63,35 66,52 69,69 72,86 76,02 79,19 82,36 85,53 88,70 91,86 95,03

Dosing Table

3

95%
Cylinder Volume

1/min 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3
3
m /hour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
Dosing Pump (Hz)
1% 1,98 2,38 2,77 3,17 3,56 3,96 4,36 4,75 5,15 5,54 5,94 6,34 6,73 7,13 7,52 7,92 8,32 8,71 9,11 9,50 9,90 10,30 10,69 11,09 11,48 11,88
2% 3,96 4,75 5,54 6,34 7,13 7,92 8,71 9,50 10,30 11,09 11,88 12,67 13,46 14,25 15,05 15,84 16,63 17,42 18,21 19,01 19,80 20,59 21,38 22,17 22,97 23,76
%Accelerator
3% 5,94 7,13 8,32 9,50 10,69 11,88 13,07 14,25 15,44 16,63 17,82 19,01 20,19 21,38 22,57 23,76 24,95 26,13 27,32 28,51 29,70 30,89 32,07 33,26 34,45 35,64
4% 7,92 9,50 11,09 12,67 14,25 15,84 17,42 19,01 20,59 22,17 23,76 25,34 26,93 28,51 30,09 31,68 33,26 34,84 36,43 38,01 39,60 41,18 42,76 44,35 45,93 47,52
5% 9,90 11,88 13,86 15,84 17,82 19,80 21,78 23,76 25,74 27,72 29,70 31,68 33,66 35,64 37,62 39,60 41,58 43,56 45,54 47,52 49,50 51,48 53,45 55,43 57,41 59,39
6% 11,88 14,25 16,63 19,01 21,38 23,76 26,13 28,51 30,89 33,26 35,64 38,01 40,39 42,76 45,14 47,52 49,89 52,27 54,64 57,02 59,39 61,77 64,15 66,52 68,90 71,27
7% 13,86 16,63 19,40 22,17 24,95 27,72 30,49 33,26 36,03 38,80 41,58 44,35 47,12 49,89 52,66 55,43 58,21 60,98 63,75 66,52 69,29 72,07 74,84 77,61 80,38 83,15
8% 15,84 19,01 22,17 25,34 28,51 31,68 34,84 38,01 41,18 44,35 47,52 50,68 53,85 57,02 60,19 63,35 66,52 69,69 72,86 76,02 79,19 82,36 85,53 88,70 91,86 95,03
9% 17,82 21,38 24,95 28,51 32,07 35,64 39,20 42,76 46,33 49,89 53,45 57,02 60,58 64,15 67,71 71,27 74,84 78,40 81,96 85,53 89,09 92,66 96,22 99,78 103,35 106,91
10% 19,80 23,76 27,72 31,68 35,64 39,60 43,56 47,52 51,48 55,43 59,39 63,35 67,31 71,27 75,23 79,19 83,15 87,11 91,07 95,03 98,99 102,95 106,91 110,87 114,83 118,79

Dosing Table

3
500 Kg/m

Cylinder Volume

1/min 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3
3
m /hour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
1% 0,42 0,50 0,58 0,67 0,75 0,83 0,92 1,00 1,08 1,17 1,25 1,33 1,42 1,50 1,58 1,67 1,75 1,83 1,92 2,00 2,08 2,17 2,25 2,33 2,42 2,50
% Accelerator
2% 0,83 1,00 1,17 1,33 1,50 1,67 1,83 2,00 2,17 2,33 2,50 2,67 2,83 3,00 3,17 3,33 3,50 3,67 3,83 4,00 4,17 4,33 4,50 4,67 4,83 5,00
3% 1,25 1,50 1,75 2,00 2,25 2,50 2,75 3,00 3,25 3,50 3,75 4,00 4,25 4,50 4,75 5,00 5,25 5,50 5,75 6,00 6,25 6,50 6,75 7,00 7,25 7,50
4% 1,67 2,00 2,33 2,67 3,00 3,33 3,67 4,00 4,33 4,67 5,00 5,34 5,67 6,00 6,34 6,67 7,00 7,34 7,67 8,00 8,34 8,67 9,00 9,34 9,67 10,00
5% 2,08 2,50 2,92 3,33 3,75 4,17 4,58 5,00 5,42 5,84 6,25 6,67 7,09 7,50 7,92 8,34 8,75 9,17 9,59 10,00 10,42 10,84 11,25 11,67 12,09 12,50
6% 2,50 3,00 3,50 4,00 4,50 5,00 5,50 6,00 6,50 7,00 7,50 8,00 8,50 9,00 9,50 10,00 10,50 11,00 11,50 12,00 12,50 13,00 13,50 14,00 14,50 15,00
7% 2,92 3,50 4,08 4,67 5,25 5,84 6,42 7,00 7,59 8,17 8,75 9,34 9,92 10,50 11,09 11,67 12,25 12,84 13,42 14,00 14,59 15,17 15,76 16,34 16,92 17,51
8% 3,33 4,00 4,67 5,34 6,00 6,67 7,34 8,00 8,67 9,34 10,00 10,67 11,34 12,00 12,67 13,34 14,00 14,67 15,34 16,01 16,67 17,34 18,01 18,67 19,34 20,01
9% 3,75 4,50 5,25 6,00 6,75 7,50 8,25 9,00 9,75 10,50 11,25 12,00 12,75 13,50 14,25 15,00 15,76 16,51 17,26 18,01 18,76 19,51 20,26 21,01 21,76 22,51
10% 4,17 5,00 5,84 6,67 7,50 8,34 9,17 10,00 10,84 11,67 12,50 13,34 14,17 15,00 15,84 16,67 17,51 18,34 19,17 20,01 20,84 21,67 22,51 23,34 24,17 25,01

1160. sokak no: 9 Ostim Ankara Tel: + 90 312 354 99 77 Fax: + 90 312 385 56 11
Dosing Table

3

95%
Cylinder Volume

1/min 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3
3
m /hour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
Dosing Pump (ƌƉŵͿ
1% 1,67 2,00 2,33 2,67 3,00 3,33 3,67 4,00 4,33 4,67 5,00 5,34 5,67 6,00 6,34 6,67 7,00 7,34 7,67 8,00 8,34 8,67 9,00 9,34 9,67 10,00
2% 3,33 4,00 4,67 5,34 6,00 6,67 7,34 8,00 8,67 9,34 10,00 10,67 11,34 12,00 12,67 13,34 14,00 14,67 15,34 16,01 16,67 17,34 18,01 18,67 19,34 20,01
% Accelerator
3% 5,00 6,00 7,00 8,00 9,00 10,00 11,00 12,00 13,00 14,00 15,00 16,01 17,01 18,01 19,01 20,01 21,01 22,01 23,01 24,01 25,01 26,01 27,01 28,01 29,01 30,01
4% 6,67 8,00 9,34 10,67 12,00 13,34 14,67 16,01 17,34 18,67 20,01 21,34 22,67 24,01 25,34 26,68 28,01 29,34 30,68 32,01 33,34 34,68 36,01 37,35 38,68 40,01
5% 8,34 10,00 11,67 13,34 15,00 16,67 18,34 20,01 21,67 23,34 25,01 26,68 28,34 30,01 31,68 33,34 35,01 36,68 38,35 40,01 41,68 43,35 45,01 46,68 48,35 50,02
6% 10,00 12,00 14,00 16,01 18,01 20,01 22,01 24,01 26,01 28,01 30,01 32,01 34,01 36,01 38,01 40,01 42,01 44,01 46,02 48,02 50,02 52,02 54,02 56,02 58,02 60,02
7% 11,67 14,00 16,34 18,67 21,01 23,34 25,68 28,01 30,34 32,68 35,01 37,35 39,68 42,01 44,35 46,68 49,02 51,35 53,68 56,02 58,35 60,69 63,02 65,35 67,69 70,02
8% 13,34 16,01 18,67 21,34 24,01 26,68 29,34 32,01 34,68 37,35 40,01 42,68 45,35 48,02 50,68 53,35 56,02 58,69 61,35 64,02 66,69 69,36 72,02 74,69 77,36 80,03
9% 15,00 18,01 21,01 24,01 27,01 30,01 33,01 36,01 39,01 42,01 45,01 48,02 51,02 54,02 57,02 60,02 63,02 66,02 69,02 72,02 75,02 78,03 81,03 84,03 87,03 90,03
10% 16,67 20,01 23,34 26,68 30,01 33,34 36,68 40,01 43,35 46,68 50,02 53,35 56,69 60,02 63,35 66,69 70,02 73,36 76,69 80,03 83,36 86,69 90,03 93,36 96,70 100,03

Dosing Table

3

95%
Cylinder Volume

1/min 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
3
3
m /hour 7,25 8,70 10,15 11,60 13,05 14,50 15,96 17,41 18,86 20,31 21,76 23,21 24,66 26,11 27,56 29,01 30,46 31,91 33,36 34,81 36,26 37,71 39,16 40,61 42,06 43,51
Dosing Pump (Hz)
1% 2,08 2,50 2,92 3,33 3,75 4,17 4,58 5,00 5,42 5,84 6,25 6,67 7,09 7,50 7,92 8,34 8,75 9,17 9,59 10,00 10,42 10,84 11,25 11,67 12,09 12,50
2% 4,17 5,00 5,84 6,67 7,50 8,34 9,17 10,00 10,84 11,67 12,50 13,34 14,17 15,00 15,84 16,67 17,51 18,34 19,17 20,01 20,84 21,67 22,51 23,34 24,17 25,01
%Accelerator
3% 6,25 7,50 8,75 10,00 11,25 12,50 13,75 15,00 16,26 17,51 18,76 20,01 21,26 22,51 23,76 25,01 26,26 27,51 28,76 30,01 31,26 32,51 33,76 35,01 36,26 37,51
4% 8,34 10,00 11,67 13,34 15,00 16,67 18,34 20,01 21,67 23,34 25,01 26,68 28,34 30,01 31,68 33,34 35,01 36,68 38,35 40,01 41,68 43,35 45,01 46,68 48,35 50,02
5% 10,42 12,50 14,59 16,67 18,76 20,84 22,92 25,01 27,09 29,18 31,26 33,34 35,43 37,51 39,60 41,68 43,76 45,85 47,93 50,02 52,10 54,18 56,27 58,35 60,44 62,52
6% 12,50 15,00 17,51 20,01 22,51 25,01 27,51 30,01 32,51 35,01 37,51 40,01 42,51 45,01 47,52 50,02 52,52 55,02 57,52 60,02 62,52 65,02 67,52 70,02 72,52 75,02
7% 14,59 17,51 20,42 23,34 26,26 29,18 32,09 35,01 37,93 40,85 43,76 46,68 49,60 52,52 55,43 58,35 61,27 64,19 67,11 70,02 72,94 75,86 78,78 81,69 84,61 87,53
8% 16,67 20,01 23,34 26,68 30,01 33,34 36,68 40,01 43,35 46,68 50,02 53,35 56,69 60,02 63,35 66,69 70,02 73,36 76,69 80,03 83,36 86,69 90,03 93,36 96,70 100,03
9% 18,76 22,51 26,26 30,01 33,76 37,51 41,26 45,01 48,77 52,52 56,27 60,02 63,77 67,52 71,27 75,02 78,78 82,53 86,28 90,03 93,78 97,53 101,28 105,03 108,79 112,54
10% 20,84 25,01 29,18 33,34 37,51 41,68 45,85 50,02 54,18 58,35 62,52 66,69 70,86 75,02 79,19 83,36 87,53 91,70 95,86 100,03 104,20 108,37 112,54 116,70 120,87 125,04

IS21 CONCRETE SPRAYING MACHINE DOSING SYSTEM

1. STANDART SYSTEM
The system is operated accelerator ratios adjusts by manually. Accelerator ratios value (maximum 75
Hz – minimum 15 Hz) sets from the additive gauge on the electrical panel by authorized and qualified
personnel. Accelerator Hz value is set according to dosing table. The machine operator can increase
and decrease accelerator ratio on the electrical panel. (Fig. 1)
Hz value increase
Hz value decrease
Hz set
Fig. 1
1
Accelerator ratios is increased and decreased by remote control. (Fig. 2)
Fig. 2
Dosing pump is operated electrical engine and gearbox drive. Electrical engine is 1,5 kW, gearbox ratio
36,24. (Fig. 3)
Dosing Pump
Engine - Gearbox
Fig. 3
Water line, accelerator line, conduit line and discharge line on the pump. There are valves on
the water and accelerator line and these lines control by valves. When the valves are opened
position, the accelerator is transferred.
2
After completing the concrete spraying process, the accelerator line should be closed off by
the valve and the dosing system should be cleaned with water before closing the system.
During the concrete spraying, the instant congestion in the accelerator-water line is removed
via the discharge line. (Fig. 4)
WATER LINE
ACCELERATOR
LINE CONDUIT
LINE
DISCHARGE LINE
Fig. 4
DOSING PUMP
ACCELERATOR
TANK CONDUIT LINE
WATER TANK
Fig. 5
3
2- PLC SYSTEM
The PLC system determines the number of strokes by means of sensors on the water tank and
sets the amount of accelerator. The values in the PLC unit are determined by the Titan
authorized personnel according to the dosing tables. The system automatically adjusts the
percentage of accelerator according to the number of strokes read from the sensors.
PLC UNIT
Fig. 6
PLC unit
First page – It shows "Total Amount Concrete" and "Total Amount Additive" (Fig. 7)
Fig. 7
4
Second page – PLC unit shows amount and percent of additive in the concrete. You can follow
dosing amount.
(1)
(2)
Reset (1) – “Reset of total amount concrete”

Reset (2) – “Reset of Additive”
The amount of accelerator (kg) and concrete (m³) used on the PLC unit can be monitored.
ATTENTION:
The same the dosing pump, water – accelerator – conduit – discharge line used the both
systems.
The difference between the two systems is the accelerator screens on the electric panel.
5
HYDRAULIC PUMP
OPERATING MANUAL
Adjusting Levers
COMPACT CATALOGUE
MONOBLOCK
DIRECTIONAL CONTROL VALVES
SD4
Features
Simple, compact designed, this valve is only one section for open centre and closed centre hydraulic systems.
H Fitted with a main pressure relief valve.
H Diameter 16 mm -- 0.63 in interchangeable spools.
H Available manual and remote with flexible cables spool control kits.
Working conditions
This catalogue shows technical specifications and diagrams measured with mineral oil of 46 mm2/s -- 46 cSt viscosity at 40°C temper-
ature.
Nominal flow rating 45 l/min

Operating pressure (maximum) 250 bar 3600 psi
Back pressure (maximum) on outlet port T 25 bar 260 psi
Dp=100 bar -- 1450 psi
Internal leakage A(B)®T 3 cm3/min 0.18 in 3/min
fluid and valve at 40°C -- 104°F
Fluid Mineral base oil
Fluid temperature with NBR (BUNA--N) seals from --20° to 80°C
with FPM (VITON) seals from --20° to 100°C
Viscosity operating range from 15 to 75 mm2/s from 15 to 75 cSt
min. 12 mm2/s 12 cSt
max. 400 mm2/s 400 cSt
Max level of contamination 19/16 -- ISO 4406
Ambient temperature from --40° to 60°C
NOTE -- For different conditions please contact Customer Service.
Additional information
This catalogue shows the product in the most standard configurations.
Please contact Customer Service Dpt. for more detailed information or
special request.
WARNING!
All specifications of this catalogue refer to the standard product at this date.
Walvoil, oriented to a continuous improvement, reserves the right to
discontinue, modify or revise the specifications, without notice.
WALVOIL IS NOT RESPONSIBLE FOR ANY DAMAGE CAUSED BY AN 7th edition October 2000:
INCORRECT USE OF THE PRODUCT. This edition supercedes all prior documents.
2 DAC002E
SD4
Dimensional data
WALVOIL Production batch :
MADE IN ITALY
101111001
P0000001
P0000001
P00 = production year (2000)
WALVOIL
101111001 00001 = progressive number
MADE IN ITALY
Valve code
92 55
3.62 2.17
31 46 37
1.22 1.81 1.46
1.57
40
8.2
0.32
184.5 max
Æ
3.78
96
1.57
40
2.76
70
7.26
1.46
37
1.10
28
0.43
Position 1
11
0.79
20
15°
1.73
Position 0
44
15°
Position 2
20
23 30 M8
1.18 0.79
0.91
85.5
3.37
Standard threads
BSP UN--UNF METRIC
PORT
(ISO 228/1) (ISO 11926--1) (ISO 262)
Inlet P 3/4--16 UNF--2B (SAE 8)

A and B ports G 3/8 9/16--18 UNF--2B (SAE 6) M18x1.5
Outlet T 3/4--16 UNF--2B (SAE 8)
DAC002E 3
SD4
Hydraulic circuit
Standard valve is supplied with positive overlap spool (1CP).
AB
P
T
120
1750
Ex.: SD4/1(KG3--120)/1CP8L
Right inlet
A simmetrical body allows the reverse assembly of spool and relative control kit and lever (ED configuration).
BA
P
T
120
1750
Ex.: SD4/1(KG3--120)/ED--1CP8L
4 DAC002E
SD4
Performance data (pressure drop vs. flow)
Open centre
From inlet to outlet.
10
(bar)
8 (psi)
A 100
Pressure drop
6
P T
4
B 50
0
0 15 30 45 60
Flow (l/min)
Inlet to work port

From inlet to A port (spool in position 1) or B port (spool in position 2).
10
(bar)
8 (psi)
A 100
Pressure drop
6
P T
4
B 50
0
0 15 30 45 60
Flow (l/min)
Work port to outlet

From A port (spool in position 2) or B port (spool in position 1) to outlet.
10
(bar)
8 (psi)
A 100
Pressure drop
6
P T
4
B 50
0
0 15 30 45 60
Flow (l/min)
NOTE -- Measured with spool type 1CP.
DAC002E 5
SD4
Ordering codes
Example:
SD4 / 1 (KG3--120) / 1CP 8 L *
1. 2. 3. 4. 5.
Pressure relief valve setting in bar
4.
1. Body kits * 8
TYPE CODE DESCRIPTION
1 5KC1113000 1 section
Include boby and seals.
2. Inlet relief options 9--10

TYPE CODE DESCRIPTION I
VMD5/1 direct pressure relief valve type K (standard)
(KG2-- 80) 5KIT105122 Range 40 to 80 bar / 580 to 1150 psi
standard setting 80 bar / 1150 psi
11--12
15--16
VMD5/1 direct pressure relief valve type Y
(YG2-- 80) 5KIT105212 Range 63 to 160 bar / 900 to 2300 psi
(YG3-- 175) 5KIT105213 Range 125 to 250 bar / 1800 to 3600 psi
Standard setting is referred to 10 l/min flow. 1.
17
SV XTAP623282 Relief blanking plug
3. Spool options 2.
TYPE CODE CIRCUIT DESCRIPTION
1CP 3CU1110110 Double acting with positive overlap, 18
3 positions, A and B closed in neutral position K
1N 3CU1110120 Double acting, 3 positions, A and B closed in
neutral position, negative overlap
2 3CU1125130 Double acting, 3 positions, with A open to tank
in neutral position
Y
3 3CU1131130 Single acting on A, 3 positions, B plugged;
requires G3/8 plug (see part I )
4 3CU1135140 Single acting on B, 3 positions, A plugged
requires G3/8 plug (see part I )
6 3CU1150130 Double acting, 3 positions, closed center SV
7 3CU1155130 Double acting, 3 positions, closed center with
A and B to tank in neutral position
NOTE (*) -- Items are referred to BSP thread.
6 DAC002E
SD4
Ordering codes
II
4. “A” side spool positioners

5. TYPE CODE DESCRIPTION
8 5V08104000 With spring return in neutral position
9 5V09104010 With detent in position 1
10 5V10104010 With detent in position 2
11 5V11104000 With detent in position 1, neutral and 2
L 12 5V12104000 With detent in position 1 and 2
15 5V15104000 With detent in position 1 and neutral
16 5V16104000 With detent in position 2 and neutral
17 5V17104000 With spring return position 1
18 5V18104000 With spring return position 2
5. “B” side options

L 5LEV105000 Standard lever box
LEB 5LEV605000 Safety lever with handlever, detent in 3
LEB
positions
SLP 5COP105000 Without lever, with dust proof plate
TP 5TEL105005 Cable connection
I Port plug *
3. TYPE CODE DESCRIPTION
G3/8 3XTAP722160 Plug for single acting spool
SLP
II Optional handlever
AL01/M8x120 170011012 Standard handlever L= 120mm/4.72in
TP
For special configurations see pages 9 and 10
DAC002E 7
SD4
Spools options
1 0 2 1 0 2 1 0 2
A B A B A
1CP 2 3
P T P T P T
“B” port plugged
1 0 2 1 0 2 1 0 2
B A B A B
4 6 7
P T P T P T
“A” port plugged
“A” side spool positioners
40 44.5 49
1.57 1.75 1.93
1 0 2 8 1 0 2 10 1 0 2 9
1 0 2
11 1 0 2 17
1 2 12
1 0 15
0 2 16
1 0 2 18
8 DAC002E
SD4
Special configurations
Directional valve with rotary control kit

57.5
2.26
92 55
3.62 2.17
37.5
1.48
Standard body kit

182 max
3.78
96
7.17
208.5
8.21
- 0.21
6.5
Æ
1.30
--5.5
33
0.26 Optional handlever

code: 3XGIU422620
+0.21
+5.5
24.2
Stroke
0.95
Æ
20
0.79
180
Angle excursion ± 90°
7.09
AB
P
T
120
1750
Ex.: SD4/1 (KG3--120)/ 1N R SLP
Dust proof plate kit: code 5COP105000

Rotary positionerl kit: code 5ROT104000
Spool: code 3CU1110561 (negative overlap)
DAC002E 9
SD4
Special configurations
Detent with kick--out from position 1 to neutral position

Spool control kit with fix setting, available with kick--out pressure of 63 and 80 bar (900 and 1150 psi).
92 55
3.62 2.17
71.5
2.81
216 max.
Special body kit:

code 5KC1113600
8.50
3.78
96
23.5
0.93
47.5
1.87
M8 20
0.79
85.5
3.37
AB
120
1750
Ex.: SD4/1 (KG3--120)/ 1N 9A(80) LA

Special lever box: code 5LEV104000
Positioner kit with 63 bar / 900 psi setting code 5V09504000
Positioner kit with 80 bar / 1150 psi setting code 5V09504080
Spool: code 3CU1110300 (negative overlap)
10 DAC002E
SD4
Installation and maintenance
The SD4 valve is assembled and tested as per the technical specification of this catalogue.
Before the final installation on your equipment, follow the below recommendations:
-- the valve can be assembled in any position, in order to prevent body deformation and spool sticking mount the product on a flat
surface;
-- in order to prevent the possibility of water entering the lever box and spool control kit, do not use high pressure wash down directly
on the valve;
-- prior to painting, ensure plastic port plugs are tightly in place.
A
B
Fitting tightening torque - Nm / lbft

THREADS TYPE P port A and B ports T port
BSP (ISO 228/1) G 3/8 G 3/8 G 3/8
With O--Ring seal 35 / 25.8 35 / 25.8 35 / 25.8
With copper washer 40 / 29.5 40 / 29.5 40 / 29.5
With steel and rubber washer 30 / 22.1 30 / 22.1 30 / 22.1
UN--UNF (ISO 11926--1) 3/4--16 UNF--2B (SAE 8) 9/16--18 UNF--2B (SAE 6) 3/4--16 UNF--2B (SAE 8)
With O--Ring seal 50 / 36.9 30 / 22.1 50 / 36.9
METRIC (ISO 262) M18 x 1.5 M18 x 1.5 M18 x 1.5
With O--Ring seal 35 / 25.8 35 / 25.8 35 / 25.8
With copper washer 40 / 29.5 40 / 29.5 40 / 29.5
with steel and rubber washer 40 / 29.5 40 / 29.5 40 / 29.5
NOTE -- These torque are recommended. Assembly tightening torque depends on many factors, including lubrication, coating and
surface finish. The manufacturer shall be consulted.
DAC002E 11
WALVOIL S.P.A.
42100 REGGIO EMILIA · ITALY · VIA ADIGE, 13/D
TEL. +39.0522.932411 · FAX +39.0522.300984
E--MAIL: INFO@WALVOIL.COM · HTTP: //WWW.WALVOIL.COM
SALES DEPARTMENT
TEL. +39.0522.932555 · FAX +39.0522.932455
D1409808I
DAC002E
Steering Unit
Hydrostatic
Steering Unit Type
OSPB, OSPC and
OSPF
Service Manual
Hydrostatic Steering Unit OSPB, OSPC and OSPF
Service Manual
Table of Contens
Revision History Table of Revisions

Date Page Changed Rev
Dec 2008 26 Tightening torque changed BC
Jan 2010 32 Japan location BD
Sep 2010 32 New back cover BE
May 2011 12 Hexagon size BF
Aug 2011 3-4 Drawing BG
Table of contens............................................................................................................................................... 2
Exploded view OSPB...................................................................................................................................... 3
Exploded view OSPC / OSPF........................................................................................................................ 4
Tools..................................................................................................................................................................... 5
Dismantling....................................................................................................................................................... 7
Dismantling the pressure relief valve for OSPC..................................................................................12
Assembling......................................................................................................................................................15
Assembly pattern for standard bearing................................................................................................18
Installation instruction for O-ring / roto Glyd.....................................................................................19
Assambly of the pressure relief valve for OSPC..................................................................................26
Assambly of the shock valves for OSPC/OSPC LS/OSPC LSR.........................................................27
Maximum tightening torque and hydraulic connections..............................................................29
© 2011 Sauer-Danfoss. All rights reserved.
Sauer-Danfoss accepts no responsibility for possible errors in catalogs, brochures and other printed material.
Sauer -Danfoss reserves the right to alter its products without prior notice. This also applies to products already
ordered provided that such alterations can be made without affecting agreed specifications. All trademarks
in this material are properties of their respective owners. Sauer-Danfoss, the Sauer-Danfoss logotype, the
Sauer-Danfoss S-icon, PLUS+1™, what really matters is inside® and Know-How in Motion™ are trademarks of the
Sauer-Danfoss Group.
Front cover illustrations: F300617, F300618, F300619
Drawing:150-577 fa
2 520L0066 • Rev BG • Aug 2011

Service Manual
Exploded View OSPB
1 Dust seal ring

2 Housing + spool + sleeve
3 Ball 8.5 mm [0.33 in]
4 Thread bushing
5 O-ring with kin-ring or
Roto Glyd
7 Bearing assembly 16 Distributor plate
10 Ring for springs 17 Gearwheel
11 Cross pin 6 • 41 mm 18 O-ring 75.92 • 1,78 mm [2.99 • 0.07 in]
[0.24 • 1.61 in] 19 End cover
12 Neutral position springs 20 Washer 8.2 • 11,9 • 1.0 mm [0.32 • 0.47 • 0.04 in]
13 Cardan shaft 22 Special screw
14 Spacer 23 Screw
15 O-ring 80,5 • 1,5 mm 24 Name label
[3.17 • 0.06 in] 26 Spacer
520L0066 • Rev BG • Aug 2011 3

Service Manual
Exploded View OSPC / OSPF
1 Dust seal ring 14 Spacer 24 Name plate

2 Housing, spool and sleeve. 13 Cardan shaft 30 Complete relief valve
Check valve and the seats for relief 12 Set of springs 31 Spring wire
and shock valves are locktited. 15 O-ring 32 Complete shock valve
3 Ball 8.5 mm [0.33 in] 16 Distributor plate 33 Ball 3/16 in
4 Thread bushing 17 Gearwheel set 38 Spring
5 O-ring used with kin-ring (item 6) 18 O-ring 34 Rolled pin
6 Kin-ring 19 End cover 36 Bushing
7 Bearing assembly 20 Washer 35 Ball
10 Ring 22 Special screw 39 Kin ring
11 Cross pin 23 Screw 40 O-ring
4 520L0066 • Rev BG • Aug 2011

Service Manual
Tools
Tools Holding tool

Code number: SJ 150-9000-2
F300 937
Guide ring
F301 015
Assembly tool for O-ring and kin-ring /

Roto Glyd
Code number: SJ 150N4014-1
F300 940
Assembly tool for lip seal

F300 944
520L0066 • Rev BG • Aug 2011 5

Service Manual
Tools
Tools Assembly tool for cardan shaft.

F300 945
Assembly tool for dust seal.

F300 946
Torque wrench 0 - 70 N.m.

13 mm socket spanner.
6.8 and 12 mm sockets.
12 mm screwdriver.
2 mm [0.08 in] screwdriver.
13 mmring spanner.
6.8 and 12 mm socket spanners.
Plastic hammer.
Tweezers.
The tools are not available from Sauer-

Danfoss F300 939
6 520L0066 • Rev BG • Aug 2011

Service Manual
Dismantling
Dismantling Dismantle steering column from steering

unit and place the steering unit in the
holding tool.
Screw out the screws in the end cover
(6-off plus one special screw).
F300 947
Remove the end cover, sideways.
F300 948
Lift the gearwheel set (with spacer if

fitted) off the unit. Take aut the two
O-rings.
F300 949
Remove the cardan shaft
F300 950
520L0066 • Rev BG • Aug 2011 7

Service Manual
Dismantling
Dismantling Remove distributor plate.
F300 951
Screw out the threaded bush over the

check valve.
F300 953
Remove O-ring
F300 952
OSPB, OSPB LS, OSPBX LS:

Shake out the check valve ball (∅8 mm)
OSPC LS, OSPC LSR:

Shake out the check valve ball and
suction valve pins and balls.
On some pins in the OSPC there are

two springs (see page 4, pos. 38).
Replace this pins prior to the reassembly!
F300 954
8 520L0066 • Rev BG • Aug 2011

Service Manual
Dismantling
Dismantling Take care to keep the cross pin in the

sleeve and spool horizontal. The pin
can be seen through the open end
of the spool. Press the spool inwards
and the sleeve, ring, bearing races and
needle bearing will be pushed out of the
housing together.
F300 955
Take ring, bearing races and needle

bearing from sleeve and spool. The outer
(thin) bearing race can sometimes “stick”
in the housing, therefore check that it
has come out.
F300 956
Press out the cross pin. Use the special

screw from the end cover.
Note next point/paragraph!
F300 957
CN OSPF
OSPB CN and OSPC CN
A small mark has been made with a
pumice stone on both spool and sleeve
close to one of the slots for the neutral m
position springs (see drawing).
If the mark is not visible, remember to

leave a mark of your own on sleeve and
spool before the neutral position springs
are dismantled.
For OSPF both marks should be placed F301 014
opposite each other!

520L0066 • Rev BG • Aug 2011 9
Service Manual
Dismantling
Dismantling Carefully press the spool out of the

sleeve.
F300 958
Press the neutral position springs out of

their slots in the spool.
F300 959
Remove dust seal and O-ring / Kin-ring /

Roto Glyd.
F300 960
Remove plugs from shock valves using a

6 mm Ihexagon socket
spanner
F300 961
10 520L0066 • Rev BG • Aug 2011

Service Manual
Dismantling
Dismantling Remove seal washers (2-off ).
F300 962
Unscrew the setting screws using a

6 mm I hexagon socket spanner.
F300 963
Shake out the two springs and two valve

balls into your hand. The valve seats are
bonded into the housing and cannot be
removed.
F300 964
The shock valves are now dismantled.
F300 965
520L0066 • Rev BG • Aug 2011 11

Service Manual
Dismantling the Pressure Relief Valve for OSPC
Dismantling Screw out the plug using and

8 mm Ihexagon socket spanner.
Remove seal washers.
F300 966
Unscrew the setting screw using an

6 mm Ihexagon socket spanner.
F300 968
Shake out spring and piston. The valve

seat is bonded into the housing and
cannot be removed.
F300 942
The pressure relief valve is now

dismantled.
F300 967
12 520L0066 • Rev BG • Aug 2011

Service Manual
Dismantling the Pressure Relief Valve
Dismantling OSPC The steering unit OSPC is now

completely dismantled.
Replace this pins prior to the reassembly!
F300 971
Cleaning Lubrication
Clean all parts carefully in Shellsol K or Before assembly, lubricate all parts with
the like. hydraulic oil.
Inspection and replacement

Replace all seals and washers.
Check all parts carefully and make any
replacements necessary.
520L0066 • Rev BG • Aug 2011 13

Service Manual
Notes
Notes
14 520L0066 • Rev BG • Aug 2011

Service Manual
Assembling
Assembling
Place the two flat neutral position

springs in the slot.
Place the curved springs between
the flat ones and press them into F300 975
place.
Line up the spring set.
F300 976
Guide the spool into the sleeve. Make

sure that spool and sleeve for OSPB
LS, OSPBX LS, OSPC LS, OSPC LSR and
OSPF are placed correctly in relation
to each other (see page 10).
F300 977
520L0066 • Rev BG • Aug 2011 15

Service Manual
Assembling
Assembling Assemble spool and sleeve.
OSPB LS, OSPBX LS, OSPC LS, OSPC

LSR and OSPF
When assembling spool and

sleeveonly one of two possible ways
of positioning the spring slots is
correct. There are three slots in the
spool and three holes in the sleeve in
the end of the spool/sleeve opposite
to the end with spring slots. Place F300 978
the slots and holes opposite each

other so that parts of the holes in the
sleeve are visible through the slots in
the spool.
OSPB CN and OSPC CN

Assemble the spool/sleeve and make
sure the marks on spool and sleeve
are opposite each other (see drawing
page 10).
F301 016
Press the springs together and push

the neutral position springs into
place in the slave.
F300 979
Line up the springs and centre them.
F300 980
16 520L0066 • Rev BG • Aug 2011

Service Manual
Assembling
Assembling Guide the ring down over the sleeve.
The ring should be able to move - free of

springs.
F300 981
Fit the cross pin into the spool/sleeve.
F300 982
Fit bearing races and needle bearings as

shown on the drawing next page.
F300 983
520L0066 • Rev BG • Aug 2011 17

Service Manual
Assembly Pattern for Standard Bearing
Assembling for Assembly pattern for standard bearing

Standard Bearing
1 Outer bearing race
2 Needlebearing
3 Inner bearing race
4 Spool
5 Sleeve
Assembly pattern for double bearing
1 Washer for axial bearing

2 Outer needlebearing
3 Outer bearing race
4 Spool
5 Sleeve
6 Inner needlebearing
7 Inner bearing race
The inside chamfer on the inner bearing race must face the inner spool.
18 520L0066 • Rev BG • Aug 2011

Service Manual
Installation Instruction for O-ring / Kin-ring / Roto Glyd
Installation Turn the steering unit until the bore

Instructions for is horizontal. Guide the outer part of
O-ring / Kin-ring the assembly tool into the bore for the
Roto glyd spool/sleeve.
F300 984
Grease o-ring and king-ring/roto Glyd

with hydraulic oil and place them on the
tool.
F300 985
Hold the outer part of the assembly

tool in the bottom of the steering unit
housing and guide the inner part of the
tool right to the bottom.
F300 986
Press and turn the o-ring/kin-ring into

position in the housing.
F300 987
520L0066 • Rev BG • Aug 2011 19

Service Manual
Installation Instruction for O-ring / Kin-ring / Roto Glyd
Installation Draw the inner and outer parts of the

Instructions for assembly tool out of the steering unit
O-ring / Kin-ring / bore, leaving the guide from the inner
Roto Glyd part in the bore.
F300 988
20 520L0066 • Rev BG • Aug 2011

Service Manual
Installation Instruction for Lip Seal
Installation Lubricate the lip seal with hydraulic oil

Instructions for and place it on the assembly tool.
Lip Seal
F300 989
Guide the assembly tool right to the

bottom.
F300 990
Press and turn the lip seal into place in

the housing.
F300 991
With a light turning movement, guide

the spool and sleeve into the bore.
Fit the spool set holding the cross pin

horizontal.
F300 992
520L0066 • Rev BG • Aug 2011 21

Service Manual
Installation The spool set will push out the assembly

Instructions for tool guide. The o-ring and kin-ring/roto
Lip Seal Glyd are now in position.
F300 993
Turn the stearing unit until the bore is

vertical again. Put the check valve ball
into the hole indicated by the arrow.
F300 994
Screw the threaded bush lightly into the

check valve bore. The top of the bush
must lie just below the surface of the
housing.
F300 953
Place a ball in the two holes indicated by

the arrows
F300 995
22 520L0066 • Rev BG • Aug 2011

Service Manual
Installation Place a new pin in the same two holes.

Instructions for
Lip Seal
F300 996
In some cases a spring has to be fitted

(see page 4 pos. 38) on the pin before it
is placed in the
housing.
F300 997
Grease the o-ring with mineral oil

approx. viscosity 500 mm2/s [SUS]
at 20°C [68 °F].
F300 998
Place the distributor plate so that the

channel holes match the holes in the
housing.
F300 999
520L0066 • Rev BG • Aug 2011 23

Service Manual
Installation Guide the cardan shaft down into the

Instructions for bore so that the slot is parallel with the
Lip Seal connection flange.
F301 000
Place the cardan shaft as shown - so that

it is held in position by the mounting
fork.

F301 001
Grease the two o-rings with mineral oil

approx. viscosity 500 mm2/s [SUS] at 20°C
[°F] and place them in the two grooves in
the gear rim. Fit the gearwheel and rim
on the cardan shaft.
F300 949
Caution
Fit the gearwheel (rotor) and cardan

shaft so that a tooth base in the rotor is
positioned in relation to the shaft slot
as shown. Turn the gear rim so that the
seven trough holes match the holes in
the housing.
F301 002
24 520L0066 • Rev BG • Aug 2011

Service Manual
Installation Fit the spacer, if any.

Instructions for
Lip Seal
F301 003
Place the end cover in position.
F301 004
Fit the special screw with washer and

place it in the hole shown.
F301 005
Fit the six screws with washers

and insert them.
Cross-tighten all the screws and the
rolled pin with a torque of 
30 +/-6 N.m [265.5 +/- 53 lbf.in].
The OSPB, OSPB LS and OSPBX LS can
now be function tested.
F300 947
520L0066 • Rev BG • Aug 2011 25

Service Manual
Assambly of the Pressure Relief Valve for OSPC
Assembly of the Pressure Fit the piston.

Relief Valve for OSPC
F300 938
Fit the spring
F301 013
Screw in the setting screw with an

8 mm hexagon socket spanner.
Make the pressure setting on a panel or
the vehicle.
F300 968
Screw plug with dust seal into the

housing using an 8 mm Ihexagon
socket spanner.
Tightening torque: 65 +/-5 N.m.
[575.3 +/- 44.2 lbf.in]
F300 941
26 520L0066 • Rev BG • Aug 2011

Service Manual
Assambly of the Shock Valves for OSPC/OSPC LS/OSPC LSR
Assambly of the Shock Put a ball in the two holes indicated by

Valves for OSPC/OSPC LS/ the arrows.
OSPC LSR
F301 006
Place springs and valve cones over the

two balls.
The blue spring applies to setting

range 90-180 bar [1305-2610 psi]. The
untreated spring applies to setting range
170-260 bar [2465-3770 psi]
F301 007
Screw in the two setting screws using a

6 mm Ihexagon socket spanner. Make
the pressure
setting on a panel or the vehicle.
F301 008
Screw plug with seal ring into the two

shock valves and tighten them with a
torque of : 
30 +10 N.m [265.5 + 88.5 lbf.in] using a 6
mm Ihexagon socket spanner.
Steering unit type OSPC, OSPC LS or
OSPC LSR is now assembled.
F301 009
520L0066 • Rev BG • Aug 2011 27

Service Manual
Assambly of the Shock Valves for OSPC/OSPC LS/OSPC LSR
Assambly of the Shock Place the dust seal ring in the housing.
Valves for OSPC/OSPC LS/ With the OSPC, OSPC LS and OSPC LSR
OSPC LSR the dust seal ring must be placed only
after the pressure relief valve and shock
valves have been fitted.
F301 010
Fit the dust seal ring in the housing using

special tool SJ 150-9000-22 (see page 5)
and a
plastic hammer.
F301 011
Press the plastic plugs into the

connection ports.
Do not use a hammer!
F301 012
28 520L0066 • Rev BG • Aug 2011

Service Manual
Maximum Tightening Torque and Hydraulic Connections
Maximum Tightening T: Tank

Torque and Hydraulic
Connections L: Left port
P: Pump
R: Right port
Maximum tightening torque N.m [lbf.in]

Screwed With cooper With aluminium
With cutting edge With O-ring
connection washer washer
G 1/4 35 [309] 35 [309] 35 [309] -
G 3/8 70 [619] 45 [398] 50 [442] -
G 1/2 100 [885] 55 [486] 80 [708] -
7/16 -20 UNF - - - 20 [177]
3/4 -16 UNF - - - 60 [531]
M 12 • 1.5 30 [265] 20 [177] 30 [265] 25 [221]
M18 • 1.5 80 [708] 55 [486] 70 [619] 50 [442]
M22 • 1.5 100 [885] 65 [575] 80 [708] 60 [531]
520L0066 • Rev BG • Aug 2011 29

Service Manual
Notes
Notes
30 520L0066 • Rev BG • Aug 2011

Service Manual
Notes
Notes
520L0066 • Rev BG • Aug 2011 31

Products we offer: Sauer-Danfoss is a global manufacturer and supplier of high-
quality hydraulic and electronic components. We specialize in
• Bent Axis Motors providing state-of-the-art technology and solutions that excel in
the harsh operating conditions of the mobile off-highway market.
• Closed Circuit Axial Piston Pumps
Building on our extensive applications expertise, we work closely
and Motors
with our customers to ensure exceptional performance for a broad
• Displays range of off-highway vehicles.
• Electrohydraulic Power Steering
We help OEMs around the world speed up system development,
• Electrohydraulics reduce costs and bring vehicles to market faster.
Sauer-Danfoss – Your Strongest Partner in Mobile Hydraulics.
• Hydraulic Power Steering
• Integrated Systems
• Joysticks and Control Handles
Go to www.sauer-danfoss.com for further product information.
• Microcontrollers and Software
• Open Circuit Axial Piston Pumps
• Orbital Motors Wherever off-highway vehicles are at work, so is Sauer-Danfoss.
• PLUS+1™ GUIDE
We offer expert worldwide support for our customers, ensuring
• Proportional Valves the best possible solutions for outstanding performance. And with
an extensive network of Global Service Partners, we also provide
• Sensors
comprehensive global service for all of our components.
• Steering
• Transit Mixer Drives
Please contact the Sauer-Danfoss representative nearest you.
Local address:
Members of the Sauer-Danfoss Group:
Comatrol
www.comatrol.com
Schwarzmüller-Inverter
www.schwarzmueller-inverter.com
Sauer-Danfoss (US) Company Sauer-Danfoss ApS
2800 East 13th Street DK-6430 Nordborg, Denmark
Ames, IA 50010, USA Phone: +45 7488 4444
Turolla
Phone: +1 515 239 6000 Fax: +45 7488 4400
www.turollaocg.com Fax: +1 515 239 6618
Hydro-Gear Sauer-Danfoss GmbH & Co. OHG Sauer-Danfoss-Daikin LTD.

www.hydro-gear.com Postfach 2460, D-24531 Neumünster Shin-Osaka TERASAKI 3rd Bldg. 6F
Krokamp 35, D-24539 Neumünster, Germany 1-5-28 Nishimiyahara, Yodogawa-ku
Phone: +49 4321 871 0 Osaka 532-0004, Japan
Sauer-Danfoss-Daikin Fax: +49 4321 871 122 Phone: +81 6 6395 6066
Fax: +81 6 6395 8585
www.sauer-danfoss-daikin.com
520L0066 • Rev BG • Aug 2011

www.sauer-danfoss.com
Electric Motor Driven

Pumps
1
03890327-E
K3VL
Swash-plate type Axial piston pump
Service Manual
2
Contents
1 Disassembly and Assembly of the Pump 3

1-1 Tools 3
1-2 Procedure of Disassembly 4
1-3 Procedure of Assembly 9
Attached Drawing No.1 Exploded Drawing 14
Attached Drawing No.2 K3VL45/A Cross Section 15
2 Disassembly and Assembly of Pressure Cut-off Load Sensing Regulator 19

2-1 Tools 19
Attached Drawing No.7 Cross Section KR3L-* * 25
Attached Drawing No.8 Cross Section KR3B-* * 26
3 Disassembly and Assembly of Torque Control Module 27

3-1 Tools 27
Attached Drawing No.10 Cross Section KR3*-* * 35
4 Judging Standard for Maintenance 36

4-1 Judging Standard for replacing worn parts 36
4-2 Judging Standard of cylinder, valve plate, swash plate, and
shoe plate 37
3
1 Disassembly and Assembly of the Pump

1-1 Tools
The following tables show tools required when disassembling and
assembling K3VL pumps.
Mark means that the

Tool name and size tool is required. Part name
Size of the pump
Hexagon
B Hexagon Plug
socket
Name Width 45 80 112 140 socket (ROH type) Others
head set
(mm) head bolt
screw
4 M8 NPTF 1/16 plug
5 M6 G 1/8 M10
6 M8 G 1/4 M12,M14
8 M10 G 3/8 M16,M18
Allen wrench
10 M12 G 1/2 M20
12 M14 G 3/4
14 M16,M18 Servo piston
17 M20,M22
B Plug
Plug (UNF
Name Width 45 80 112 140 Nut (ISO thread)
thread)
(mm)
22 3/4 UNF
Double ring 24 M16 M14×1.5

spanner,
Socket wrench, 30 M22×1.5
Spanner
32 M20 1-1/16 UNF
36 M27×2
14.3 7/16 UNF
Adjustable
single Medium size, 1 piece
wrench
Screw driver Medium size, 2 pieces
Hammer Plastic hammer, 1piece
Pliers for snap ring(see below)
Pliers
Pliers for retaining ring(see below)
Torque
Capable of tightening with specified torque
wrench
Mark stands for “ required for SAE mounting type.”
Mark stands for “ required for ISO mounting type.”
Mark stands for “ not required”
Plier for snap ring Plier for retaining ring

4
1-2 Procedure of Disassembly
Before disassembling, read all pages of this disassembly section.

When disassembling, follow the order of procedures written in the next table.
Numbers in the parentheses next to the part name shows the part number in
the following drawings:
Attached Drawing No.1 Exploded Drawing
Attached Drawing No.2 K3VL45/A Cross Section
5
Notes
¹ Work
Select an appropriate place to (1) The place must be clean.
1 disassemble. (2) Spread rubber sheet, cloth, etc. to
prevent parts from being damaged.
Remove dust, rust, and so on from the
2
surface of the pump with cleaning oil.
Remove the drain plug (467) and drain (1) Drain off as much oil as possible.
3 off hydraulic oil out of pump casing
(271).
Remove hexagon socket head bolts (411 (1) When disassembling the regulator,
in case of K3VL45, 80), (411 and 412 in refer to the manual of the regulator.
case of K3VL112, 140), and then remove (2) Be careful not to drop O-ring from
the regulator from the casing. the gasket surface of the regulator.
(3) Prevent dust from entering into the
regulator.
Loosen hexagon socket head bolt (401, (1) Remove the regulator before
402) tightening valve cover(312) and the loosening the bolts.
pump casing. (2) In case through drive kit is installed,
remove sub-plate adapter (317) and
coupling (116) beforehand.
(3) Oil will come out from between pump
casing (271) and valve cover (312). Be
5 careful and remove oil to keep the
place clean.
6
¹ Work Notes
Place the pump horizontally on (1) Pull out valve cover perpendicular to
workbench. Separate pump casing (271) the direction of the shaft. (In order to
from valve cover (312). prevent damage of the needle bearing
and the contacting surface of the
shaft.)
(2) Be careful not to damage the
contacting surfaces between valve
6 cover and pump casing.
(3) When removing valve cover, valve
plate comes out attached to valve
cover. But valve plate may easily
detach from valve cover and fall
down. Be careful not to damage valve
plate.
When necessary, remove needle bearing (1) Do not remove needle bearing unless
(124) and valve plate (313) from valve the bearing is considered to be near
cover(312). the end of its expected life.
7
(2) Dot not loosen nut (808). Delivery
flow rate will change when nut is
loosened.
Pull cylinder (141) out from pump (1) Be careful not to damage sliding
casing straight over drive shaft. Pull out surfaces of cylinder (141), spherical
pistons (151), set plate (153), spherical bush (156), shoe (152), piston (151),
bush(156), cylinder springs (157) at the and swash-plate (212).
same time. (2) Be careful not to damage surface of
the shaft contacting needle bearings.
8
7
¹ Work Notes
Remove retaining ring (406) in case of (1) In case of K3VL80, 112, 140, seal
K3VL45 or hexagon socket head bolts cover (261) is easily removed when
(406) in case of K3VL80, 112, 140. two bolts are inserted into holes (with
Remove seal cover (261). female thread).
(2) Be careful not to damage oil seal
(774) on seal cover (261).
(3) In case of spline shaft, cover spline
9 part with plastic tape so as not to
damage oil seal.
In case of key shaft, remove key
before seal cover is removed.
Tapping drive shaft (111) lightly on the (1) Hold front side of shaft when
end of valve cover side with a plastic tapping to prevent shaft from flying
hammer, extract drive shaft from pump out.
casing. (2) Tap shaft horizontally (in accordance
with shaft direction) not to damage
front roller bearing.
(3) As front roller bearing and shaft are
10 fit tightly (shrinkage fit), do not
remove front roller bearing unless it
is considered to be near the end of its
expected life.
Pushing down servo piston (532), (1) Be careful not to damage shoe plate,
remove shoe plate (211) and swash plate and the sliding round surface of swash
(212) from pump casing. plate.
11
8
¹ Work Notes
(1) Use both hands to lift up swash
Remove swash plate support (251) from
plate support (251) .
pump casing (271).
13
Only when necessary, remove servo (1) When removing servo piston, use a
piston (532), tilting pin (548), special jig not to damage head part of
outer/inner servo bias springs (535, tilting pin.
536), spring seat (537), and plug (538). (2) Adhesive (Three bond No.1305B) has
been applied on the connecting part
14
between tilting pin and servo piston.
Be careful not to damage servo piston.
(3) Be careful not to clamp fingers by
springs when removing tilting pin
from pump casing.
9
1-3 Procedure of Assembly
When assembling, the order of procedures is the reverse of disassembly.

Be careful of next items.
(1) Before assembling, make sure that all parts are prepared and all damaged parts
are fixed or replaced by new ones.
(2) Before assembling, wash each part with clean oil and dry it with compressed air.
Select an appropriate clean place to assemble. When dust enters, it may cause
trouble.
(3) When assembling, apply clean working fluid on the sliding surfaces and
bearings.
(4) Do not reuse O-ring, oil seal, and other seal parts.
Replace with new one.
(5) When assembling parts that easily detach, like an O-ring, apply clean grease to
prevent them from dropping downward.
(6) Tighten fitting bolts and plugs using a torque wrench with standard torques
shown on the drawing of each size.
10
¹ Work Notes
Select an appropriate place to assemble. (1) The place must be clean.
1 (2) Spread rubber sheet, cloth, etc. to
Fit swash plate support in (251) in (1) In case servo piston, tilting pin, servo
pump casing (271). bias springs, spring seat, and plug
were removed, reinstall all parts
before fitting swash plate support.
(2) Be careful not to clamp fingers by
springs when installing springs.
(3) Use a special jig not to damage head
part of tilting pin and feed-back pin.
Apply adhesive (Three bond No.
2
1305B) on thread of servo piston.
(4) Pin (884) has been installed on the
inside surface of pump casing. When
installing swash plate support, make
sure that pin enters into the slit of
swash plate support(251).
(5) Be careful not to install swash plate
support (251) in oblique.
Insert tilting pin(530) of the servo piston (1) When inserting, while pushing down
(532) sub-assembly into tilting bush of servo piston, insert tilting pin into
swash plate assembly (030), then install tilting bush and insert swash plate
swash plate assembly (030), and shoe into grove of swash plate support
plate (211) in pump casing (271). correctly.
(2) If grease is applied on rounding
surfaces of swash plate and swash
plate support, it is easier to install.
3
11
¹. Work Notes
Insert drive shaft (111) into pump (1) When tapping shaft, keep shaft in
casing (271) tapping shaft lightly so that vertical direction.
height of surface of the pump casing and If tapped strongly, roller bearing
height of end of roller bearing are nearly may be broken.
the same. (2) Be careful not to push the top surface
of roller bearing deeper than the
surface of pump casing. If the top
surface is deeper than the surface of
pump casing, there is a possibility for
swash plate support to be detached.
Tape the splined or keyed area of the (1) Apply a little grease on lip of oil seal
shaft. installed in seal cover.
Insert seal cover (261) slightly into (2) Be careful not to damage lip of oil
pump casing. seal.
In case of K3VL80, 112, 140, tighten (3) Make sure to tighten the four
hexagon socket head bolts (406) hexagon socket head screws evenly.
uniformly to stopping position of the (4) In case of K3VL45, install O-
seal cover and then tighten bolts with a ring(710), apply grease on outside
standard torque. surface of seal cover, and be careful
In case of K3VL45, use the hammer to not to damage O-ring(710).
lightly tap the seal cover to the position
where the groove for locking ring can be
5 seen and then install retaining ring
(406).
12
¹ Work Notes
Assemble cylinder (141), piston-sub (1)Incase of K3VL45/A
(011), spherical bush (156), set plate Install cylinder spring, ring guide,
(153), and cylinder spring (157) into a and retaining ring into cylinder and
sub assembly. then assemble pin, spacer, spherical
bush, set plate, piston-sub to set a sub-
assembly.
(2) Be careful not to damage sliding
6 surfaces between piston and cylinder
bore, and between cylinder and valve
plate.
Place pump casing (271) horizontally (1) Be careful not to drop parts for
with surface of regulator downward. piston-cylinder sub such as cylinder
Install piston-cylinder sub into pump spring and roller.
casing. (2) Be careful not to damage bearing-
contacting surface of the shaft when
installing a piston- cylinder sub.
Install valve plate (313) on valve cover (1) In case that stopper (534), max flow
(312). set screw (954), and max flow set
screw lock nut (808) have been
removed, install these parts on valve
cover (312) beforehand.
(2) Do not mistake suction/delivery
direction of valve plate (313). When
8
installing valve plate, make sure that
pin (885) enters into the slit of valve
plate (313).
(3) If grease is applied on contacting
surfaces of valve plate (313) and valve
cover (312), it is easier to install valve
cover (312).
13
¹ Work Notes
Install valve cover (312) on pump casing (1) In assembling valve cover, be careful
(271). not to damage shaft and contacting
Tighten hexagon socket head bolts (411 surface of needle bearing.
in case of K3VL45, 80), (411 and 412 in
case of K3VL112, 140),
Install regulators on the valve cover (1) Make sure that O ring on the gasket
(312) or pump casing (271) . surface of regulator does not drop out.
When installing torque limit regulator ,
make sure that feed back lever (611) of
regulator is engaged with feed back pin .
10
14

15

16

17

18

19
2 Disassembly and Assembly of Pressure Cut-off / Load Sensing Regulator

2-1 Tools
assembling pressure cut-off load sensing regulator
Mark means that the
Type of regulator
Hexagon
B Hexagon
KR3L- KR3B- Plug socket
Name Width socket Others
** ** (ROH type) head set
(mm) head bolt
screw
2 GPM1/32 plug
4 M8 NPTF 1/16 plug
Allen wrench
5 6 G 1/8 M10
6 M8 G 1/4 M12,M14
B
KR3L- KR3B-
Name Width Parts
** **
(mm)
13 Max flow set screw lock nut
19 KR3L: plug for differential spool
Double ring
27
spanner, (Adapter with M thread)
Socket
KR3L:plug for cut-off spool
wrench, 30
KR3B:plug for differential spool
Spanner
32 KR3B:plugfor cut-off spool
14.3 7/16 UNF plug(for PC, PL port )
Adjustable
single Medium size, 1 piece
wrench
Hammer Plastic hammer, 1piece
Torque
wrench
Mark stands for “ required for ISO mounting type.”

Mark stands for “ not required”
20
Before disassembling, read all pages of this manual.

Attached Drawing No.7 Cross Section KR3L - * *
Attached Drawing No.8 Cross Section KR3B - * *
21
¹ Work Notes
2
Remove hexagon socket head bolts (411), (1) Be careful not to drop O-ring (701)
and then remove the regulator from the from the gasket surface of the
valve cover (312). regulator.
pump.
Remove plug (645), and then remove (1) Be careful not to damage gasket
spring (628, 629), and spring seat (624). surface of the regulator.
Remove plug (646), and then remove (2) Be careful not to drop spool (647,648)
spring (630, 631), and spring seat (625). after removing plug.
(3) Do not remove nut (802), set screw
(643, 644), stopper (626, 627), unless
required.
Loosen ROH plug (423), and remove (1) Be careful not to damage spool.
5
spool (647,648).
Only when necessary, remove plug (1) Be careful not to lose plug and
6 (490,491), and orifice (492,493,494). orifice.
22

(2) Before assembling, wash each part with clean oil and dry it with compressed air.
Select an appropriate clean place to assemble. When dust enters, it may cause
trouble.
(3) When assembling, apply clean working fluid on the sliding surfaces and.
(4) Do not reuse O-ring, oil seal, and other seal parts. Replace with new one.
23
¹ Work Notes
Install ROH plug (423) and then insert (1) In case the plug (490,491) and
spool (647,648). orifice (492,493,494) have been
removed, install these parts into
regulator casing beforehand.
(2) When inserting spool, be careful not
2 to damage sliding surface of the
spool.
(3) In case of KR3L-**, be careful not to
confuse cut-off spool and differential
spool. Shapes of these spools are
different.
Insert spring (628,629) and spring seat (1) In case when nut (801), set screw
(624) into plug (645). (643,644), stopper (626,627) have
Install plug (645) on casing. been removed, install these parts
Insert spring (630,631) and spring seat beforehand.
(625) into plug (646). (2) Be careful not to install spring and
Install plug (646) on casing. spring seat inclined or incorrectly.
(3) Install plug for differential spool
(645) before installing plug for cut-
off spool to make installing easier.
Install regulator on pump casing by (1) Make sure O-ring (701) is installed
tightening 4 hexagon socket head bolts correctly.
(411). (2) Tighten 4 bolts evenly.
4
24

25
Attached Drawing No.7 Cross Section KR3L - * *

26
Attached Drawing No.8 Cross Section KR3B - * *

27
3 Disassembly and Assembly of Torque Control Regulator

3-1 Tools
assembling torque control regulator
Mark means that the
Type of regulator
Hexagon
B 4 Hexagon
Plug socket
Name Width KR38-** socket Others
(ROH type) head set
(mm) H head bolt
screw
4 M8 NPTF 1/16 plug
Allen wrench 5 M6 G 1/8 M10
8 M10 G 3/8 M16,M18 0R0M18
B
Name Width KR38-** Parts
(mm)
Double ring 13 Inner adjustment lock-nut
spanner, 27 Adjustment plug
Socket wrench,
41 Outer adjustment lock-nut
Spanner
Adjustable
single Medium size, 1piece
wrench
Hammer Plastic hammer
Pliers Pliers for retaining ring(see page 3)
Steel bar made of material for key,
Steel bar
Size approx. 10×8×200 mm
Torque
wrench
Bolt M4×0.75 (used for pulling out pivot plug)
28
Before disassembling, read all pages of this manual.

Attached Drawing No.10 Cross Section KR3* - * *
29
¹ Work Notes
2
Remove hexagon socket head bolts (412), (1) Be careful not to drop O-rings
and then remove the regulator from the (701,705) from the gasket surface of
casing. the regulator.
regulator.
Loosen lock nut (630). (1) Be careful not to damage gasket

Remove adjusting plug (628), spring surface of the regulator.
(625,626), spring seat (624). (2) Be careful not to drop spool (621),
when and after removing adjusting
plug.
(3) Do not remove nut (801), set screw
(924), adjustment stem (627), unless
4 required.
30
No. Work Notes

Remove locking ring (680). (1) Size of thread (for pulling out pivot
Using bolt, remove pivot plug(614) and plug) is M4×1.
feed back lever(611). (2) Feedback lever is connected to
sleeve (622) with pin (670).
While lifting up pivot plug (614) with
screw, lift feedback lever (611) to the
direction shown by the arrow in
order to remove feedback lever (611)
.
Pivot plug(614)
Remove ROM plug (650) and then push (1) Be careful not to damage spool and
out spool (621), sleeve(622). sleeve.
6
31

(2) Before assembling, wash each part with clean oil and dry it with compressed
air. Select an appropriate clean place to assemble. When dust enters,
it may cause trouble.
(3) When assembling, apply clean working fluid on the sliding surfaces.
(4) Do not reuse O-ring, oil seal, and other seal parts. Replace with new one.
32
¹ Work Notes
Adjust the position of the hole for feed (1) In case that plug (660) have been
back pin on sleeve to be seen from removed, install plug into regulator
outside the hole for pivot plug on casing beforehand.
regulator casing, insert sleeve (622) and (2) Be careful not to damage sliding
spool (621). surfaces when assembling sleeve and
spool.
Install feedback lever so that pin (670)

of feedback lever (611) enters into a hole
of sleeve.
(1) Adjust the position of the feedback

lever (611) so that the pivot pin hole
on the feed back lever can be seen
from the pivot plug hole on casing.
33
Install pivot plug (614) so that pin (1) Insert bolt for pulling out on pivot
(670)of pivot plug enters into hole of plug.
feedback lever (611). Apply grease on the surface of pivot
Fix pivot plug by retaining ring (680). plug to make inserting easy.
Tapping bolt lightly, insert pivot
plug into casing.
Install spring (625, 626) and spring seat (1) In case that nut (801), set screw
(624) into adjusting plug (628). (924), and adjustment stem (627)
Install these parts on regulator casing. have been removed, install these
parts into adjusting plug beforehand.
(2) Be careful not to install spring and
spring inclined or incorrectly.
Put regulator on pump casing so that (1) Make sure O-ring is installed
feed back lever engages with feed back correctly.
pin in the pump (548). (2) Tighten 4 bolts evenly.
Fix regulator by tightening hexagon
socket head bolts (412).
6
34

35
Attached Drawing No.10 Cross Section KR3* - * *

36
Judging Standard for Maintenance

4-1 Judging Standard for replacing worn parts
When each part is worn exceedingly over the following standard, replace or
adjust the part. If there is a remarkable damage, replace or adjust the part.
( Upper standard of initial value, Lower standard of limit for replacing)
standard of initial value /
standard of limit for replacing
Measuring item Measure
45 80 112 140
Clearance between 0.019 0.028 0.039 0.039 Replacement of piston or
cylinder bore and
piston (D-d) 0.040 0.056 0.067 0.067 cylinder
Endplay between 0.1 0.1 0.1 0.1 Replacement of piston-shoe
piston and shoe (ä) 0.3 0.3 0.3 0.3 assembly
3.4 3.9 4.9 4.9 Replacement of piston-shoe
Depth of shoe (t)
3.2 3.7 4.7 4.7 assembly
Free height of 51.2 31.3 41.1 39.5 Replacement of cylinder
cylinder spring (L) 50.2 30.2 40.3 38.8 spring
Combined height of 5.0 19.0 23.0 23.0
set plate and
Replacement of set plate
spherical bush
(H-h) 4.3 18.3 22.0 22.0
(unit:mm)
Clearance between cylinder bore and

Free height of cylinder springs (L)
piston. (D-d)
Endplay between piston and shoe (ä ) Combined height of set plate and
Shoe thickness (t) spherical bush (H-h)

37
4-2 Judging Standard of cylinder, valve plate, swash plate, and

shoe plate
Roughness of standard of limit for
Valve plate (sliding surface), 3-Z
repair
Swash plate (surface
contacting with shoe plate), standard of initial value
0.4Z or less
Cylinder (sliding surface) or after repaired
HYDROMOTOR
OPERATING MANUAL
Mixer Hydromotor
HYDRAULIC MOTORS MT
APPLICATION
» Conveyors
» Metal working machines
» Agricultural machines
» Road building machines
» Mining machinery
» Food industries
» Special vehicles
» Plastic and rubber machinery etc.
CONTENTS OPTIONS
Specification data ......................................26÷27 » Model - Disc valve, roll-gerotor
Function diagrams .................................... 28÷31 » Flange with wheel mount
Dimensions and mounting .........................32÷33
» Short motor
Shaft extensions ............................................ 34
» Tacho connection
Permissible Shaft Seal pressure .................... 34
Dimensions and mounting- MTS, V ......... 35÷36 » Speed sensoring
Internal Spline data ....................................... 37 » Side and rear ports
Permissible shaft loads .................................. 37 » Shafts - straight, splined and tapered
Tacho connection .......................................... 38 » Metric and BSPP ports
Order code .................................................... 38
» Other special features
GENERAL
Max. Displacement, 3
cm /rev [in /rev]
3
724,3 [44.2]
Max. Speed, [RPM] 775
Max. Torque, daNm [lb-in] cont.: 130 [11500] int.: 148 [13100]
Max. Output, kW [HP] 40 [54]
Max. Pressure Drop, bar [PSI] cont.: 200 [2900] int. 240 [348 0]
Max. Oil Flow, lpm [GPM] 150 [39.6]
Min. Speed, [RPM] 5
Permissible Shaft Loads daN [lbs] Pa=1000 [2250]
Pressure fluid Mineral based- HLP(DIN 51524) or HM(ISO 6743/4)
Temperature range,
O O
C [ F] -40÷140 [-40÷284]
Optimal Viscosity range, mm /s [SUS]
2
20 ÷ 75 [98 ÷ 347]
Filtration ISO code 20/16 (Min. recommended fluid filtration of 25 micron s)
Oil flow in drain line Pressure Losses

p p
bar PSI
Oil flow in 14 200

Pressure drop Viscosity drain line 12
2 150
bar [PSI] mm /s [ SUS] lpm [GPM ] 10
8
20 [ 98 ] 2,5 [.660 ] 100
6
140 [ 2030]
35 [ 164 ] 1,5 [.396 ] 4 50
2
20 [ 98 ] 5 [1.321 ] 0 0
210 [ 3045] 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 Q, GPM
35 [ 164 ] 3 [.793 ]
0 10 20 30 40 50 60 70 80 90 100 110 120 Q, lpm
25
MT
MOTORS
SPECIFICATION DATA
MT MT MT MT
Type
160 200 250 315
Displacement, 161,1 201,4
12.29 251,8
15.36 326,3
19.90
3 3
cm³/rev [in³/rev] in. /rev. [Cm. /rev.] [9.83] [12.29] [15.36] [19.90]
Max. Speed, Cont. 622 620 496 382
[RPM] Int.* 775 752 601 461
Max. Torque Cont. 47 [4160] 59 [5220] 73 [6460] 95 [8410]
daNm [lb-in] Int.* 56 [4960] 71 [6285] 88 [7790] 114 [10090]
Peak** 66 [5840] 82 [7260] 102 [9030] 133 [11770]
Max. Output Cont. 26,5 [36] 33,5 [45] 33,5 [45] 33,5 [45]
kW [HP] Int.* 32 [43] 40 [54] 40 [54] 40 [54]
Max. Pressure Drop Cont. 200[2900] 200 [2900] 200 [2900] 200 [2900]
bar [PSI] Int.* 240[3480] 240 [3480] 240 [3480] 240 [3480]
Peak** 280[4050] 280 [4050] 280 [4050] 280 [4050]
Max. Oil Flow Cont. 100 [26] 125 [33] 125 [33] 125 [33]
lpm [GPM] Int.* 125[33] 150 [39.6] 150 [39.6] 150 [39.6]
Max. Inlet Pressure Cont. 210[3050] 210 [3050] 210 [3050] 210 [3050]
bar [PSI] Int.* 250[3600] 250 [3600] 250 [3600] 250 [3600]
Peak** 300[4350] 300 [4350] 300 [4350] 300 [4350]
Max. Return Pressure Cont. 140[2030] 140 [2030] 140 [2030] 140 [2000]
with Drain Line Int.* 175[2540] 175 [2540] 175 [2540] 175 [2500]
bar [PSI] Peak** 210[3050] 210 [3050] 210 [3050] 210 [3000]
Max. Starting Pressure with
Unloaded Shaft, bar [PSI] 10 [150] 10 [150] 10 [150] 10 [150]
Min. Starting Torque At max. press. drop Cont. 34 [3010] 43 [3800] 53 [4690] 74 [6550]
daNm [lb-in] At max. press. drop Int.* 41 [3630] 52 [4600] 63 [5580] 89 [7880]
Min. Speed***, [RPM] 10 9 8 7
Weight, kg [lb] MT 20 [44.1] 21,5 [47.4] 21 [46.3] 22 [48.5]
For Rear Ports MTW 22 [48.5] 22,5 [49.6] 23 [50.7] 24 [52.9]
+0,450[ .992] MTS 15 [33.1] 15,5 [34.2] 16 [35.3] 17 [37.5]
MTV 11 [24.3] 11,5 [25.4] 12 [26.5] 13 [28.7]
* Intermittent operation: the permissible values may occur for max. 10% of every minute.
** Peak load: the permissible values may occur for max. 1% of every minute.
*** For speeds lower than given, consult factory or your regional manager.
1. Intermittent speed and intermittent pressure must not occur simultaneously.

2. Recommended filtration is per ISO cleanliness code 20/16. A nominal f iltration of 25 micron or better.
3. Recommend using a premium quality, anti-wear type mineral based hydraulic oil HLP(DIN51524) or HM ( ISO 6743/4).
If using synthetic fluids consult the factory for alternative seal materials.
4. Recommended minimum oil viscosity 13 mm²/s [70 SUS] at 50°C [122°F].
5. Recommended maximum system operating temperature is 82°C [180°F].
6. To assure optimum motor life fill with fluid prior to loading and run at moderate load and speed for 10-15 minutes.
26
MT
MOTORS
SPECIFICATION DATA (continued)
Type MT MT MT MT
400 500 630 725
Displacement, 410,9
25.06 523,6
31.95 631,2
38.52 724,3
44.2
3 3
cm³/rev [in³/rev] in. /rev. [Cm. /rev.] [25.06] [31.95] [38.52] [44.2]
Max. Speed, Cont. 304 238 197 172
[RPM] Int.* 368 289 234 209
Max. Torque Cont. 108 [9560] 122 [10800] 130 [11500] 127 [11240]
daNm [lb-in] Int.* 126 [11150] 137 [12125] 148 [13100] 147 [13010]
Peak** 144 [12745] 160 [14160] 176 [15580] 175 [15490]
Max. Output Cont. 30 [40] 26,5 [36] 24,3 [33] 20,2 [27]
kW [HP] Int.* 35 [47] 30 [40] 27,5 [37] 26,8 [36]
Max. Pressure Drop Cont. 180 [2610] 160 [2320] 140 [2010] 120 [1740]
bar [PSI] Int.* 210 [3050] 180 [2610] 160 [2320] 140 [2010]
Peak** 240 [3480] 210 [3050] 190 [2760] 165 [2395]
Max. Oil Flow Cont. 125 [33] 125 [33] 125 [33] 125 [33]
lpm [GPM] Int.* 150 [39.6] 150 [39.6] 150 [39.6] 150 [39.6]
Max. Inlet Pressure Cont. 210 [3050] 210 [3050] 210 [3600] 210 [3050]
bar [PSI] Int.* 250 [3600] 250 [3600] 250 [4350] 250 [3600]
Peak** 300 [4350] 300 [4350] 300 [2000] 300 [4350]
Max. Return Pressure Cont. 140 [2000] 140 [2000] 140 [2500] 140 [2000]
with Drain Line Int.* 175 [2500] 175 [2500] 175 [3000] 175 [2500]
bar [PSI] Peak** 210 [3000] 210 [3000] 210 [3000] 210 [3000]
Max. Starting Pressure with
Unloaded Shaft, bar [PSI] 10 [150] 10 [150] 10 [150] 10 [150]
Min. Starting Torque At max. press. drop Cont. 84 [7435] 95 [8410] 95 [8410] 95 [8410]
daNm [lb-in] At max. press. drop Int.* 97 [8585] 106 [9380] 110 [9740] 115 [10180]
Min. Speed***, [RPM] 6 5 5 5
Weight, kg [lb] MT 23 [50.7] 24 [52.9] 23,5 [51.8] 24,5 [54.0]
For Rear Ports MTW 25 [55.1] 26 [57.3] 25,5 [56.2] 26,5 [58.4]
+0,450[ .992] MTS 18 [39.7] 19 [41.9] 18,5 [40.8] 19,5 [43.0]
MTV 14 [30.9] 15 [33.1] 14,5 [32.0] 15,5 [34.2]
* Intermittent operation: the permissible values may occur for max. 10% of every minute.
** Peak load: the permissible values may occur for max. 1% of every minute.
*** For speeds lower than given, consult factory or your regional manager.
1. Intermittent speed and intermittent pressure must not occur simultaneously.

2. Recommended filtration is per ISO cleanliness code 20/16. A nominal f iltration of 25 micron or better.
3. Recommend using a premium quality, anti-wear type mineral based hydraulic oil HLP(DIN51524) or HM ( ISO 6743/4).
If using synthetic fluids consult the factory for alternative seal materials.
4. Recommended minimum oil viscosity 13 mm²/s [70 SUS] at 50°C [122°F].
5. Recommended maximum system operating temperature is 82°C [180°F].
6. To assure optimum motor life fill with fluid prior to loading and run at moderate load and speed for 10-15 minutes.
27
MT
MOTORS
FUNCTION DIAGRAMS
MT 160
Q=10 l/min
2.6 GPM
20 l/min
5.3 GPM
40 l/min
10.6 GPM
60 l/min
15.9 GPM
80 l/min
21 GPM
100 l/min
26 GPM
125 l/min
33 GPM
M M
lb-in daNm
5500
60
5000 p=240 bar
55 3480 PSI
35kW
4500
50
70%
int.
30kW
200 bar
4000 45
80% 2900 PSI
3500 40
25kW
160 bar
35 85% 2320 PSI
cont.
3000
t= 86%
20kW
30
2500
120 bar
25 1740 PSI
2000 15kW
20 10kW
1500 80 bar
15 5kW 1160 PSI
1000
10
40 bar
500 5 580 PSI
0 0
cont. int. n
-1
0 100 200 300 400 500 600 700 800 min (rpm)
MT 200
Q=10 l/min
2.6 GPM
20 l/min
5.3 GPM
40 l/min
10.6 GPM
60 l/min
15.9 GPM
80 l/min
21 GPM
100 l/min
26 GPM
125 l/min
33 GPM
150 l/min
39.6 GPM
M M
lb-in daNm
75
6500
70 p=240 bar
6000 35kW 3480 PSI
65
40kW
int.
5500
60 70%
5000 80% 200 bar
55 2900 PSI
30kW
4500 50 85%
cont.
4000 45 160 bar

25kW 2320 PSI
86%
3500 40
20kW
3000 35
120 bar
15kW 1740 PSI
30
2500
25 10kW
2000 80 bar
20
t= 87% 1160 PSI
1500
15 5kW
1000
10 40 bar
500 580 PSI
5
0 0
cont. int. n
-1
0 100 200 300 400 500 600 700 800 min (rpm)
The function diagrams data is for average performance of randomly selected motors at back pressure
o
5÷10 bar [72.5÷145 PSI] and oil with viscosity of 32 mm²/s [150 SUS] at 50°C [122 F].
28
MT
MOTORS
FUNCTION DIAGRAMS
MT 250
M M
150 l/min
39.6 GPM
80 l/min
21 GPM
100 l/min
26 GPM
125 l/min
33 GPM
Q=10 l/min
2.6 GPM
5.3 GPM
40 l/min
10.6 GPM
20 l/min
60 l/min
15.9 GPM
lb-in daNm
8500 95
8000 90
p=240 bar
7500 85 3480 PSI
7000 80
40kW
int.
75
6500 70%
200 bar
70
6000 80% 35kW 2900 PSI
65
5500 25kW
60
5000 30kW 160 bar
cont.
55 20kW
2320 PSI
4500 50 85%
4000 15kW
45
120 bar
3500 40
1740 PSI
10kW
3000 35
30
2500
N=5kW 80 bar
25
2000 t= 87% 1160 PSI
20
1500
15
1000 10 40 bar
500 580 PSI
5
0 0
cont. int. n
0 50 100 150 200 250 300 350 400 450 500 550 600 min-1 (rpm)
MT 315
150 l/min
39.6 GPM
80 l/min
21 GPM
100 l/min
26 GPM
125 l/min
33 GPM
Q=10 l/min
2.6 GPM
20 l/min
5.3 GPM
40 l/min
10.6 GPM
60 l/min
15.9 GPM
M M
lb-in daNm
120
10000 p=240 bar
110
3480 PSI
9000 100 40kW
int.
70%
80% 200 bar
8000 90 2900 PSI
35kW
7000 80 25kW
30kW
85% 160 bar
cont.
70 20kW 2320 PSI

6000
87%
60 15kW
5000 120 bar
50 10kW 1740 PSI
4000
40
3000 N=5kW 80 bar
t= 88%
30 1160 PSI
2000
20
1000 40 bar
10
580 PSI
0 0
cont. int. n
-1
0 50 100 150 200 250 300 350 400 450 min (rpm)
o
29
MT
MOTORS
FUNCTION DIAGRAMS
MT 400
80 l/min
21 GPM
125 l/min
33 GPM
150 l/min
39.6 GPM
100 l/min
26 GPM
Q=10 l/min
2.6 GPM
5.3 GPM
40 l/min
10.6 GPM
20 l/min
60 l/min
15.9 GPM
M M
lb-in daNm
130
11000 p=210 bar
120 3050 PSI
int.
70%
10000
110
180 bar
9000 100 2610 PSI
80%
8000 90 30kW 150 bar
cont.
85%
2175 PSI
7000 80
87% 25kW
70 120 bar
6000
20kW 1740 PSI
60
5000
50 90 bar
4000 15kW 1160 PSI
t= 88%
40
3000 10kW 60 bar
30 870 PSI
2000
20
5kW
N=2,5kW 30 bar
1000 10 435 PSI
70%
0 0
n
0 50 100 150 200 250 300 350 min-1 (rpm)
MT 500
80 l/min
21 GPM
150 l/min
39.6 GPM
100 l/min
26 GPM
125 l/min
33 GPM
Q=10 l/min
2.6 GPM
20 l/min
5.3 GPM
40 l/min
10.6 GPM
60 l/min
15.9 GPM
M M
lb-in daNm
150
13000
140
12000 p=180 bar
2610 PSI
int.
130
11000
120 160 bar
30kW 2320 PSI
10000
110
140 bar
9000 100 2030 PSI
25kW
cont.
20kW
8000 90 120 bar
15kW 1740 PSI
7000 80
6000 70
90 bar
60 5kW 10kW 87% 1160 PSI
5000 t= 90%
85%
50
4000 80% 60 bar
40 N=2,5kW 870 PSI
3000
30
2000
20 30 bar
1000 435 PSI
10
0 0
cont. int. n
-1
0 25 50 75 100 125 150 175 200 225 250 275 300 min (rpm)
o
30
MT
MOTORS
FUNCTION DIAGRAMS
MT 630
M M
80 l/min
21 GPM
100 l/min
26 GPM
125 l/min
33 GPM
150 l/min
39.6 GPM
Q=10 l/min
2.6 GPM
20 l/min
5.3 GPM
40 l/min
10.6 GPM
60 l/min
15.9 GPM
lb-in daNm
14000 160
150
13000
140
12000 p=160 bar
int.
130 25kW
11000 2320 PSI
120
10000 140 bar
110 20kW 2030 PSI
9000 100
cont.
8000 90 120 bar

15kW 1740 PSI
7000 80
80% 75%
6000 70
85% 90 bar
60 1160 PSI
5000
t= 87% 10kW
50
4000
40 60 bar
3000 870 PSI
30 5kW
2000 20 30 bar
2,5kW
1000 10 435 PSI
0 0
cont. int. n
-1
0 25 50 75 100 125 150 175 200 225 250 min (rpm)
MT 725
80 l/min
21 GPM
100 l/min
26 GPM
125 l/min
33 GPM
150 l/min
39.6 GPM
Q=10 l/min
2.6 GPM
20 l/min
5.3 GPM
40 l/min
10.6 GPM
60 l/min
15.9 GPM
M M
lb-in daNm
14000 160
150
13000
140
12000
130
int.
20kW p=140 bar

11000 2030 PSI
120
10000 120 bar
110
1740 PSI
9000 100
15kW
cont.
8000 90
7000 80 90 bar
1160 PSI
6000 70 10kW 73%
77%
60
5000 75%
50 t= 82% 80% 60 bar
4000 870 PSI
40
3000 5kW
30
2000 30 bar
20 435 PSI
N=2,5kW
1000 10
0 0
cont. int. n
-1
0 25 50 75 100 125 150 175 200 225 min (rpm)
o
31
MT
MOTORS
DIMENSIONS AND MOUNTING DATA

SL Shaft SL Shaft
C, CO Shaft
Shaft Dim. K Shaft C, CO Shaft
K Shaft See Page 34
SH Shaft SH Shaft
max 134
[5.276]
max 114
max 114
[4.488]
[4.488]
max 202
[7.953]
max 182
max 182
[7.165]
[7.165]
[2.36]
60
T Flange Dim.
L2
See Page 33
max L
75
75
T
L1
max
125125
L1
[2.953]
[2.953]
[4.621]
[4.921] max 125
125
max L
[4.921]
[4.621]
L2
C
Port A
Port B
Port Dim.
See Page 33 72
P(A,B) [2.835]
E Rear ports
mm [in]
C: 4xM10-10 mm [.39 in] depth

max LE
P(A,B): 2xG3/4 or 2xM27x2-17 mm [.67 in] depth

T: G 1/4 or M14x1,5 - 12 mm [.47 in] depth (plugged)
Standard Rotation Reverse Rotation
Viewed from Shaft End Viewed from Shaft End
Port A Pressurized - CW Port A Pressurized - CCW
Port A Port B Port B Pressurized - CCW Port B Pressurized - CW
Type L,mm [in] L2, mm [in] **LE, mm [in] Type L, mm [in] L2, mm [in] **LE,mm [in] *L1, mm [in]
MT 160 190 [7.48] 140 [5.51] 200 [7.87] MTW 160 123 [4.84] 73 [2.87] 133 [5.23] 16,5 [.65]
MT 200 195 [7.68] 145 [5.71] 205 [8.07] MTW 200 128 [5.04] 78 [3.07] 138 [5.43] 21,5 [.85]
MT 250 201 [7.91] 151 [5.95] 211 [8.31] MTW 250 134 [5.28] 84 [3.31] 144 [5.67] 27,8 [1.09]
MT 315 211 [8.31] 161 [6.34] 221 [8.70] MTW 315 144 [5.67] 94 [3.70] 154 [6.02] 37,0 [1.46]
MT 400 221 [8.70] 171 [6.73] 231 [9.09] MTW 400 154 [6.06] 104 [4.09] 164 [6.45] 47,5 [1.87]
MT 500 235 [9.25] 185 [7.28] 245 [9.64] MTW 500 168 [6.61] 118 [4.65] 178 [6.61] 61,5 [2.42]
MT 630 231 [9.09] 181 [7.13] 241 [9.49] MTW 630 164 [6.46] 114 [4.49] 174 [6.85] 57,5 [2.26]
MT 725 240 [9.45] 190 [7.48] 250 [9.84] MTW 725 173 [6.81] 123 [4.84] 183 [7.21] 66,5 [2.62]
* - The width of the roll-gerotor is 3,5 mm [.138 in] greater than L1.
** - For Rear Ported Motors.
32
MT
MOTORS
MOUNTING
Square Mount (4 Holes)

60
[2.36]
4xø14±0,1 ø160±0,4
[.551±.0039] [6.299±.0157] 18 8
[.709] [.315]
[4.921 -.0025 ]
[2.835±.039]
ø125 -0,063
max 143
ø72±1
[5.63]
max 143
[5.63]
W Wheel Mount
4 18,8
[.157] [.74]
4xø18±0,15 ø200±0,4
[.708±.0059] [7.874±.0157] 77,2
[3.039]
20
[.787]
[6.299-.0025 ]
[6.772 -.0025 ]
ø160 -0,063
ø172 -0,063
[2.95±.039]
max 180
ø75±1
[7.087]
[4.921-.0039 ]
ø125 -0,1
[2.953]
75
7
max 180 [.276]
[7.087] max 99,7
[3.98]
PORTS
Port A Side Ports E Rear Ports

23±0,6
[.905±.024]
72 72 7
12,5±0,5 12,5±0,5 [2.835] [.276]
[.492±.019] [.492±.019] [2.835] Port A
[.85±.019]
C
21,6±0,5
[1.732±.0118] [1.732±.0118]
[.787±.0118]
[.85±.019]
20±0,3
21,6±0,5
44±0,3
[.787±.0118]
[.85±.019]
21,6±0,5
44±0,3
20±0,3
[.85±.019]
21,6±0,5
P(A,B)
12,5±0,5 12,5±0,5 Port B
[.492±.019] [.492±.019]
Port B
mm [in]
Viewed from Shaft End Viewed from Shaft End C: 4xM10-10 mm [.39 in] depth
Port A Pressurized - CW Port A Pressurized - CCW P(A,B): 2xG3/4 or 2xM27x2-17 mm [.67 in] depth
Port B Pressurized - CCW Port B Pressurized - CW T: G 1/4 or M14x1,5 - 12 mm [.47 in] depth (plugged)
33
MT
MOTORS
SHAFT EXTENSIONS
C -ø40 straight, Parallel key A12x8x70 DIN 6885 K -tapered 1:10, Parallel key B12x8x28 DIN 6885
Max. Torque 132,8 daNm [11755 lb-in] Max. Torque 210,7 daNm [18650 lb-in]
S=46
Tightening torque
A-A 12 -0.043
50±3 daNm
12 -0.043 [4425±265 lb-in]
0 [.472-.0017 ] A
[.472-.0017 ] 45
[.248]
ø6,3
[1.692 -.0079]
+.0001 ]
[1.575+.0007
ø40 +0,002
+0,018
[2.205]
M30x2
43 -0,2
[1.771]
[1.771]
ø56
ø45
ø45
[.95 -.0079]
24,15 -0,2
M12 A 9
82 -0,2
min 25 [.984] deep Taper 1:10 [.354]
[3.228-.0079]
54±0,4 4
[2.126±.016] [.157]
82±0,2
[3.228±.0079]
CO-ø1½" straight, Parallel key 3 8"x 3 8"x 2¼" BS46 SH -ø1½" splined 17T, DP 12/24 ANSI B92.1-1976
Max. Torque 132,8 daNm [11755 lb-in] Max. Torque 132,8 daNm [11755 lb-in]
9.545 -0,02
56 +2
[.379-.0008]
[2.205 +.079 ]
[1.669-.0079 ]
ø38,1 -0,025
[1.5 -.001 ]
ø38,1 -0,05
42,4 -0,2
[1.5 -.0019]
[1.771]
[1.771]
ø45
ø45
82 -0,2 82-0,2
3/8-16 UNC [3.228-.0079] M12
[3.228-.0079]
min 25 [.984] deep min 25 [.984] deep
SL -ø34,85 p.t.o. DIN 9611 Form 1

Max. Torque 77 daNm [6815 lb-in]
102 -0,2
[4.016-.0079]
76±1
[2.992±.039]
[1.157±.0039]
[1.372 -.0047]
ø34,85 -0,12
ø29,4±0,1
38±0,25
[1.496±.01]
8,64 -0,11 A-A
[.34-.0043 ] ø28,9 -0,15 A
[1.138 -.006 ]
[1.771]
ø45
7
A [.28]
R6,7 mm [in]
[.264]
MAX. PERMISSIBLE SHAFT SEAL PRESSURE for MT motors

Max. return pressure without drain line or
P P
max. pressure in the drain line
PSI bar
1800
120
1600
1450 100
1400
1200 80 1: Drawing for Standard Shaft Seal
1090 75
1000 2: Drawing for High Pressure Seal ("U" Seal)
60
800
600 40 2
400
- continuous operations
200
20
1
- intermittent operations
0 0
0 100 200 300 400 500 600 700 800 min-1
34
MT
MOTORS
DIMENSIONS AND MOUNTING DATA - MTS and MTV
S Short Mount V Very Short Mount
max 36,1 [1.421]

min 32,9 [1.295]
-0,04
ø106-0,12
ø125 -0,063
[4.921-.0025 ] [4.173 -.0016
-.0047 ]
28
[1.102] ø105,5±0,1
[4.153±.0039]
[.315]
"O" Ring 125x3
[2.657-.075 ]
8
67,5 -1,9
4xM14
[.276]
[1.22]
7
31
"O" Ring 100x3
[.708]
max 25
[.984]
18
T
L2
[.905±.0039]
max 125
L1
23±0,1
L1
max 125
[4.921]
[4.921]
max L
L2
max L
C
Port A Port A
Port B Port B
P(A,B)
4xø14,2
[.552] ø160±0,4 Port Dim.
ø6 [6.299±.0157]
See Page 33
[.236] ø125
ø6 [.236] [4.921]
Drain port
[1.693]
[1.693]
43
43
max 125
[4.921]
[1.969]
50
[2.835]
[2.835]
72
72
ø6
[.236]
28
[1.102]
ø186
[7.323]
mm [in]
E Rear ports
C: 4xM10-10 mm [.39 in] depth

P(A,B): 2xG3/4 or 2xM27x2-17 mm [.67 in] depth
T: G 1/4 or M14x1,5 - 12 mm [.47 in] depth (plugged)
E
max L

Viewed from Shaft End Viewed from Shaft End
Port A Pressurized - CW Port A Pressurized - CCW
Port A
Port B Pressurized - CCW Port B Pressurized - CW
Port B
Type L, in.[mm] **LE,mm[ in.] Type L, in.[mm] *L1,mm [in]

MTS 160 146 [5.75] 96 [3.78] 156 [6.14] MTV 160 101 [3.98] 51,5 [2.02] 111 [4.37] 16,5 [ .65]
MTS 200 151 [5.95] 101 [3.98] 161 [6.33] MTV 200 106 [4.17] 56,5 [2.22] 116 [4.57] 21,5 [ .85]
MTS 250 157 [6.18] 107 [4.21] 167 [6.57] MTV 250 112 [4.41] 62,8 [2.47] 122 [4.80] 27,8 [1.09]
MTS 315 166 [6.53] 116 [4.56] 176 [6.93] MTV 315 121 [4.76] 72,0 [2.83] 131 [5.16] 37,0 [1.46]
MTS 400 177 [6.97] 127 [5.00] 187 [7.36] MTV 400 132 [5.19] 82,5 [3.25] 142 [5.59] 47,5 [1.87]
MTS 500 191 [7.52] 142 [5.59] 201 [7.91] MTV 500 146 [5.75] 96,5 [3.80] 156 [6.14] 61,5 [2.42]
MTS 630 187 [7.36] 138 [5.43] 197 [7.76] MTV 630 142 [5.59] 92,5 [3.64] 152 [5.98] 57,5 [2.26]
MTS 725 196 [7.72] 147 [5.79] 206 [8.11] MTV 725 151 [5.95] 101,5[4.00] 161 [6.34] 66,5 [2.62]
* - The width of the roll-gerotor is 3,5 mm [.138 in] greater than L1.
** - For Rear Ported Motors.
35
MT
MOTORS
DIMENSIONS OF THE ATTACHED COMPONENT
MTS
External Spline
46±0,3 16 DP 12/24
[1.811±.0118] 11,2±0,2 ANS B92.1-76
Internal spline
16 DP 12/24
[.441±.0079] T
ANS B 92.1-1976 I
2,3±0,05 K
[.091±.002]
5
[.197]
[1.535±.0197]
[1,988±.0197]
[.236]
ø125 +0,063
[4.921 +.0025]
min ø6
[5.228±.0079]
[2.125 +.0157 ]
[6.299±.0157]
ø50,5±0,5
[2.48+.019 ]
ø132,8±0,2
[3.62 +.039]
ø39±0,5
ø160±0,4
ø63 +0,5
min ø55
ø54 +0,4
[2,165]
ø92 +1
G
J
26±1 29+1
[1.024±.039] 69±0,4 [1.142+.039 ]
34,5±0,2
[2.717±.0157]
[1.358±.0079]
I : O- Ring 125x3 mm [4.921x.118 in]

F: Oil circulation hole
J: 4xM12-18 mm [.71 in] depth, 90
0
G: Internal drain channel

K: Conical seal ring
H: Hardened stop plate
T: Drain connection G1/4 or M14x1,5 mm [in]
MTV
26±1 22,5 -0,5
[1.024±.039] [.885 -.0197]
Internal spline
16 DP 12/24
ANS B 92.1-1976 External Spline
16 DP 12/24
1,8±0,2 ANS B92.1-76
M
1,5±0,4[.071±.0078] K
[.059±.0157]
[.236]
[1.535±.0197]
+.0008]
[2.008±.0197]
min ø6
[4.921±.0079]
[4.173 +.0024
ø106 +0,06
+0,02
ø51±0,5
min ø55
[2,165]
ø125±0,2
ø39±0,5
R0,5
[.0197] 1,6
20 0
G
F I
4xM14-26 depth min
H 0
H: Hardened stop plate
67,5 +1,8
+0,6 Four 90
[2.657 +.071
+.024 ] I : O- Ring 100x3 mm [3.94x.12 in]
F: Oil circulation hole K: Conical seal ring
G: Internal drain channel
DRAIN CONNECTION
The drain line has to be used when pressure in the return line can exceed the permissible pressure. It can be
connected:
- For MTS at the drain port of the motor;
- For MTV at the drain connection of the attached component. The maximum pressure in the drain line is limited by
the attached component and its shaft seal.
The drain line must be possible for oil to flow freely between motor and attached component and must be led to the
tank. The maximum pressure in the drain line is limited by the attached component and its seal.
36
MT
MOTORS
INTERNAL SPLINE DATA FOR THE ATTACHED COMPONENT

Standard ANS B92.1-1976, class 5
[m=2.1166; corrected x.m=1]
Fillet Root Side Fit mm inch

Number of Teeth z 16 16
Diametral Pitch DP 12/24 12/24
Pressure Angle 30° 30°
Pitch Dia. D 33,8656 1.3333
+0,4
Major Dia. Dri 38,4 1.5118±1.5275
+0,04
Minor Dia. Di 32,15 1.2657±1.2673
Space Width [Circular] Lo 4,516±0,037 .1763±.1791
Fillet Radius R 0,5 .02
+0,10
Max. Measurement L 26,9 1.063±1.059 Hardening Specification:
between Pins HV=750±50 on the surface.
d HV=560 at 0,7±0,2 mm [.035±.019in] case depth
Pin Dia. 4,835±0,001 .19026±.19034 Material: 20 MoCr4 EN 10084 or SAE8620.
PERMISSIBLE SHAFT LOADS
The output shaft runs in tapered bearings that permit high axial and radial forces. The permissible radial load on
the shaft is shown for an axial load of 0 N as function of the distance from the mounting flange to the point of
load application. The curves apply to a B10 bearing life of 2000 hours at 100 RPM .
Curve " 1 " shows max. radial shaft load. Any shaft load exceeding the values shown by the curve will seriously
reduce motor life.
Mounting Flange:
Pr Pr
0 .5 1 1.5 2 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 7.5 in
lbs daN
14000 0 20 40 60 80 100 120 140 160 180 mm W - Wheel
6000
12000
5000 1000 daN
2250 lbs.
10000
4000
8000
3000
6000
2000
4000
2000 1000
0 0
-80 -60 -40 -20 0 20 40 60 80 100 120 mm
Standard
-3 -2.5 -2 -1.5 -1 -.5 0 .5 1 1.5 2 2.5 3 3.5 4 4.5 in
mm [in]
37
MT
MOTORS
MOTORS WITH TACHO CONNECTION
33 max L 72
[2.835]
[1.299]
ø3
[.118]
[1.89]
ø48
5
[.197]
[.315]
ø8
20 16
[.787] [.63] ø34 4xM5
[1.339] 8 [.315] deep
mm [in]
ORDER CODE
1 2 3 4 5 6 7 8
MT
Pos.1 - Mounting Flange Pos.4 - Shaft Extensions*

omit - Square mount, four holes
omit - for S and V mounting flange
S - Short mount
C - ø40 straight, Parallel key A12x8x70 DIN6885
V - Very short mount
CO - ø1½ ” straight, Parallel key /8”x /8”x2¼” BS46
3 3
W - Wheel mount
K - ø45 tapered 1:10, Parallel key B12x8x28 DIN6885
Pos.2 - Port type SL - ø34,85 p.t.o. DIN 9611 Form 1
omit - Side ports SH - ø1½" splined 17T ANS B92.1-1976
E - Rear ports
Pos.5 - Shaft Seal Version (see page 34)
Pos.3 - Displacement code omit - Low pressure seal
160
3 3
- 61,6 cm /rev [9.83 in /rev] U - High pressure seal
200 - 201,4 cm3/rev [12.29 in3/rev] Pos.6 - Ports
250 - 251,8 cm3/rev [15.36 in3/rev] omit - BSPP (ISO 228)
315 - 326,3 cm3/rev [19.90 in3/rev]
M - Metric (ISO 262)
400 - 410,9 cm3/rev [25.06 in3/rev]
500 - 523,6 cm3/rev [31.95 in3/rev] Pos.7 - Special Features (see page 51)
630 - 631,2 cm3/rev [38.52 in3/rev] Pos.8 - Design Series
725 - 724,3 cm3/rev [44.20 in3/rev] omit - Factory specified
NOTES:
* The permissible output torque for shafts must not be exceeded!
The hydraulic motors are mangano-phosphatized as standard.
38
WARRANTY
M+S Hydraulic warrants, that its products, supplied directly to original equipment
manufacturer, authorized distributor or other customer, will be free of defects in material or
workmanship at the time of shipment from M+S Hydraulic and will conform to the products
technical documentation (drawings and specifications) under sale agreement with Buyer.
This warranty will apply only to defects appearing within applicable Warranty period,
mentioned below. If Buyer notifies M+S Hydraulic within the Warranty period about any
such defects, M+S, at its sole option will replace or repair the defective products or their
parts found by M+S Hydraulic to be defective in material or workmanship.
THE FOREGOING LIMITED WARRANTY IS AVAILABLE ONLY IF “M+S HYDRAULIC”

IS PROMPTLY NOTIFIED IN WRITTEN OF THE ALLEGED DEFECT AND DOES NOT
COVER FAILURE TO FUNCTION CAUSED BY DAMAGE TO THE PRODUCT,
IMPROPER INSTALLATION, UNREASONABLE USE OR ABUSE OF THE PRODUCT,
FAILURE TO PROVIDE OR USE OF IMPROPER MAINTENANCE OR USUAL,
DEGRADATION OF THE PRODUCT DUE TO PHYSICAL ENVIRONMENTS OF AN
USUAL NATURE. THE FOREGOING REMEDIES ARE THE SOLE AND EXCLUSIVE
REMEDIES AVAILABLE TO CUSTOMER. To facilitate the inspection, M+S Hydraulic may
require return of the product/part, which Buyer claims to be defective.
M+S Hydraulic shall not be liable for labor costs or any other expenses incurred during
the disassembling or reinstalling of the product/part.
In case the claimed products are returned to M+S Hydraulic in bad condition: dirty,
disassembled, with damaged or missing parts during transportation, the warranty will be
considered as not applicable and the products will not be liable to repair.
Warranty periods
New products: The Warranty period is limited to 24 consecutive months (2 years) from
the date of production of the product.
Repaired products: If the product is repaired in M+S Hydraulic during its warranty
period, the warranty period of the repaired item shall continue for the balance of original
Warranty period or for a period equal to 50% of the original new product Warranty period,
whichever is later.
Spare parts: The Warranty period for Spare parts is 12 consecutive months (1 year)
from the dispatch date of such parts from M+S Hydraulic.
LIMITATION OF LIABILITY M+S Hydraulic's liability for claim of any kind, for loss or
damage arising out of, connected with or resulting from an order, or from the performance
or branch thereof, or from the design, manufacture, sale delivery, operation or use of any of
its products shall be limited to, at M+S 's sole option, replacement, repair of any defective
product or the issuance of a credit to Customer against any future purchases. Cash
refunds will not be made under any circumstances and Customer will not be entitled to
recover any damages of any kind against M+S Hydraulic, including but not limited to
incidental or consequential damages, whether direct or indirect, known or unknown,
foreseen or unforeseen.
68, Kozloduy St., 6100 Kazanlak, Bulgaria
Tel.: ++359 431 65167
++359 431 64271
Fax: +359 431 64114
E-Mail: msh@ms-hydraulic.com
URL: http://www.ms-hydraulic.com
IS21 CONCRETE SPRAYING
MACHINE
CABLE REEL – ROBOT

OSCILLATION: 200 cc
High Pressure Washing

INTERPUMPGROUP
I ISTRUZIONI D’USO F MODE D’EMPLOI E INSTRUCCIONES DE USO
GB INSTRUCTIONS FOR USE D BEDIENUNGSANLEITUNG P INSTRUÇÕES DE USO
Questo manuale deve essere letto e compreso in accordo al libretto generico “Istruzioni d’uso e manutenzione”.
This manual must be read and followed in accordance with the generic “Instructions for Use and Maintenance” booklet.
Ce manuel doit être lu et compris en accord avec la notice générale “ Mode d’emploi et d’entretien ”.
Dieses Handbuch ist in Verbindung mit dem allgemeinen Handbuch “ Gebrauchs- und Wartungsanleitung“ zu lesen und zu verstehen.
Este manual debe leerse y comprenderse de acuerdo con el manual general “Instrucciones de uso y mantenimiento”.
Este manual deve ser lido e interpretado de acordo com o livro genérico “Instruções de uso e manutenção”.
Flow rate Pressure Power Weight

Type Débit Pressione rpm Puissance Poids
Type Förderstrom Druck t/m Leistung Gewicht
Type Caudal Presion upm Potencia Peso
63 Tipo
Tipo
Portata Pressione r/m
g/m
Potenza Massa
L/min gpm bar MPa psi Hp kW Kg Ibs Lt.
EL2002 2 0.53 200 20 2900 1450 1.1 0.81 8.15 18 0.37
EL1403 3 0.80 140 14 2030 1450 1.1 0.81 8.05 17.7 0.37
EL2007 7 1.85 200 20 2900 1450 3.7 2.72 8.15 18 0.37
EL2009 9 2.38 200 20 2900 1450 4.7 3.45 8.15 18 0.37

EL1411 11 2.90 140 14 2030 1450 4.0 2.94 8.05 17.7 0.37
S EL1713 13 3.43 170 17 2465 1450 5.8 4.26 8.05 17.7 0.37
E EL1714 14 3.69 170 17 2465 1450 6.2 4.56 8.05 17.7 0.37
UL2009 9 2.38 200 20 2900 1750 4.7 3.45 8.15 18 0.37
R UL2011 11 2.90 200 20 2900 1750 5.8 4.26 8.15 18 0.37
UL1413 13 3.43 138 13.8 2000 1750 4.7 3.45 8.05 17.7 0.37
I UL1715 15.2 4.02 170 17 2465 1750 6.7 4.92 8.05 17.7 0.37
E UL1716 16 4.22 170 17 2465 1750 7.1 5.22 8.05 17.7 0.37
EH2009 9 2.38 200 20 2900 2800 4.7 3.45 8.15 18 0.37
S EH2011 11 2.90 200 20 2900 2800 5.8 4.26 8.15 18 0.37
EH1413 13 3.43 140 14 2030 2800 4.8 3.52 8.15 18 0.37
EH1416 16 4.22 140 14 2030 2800 5.8 4.26 8.15 18 0.37
UH2008 8 2.11 200 20 2900 3400 4.2 3.08 8.15 18 0.37
UH2011 11 2.90 200 20 2900 3400 5.8 4.26 8.15 18 0.37
UH2013 13 3.43 200 20 2900 3400 6.8 5.00 8.15 18 0.37
UH2014 14 3.69 200 20 2900 3400 7.3 5.37 8.15 18 0.37
UH2016 16 4.22 200 20 2900 3400 8.3 6.10 8.15 18 0.37
VERSION I (for hydraulic motors SAE J 744 type A – 5/8”)
POS COD. DESCRIZIONE - DESCRIPTION NR

UL1716
94 90.0635.00 Anello di fermo Ø 25 UNI 7435 1
95 63.0237.65 Albero – UL1716 1
96 99.1790.00 Vite M6x6 UNI 5929 1
97 91.8371.00 Cuscinetto a sfere 6206 1
98 90.1644.00 Anello rad. Ø 30x42x7 1
99 90.4097.00 OR Ø 55.56x3.56 (159) 1
100 50.2115.51 Distanziale 1
101 10.0763.22 Flangia per motore idraulico 1
102 99.3686.00 Vite M10x30 UNI 5931 2
103 96.7103.00 Rosetta Ø 10.5x18x2 2
104 99.1868.00 Vite M6x18 UNI 5931 4
105 96.6938.00 Rosetta Ø 6.4x10x0.7 4
105 91.4685.00 Linguetta 4/4.8x18 1
5
DIMENSIONI D’INGOMBRO – OVERALL DIMENSIONS – DIMENSIONS D’ENCOMBREMENT
RAUMBEDARF – DIMENSIONES TOTALES – DIMENSÕES
C3/4” – VH
UH2008
UH2011
COD. DIS. 63.9609.00 UH2013
I – VH
UL1716
15
DIESEL ENGINE
OPERATING MANUAL
TRANSMISSION
OPERATING MANUAL
General Information
1
Care & Safety
2
Routine Maintenance
3
Basic Operation
4
Fault Finding
5
Service Service Procedures
6
Manual Electrics
7
JCB Drivetrain Systems Ltd
Wrexham Industrial Estate
WREXHAM
United Kingdom
LL13 9UF
Gearbox
8
Tel: (01978) 661140 NOTE
Fax: (01978) 661863 All references in this manual to ‘Forward’ and
‘Reverse’ assume a front-mounted engine.
PS760 - SERIES
TRANSMISSION
Publication No. 9803/9090

Issue 4
PS760 Series Transmission Manual
Record of Changes
1st Update
Date Page Issue Changes

April 2005 Cover 2 Issue number raised.
7/Cont-i 2 Contents revised.
7/1-4 2 Note regarding gear selection added.
7/2-1 2 Headings changed.
7/5-1 2 Part numbers removed.
7/9-1 2 Spelling changed.
8/12-6 2 Torque figure changed.
8/12-8 2 Torque figure changed.
1
PS760 Series Transmission Manual
Record of Changes
2nd Update
Date Page Issue Changes

February 2006 Cover 3 Issue number raised.
1/1-1 2 Illustration revised.
2/2-5 2 Revised content.
5/1-2 2 New content.
6/1-11 2 Illustration revised
6/2-1 2 Revised content
7/5-1 3 Revised content - Load Modes.
7/5-5 2 Revised Caption - ECU 2.
7/5-6 2 Revised Caption - ECU 2.
7/5-7 2 New content - ECU 2.2.
7/9-4 2 New content - Warning Alarms.
7/6-1 to 6-20 2 Revised content - ShiftMaster Diagnostics 2.2.
7/7-1 to 7-28 2 Revised content - ShiftMaster Setup 2.2.
1
Introduction
This publication is designed for the benefit of Service Engineers.
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques
associated with the maintenance and repair of hydraulic equipment.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of
course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe
connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all
else
SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools.

2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants etc.
4 = Basic Operation
5 = Fault Finding
The remaining sections deal with Dismantling, Overhaul etc. of specific components:
6 = Service Procedures - includes test procedures and renewal of serviceable components

7 = Electrics
8 = Gearbox
The page numbering in each section is not continuous. This allows for the insertion of new items in later issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
Page cross references are generally made by presenting the subject title printed in bold, followed by the title of the section
containing the subject. For example:
“24 If the axle is still on the machine, fit the brake calipers (see Brake Caliper Removal and Replacement, Section 6).”
Note: If only the subject title in bold is given, i.e. no section title, the cross reference is to another part of the same section.
Use the contents list at the beginning of each section to find the exact page number.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.
‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.
9803/9090 Issue 1
Section 1 General Information Section 1
i i
Contents Page No.
Unit Identification 1-1
Torque Settings 2-1
Service Tools Numerical List 3-1
Service Tools 4-1
Sealing and Retaining Compounds 5-1
9803/9090 Issue 1
1-1 1-1
Unit Identification
Powershift Serial Plate
The powershift serial number is stamped on a plate which is

mounted to the rear of the unit as shown.
1 When replacement parts are required, always ensure

that the correct parts are obtained, e.g. in the case of
gear replacements, always check the part number
stamped on the gear, and the number of teeth.
2 When ordering replacement parts, quote the details on

the serial plate shown.
3 It is essential that all gaskets and seals removed while

dismantling, should be renewed on reassembly.
4 On reassembly care should be taken that all parts are A401030

correctly replaced since any component omitted or
incorrectly assembled can lead to a complete failure.
5 Lubricants should comply with the recommended list

as provided in this manual. It is important to adhere to
the oil changing procedure.
6 It is advisable to lightly lubricate with a recommended

lubricant, parts such as gears, shafts, thrust washers
and oil seals during reassembly.
9803/9090 Issue 4
2-1 2-1
Torque Settings
Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the
figures stated. For lubricated threads the values should be REDUCED by one third.
UNF Grade 'S' Bolts
Bolt Size Hexagon (A/F) Torque Settings

in (mm) in Nm kgf m lbf ft
1/4 (6.3) 7/16 14 1.4 10

5/16 (7.9) 1/2 28 2.8 20
3/8 (9.5) 9/16 49 5.0 36
7/16 (11.1) 5/8 78 8.0 58
1/2 (12.7) 3/4 117 12.0 87
9/16 (14.3) 13/16 170 17.3 125
5/8 (15.9) 15/16 238 24.3 175
3/4 (19.0) 11/8 407 41.5 300
7/8 (22.2) 15/16 650 66.3 480
1 (25.4) 11/2 970 99.0 715
11/4 (31.7) 17/8 1940 198.0 1430
11/2 (38.1) 21/4 3390 345.0 2500
Metric Grade 8.8 Bolts

(mm) mm Nm kgf m lbf ft
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Rivet Nut Bolts/Screws
Bolt Size Torque Settings (for steel rivet nuts)

(mm) Nm kgf m lbf ft
M3 (3) 1.2 0.12 0.9

M4 (4) 3.0 0.3 2.0
M5 (5) 6.0 0.6 4.5
M6 (6) 10.0 1.0 7.5
M8 (8) 24.0 2.5 18.0
M10 (10) 48.0 4.9 35.5
M12 (12) 82.0 8.4 60.5
Note: All bolts used on Powershift gearboxes are high tensile and must not be replaced by bolts of a lesser tensile
specification.
9803/9040 Issue 1
3-1 3-1
Service Tools Numerical List

Page No. Page No.
460/15708 Flow Test Adapter 4-1 The following parts are replacement items for kits and would
460/15707 Banjo Bolt 4-1 normally be included in the kit numbers quoted on this page.
1406/0018 Bonded Washer 4-1
1406/0021 Bonded Washer 4-2 Service Tools Numerical List Page No.
1604/0004 Male Adapter 4-1
1604/0006 Male Adapter 4-2 Replacement items for kit no. 892/00253
1604/0008 Adapter 4-2 892/00201 Replacement Gauge 4-2
1606/0012 Male Adapter 4-2 892/00202 Replacement Gauge 4-2
1606/0015 Male Adapter 4-2 892/00203 Replacement Gauge 4-2
1612/0006 Adapter 4-2 892/00254 Replacement Hose 4-2
2401/0222 O-ring 4-1
2403/0110 O-ring 4-1
2403/0108 O-ring 4-1
816/20008 Adapter 4-2
816/20013 Adapter 4-2
823/10420 Shim Kit - Powershift gearbox,
layshaft clutch 4-3
892/00078 Connector 4-2
892/00253 Pressure Test Kit 4-2
892/00268 Flow Monitoring Unit 4-2
892/00269 Sensor Head 4-2
892/00270 Load Valve 4-2
892/00271 Adapter 4-2
892/00272 Adapter 4-2
892/00273 Sensor Head 4-2
892/00275 Adapter 4-2
892/00276 Adapter 4-2
892/00277 Adapter 4-2
892/00293 Connector Pipe 4-2
892/00294 Connector Pipe 4-2
892/00347 Connector - Hose to gauge 4-2
892/00706 Test Probe 4-2
892/00812 Drive Coupling Spanner 4-1
892/00918 Solid Spacer Setting Kit 4-8
892/00964 Test Point (1/8 BSP) 4-2
892/00965 Test Point (3/8 BSP) 4-2
892/00966 Test Point (1/4 BSP 4-2
892/01082 Powershift - Assembly Cradle 4-5
892/01083 Powershift - Assembly tool,
transfer gear 4-3
892/01084 Powershift - Transfer gear, bearing
assembly 4-3
892/01085 Powershift - Seal fitting tool 4-3
892/01094 Transmission Jack 4-3
892/01096 Speed Sensor Test Harness 4-3
892/01110 Torque Converter Alignment Tool 4-7
892/01174 Electronic Service Tool Kit 4-6
993/59300 2/4WD Pressure Test Adapter 4-3
993/69800 Seal Kit 4-2
998/10738 Powershift Clutch - Adapter Spanner 4-2
9803/9090 Issue 1
4-1 4-1
Service Tools
993/59300 2/4 WD Pressure Test Adaptor & Clamp
892/00812 Drive Coupling Spanner
S107750 S196750
Powershift Gearbox Flow Test Adaptor

1 460/15708 Flow Test Adapter
2 460/15707 Banjo Bolt
3 2401/0222 O-ring
4 2403/0110 O-ring
5 2403/0108 O-ring
6 1604/0004 Adapter
7 1406/0018 Sealing Washer
2
4
5
1
3
6 A313250
9803/9090 Issue 1
4-2 4-2
Hydraulic Circuit Pressure Test Kit (also used for main hydraulic
system tests)
892/00253 Pressure Test Kit

:892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in2)
S267300 :892/00254 Replacement Hose
993/69800 Seal Kit for 892/00254 (can also be used with
probe 892/00706)
892/00706 Test Probe
892/00347 Connector - Hose to gauge
S188121
Flow Test Equipment (also used for main hydraulic system

tests)
892/00268 Flow Monitoring Unit

892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)
892/00293 Connector Pipe
892/00270 Load Valve
1406/0021 Bonded Washer
1604/0006 Adapter 3/4 in M x 3/4 in M BSP
1612/0006 Adapter 3/4 in F x 3/4 in M BSP
892/00273 Sensor Head 0 - 380 l/min
892/00294 Connector Pipe
1606/0015 Adapter 1.1/4 in M BSP x 1 in M BSP
892/00078 Connector 1 in F x 1 in F BSP
1604/0008 Adapter 1 in M x 1 in M BSP S188151
1606/0012 Adapter 1 in M x 3/4 in M BSP
816/20013 Adapter 3/4 in F x 1 in M BSP
998/10738 Adaptor Spanner

- Powershift 2/4WD Clutch (Germany)
S316250
Test Point
1 892/00964 Test point (1/8 BSP) Powershift
2 892/00965 Test point (3/8 BSP) Powershift
3 892/00966 Test point (1/4 BSP) Synchro Shuttle A410370
These test points can be left in position after testing.
9803/9090 Issue 1
4-3 4-3
Service Tools (cont'd)
892/01083 Powershift - Assembly tool,

transfer gear
892/01084 Powershift - Transfer gear, bearing
assembly
892/01085 Powershift - Seal fitting tool
892/01094 Transmission Jack
When removing the Powershift gearbox use of a special

transmission jack is strongly recommended. This jack
can also be used when removing Synchro Shuttle
gearboxes.
Note that the jack must be used with special support
plates, see the facing page for details.
A402680
823/10420 Thrust Washer Kit - Powershift

gearbox - Layshaft clutch
Comprises of:
Washer thickness mm
823/10421 4.3
823/10422 4.4
823/10423 4.5
823/10424 4.6
823/10425 4.7
823/10426 4.8
892/01096 Speed Sensor Test Harness -

Powershift Gearbox
711300
9803/9090 Issue 1
4-4 4-4
Powershift gearbox - support plates for use with

hydraulic jack. Plates should be locally manufactured
from 5 mm thick mild steel plate.
Rear plate - 4 speed

and 6 speed.
Front plate - 6 speed.
Front plate - 4 speed.
A706940
9803/9090 Issue 1
4-5 4-5
892/01082 Powershift - Assembly Cradle
Note: Support legs will also be required. These must be

locally manufactured so that the gearbox can be
supported as shown at A.
620.0
325.0 171.6
151.9 103.4 20.0
111.6
R 5.0
TYP
10.0
168.0
160.0
49
73.2 REF
1.0
107.3
2
R1
48
51.8
R125
.0
600.0
140.1
60.7
9
216.6
153.2
263.6
325.6 REF
R137.0
9
TYP 9 PLACES
0
09.
R1
R6
2 .0
20.0
25.0
== 2.9 30
TYP 9 PLACES 53.2
95.0
142.3 118.7
746110
A
9803/9090 Issue 1
4-6 4-6
Powershift Gearbox - hydraulic pump removal tools
The tools detailed below enable the pump to be removed

with the torque converter housing in place.
1 Reaction bar. Locally manufacture from mild steel bar.

Drill the 2 holes through the bar as shown.
2 2 off lengths of M10 x 1.5 threaded rod 250 mm (10 in)

long.
3 2 off M10 x 1.5 nuts.
A set of M10 x 1.5 taps will also be required.
1
2
12 mm 500 mm
121.5 mm
32 mm
11.0 mm
A406000
Powershift Gearbox - 6 Speed (ShiftMaster) 3

Electronic Service Tool Kit
C D
B E
A
J F
H G
892/01174 Kit comprises:
1 Data Link Adaptor (DLA), enables data exchange

1 4
between the machine ECU (Electronic Control Unit) and
a laptop PC loaded with the applicable ShiftMaster
diagnostics software.
2 Interconnecting cable, DLA to laptop PC. Several cables

are included to enable compatibility with different PC
port types.
3 Interconnecting cable, DLA to machine ECU diagnostics

socket.
4 Kit carrying case. 2
C012140
9803/9090 Issue 1
4-7 4-7
892/01110 Torque Converter Alignment Tool

(for 12” and W300 torque converters)
370.0
185.0
65.0
A A
171.0
0.3 X
342.0 2 DOWELS
8 x 32 LONG
PRESS FIT
TYP
TYP
57.0
x 45
5 3 x 35(25) 43.4
10.0
10.0
43.3
1.0
0.3 X
30.2
X
12.0
30.1
8.0 REF
TYP
2 DOWELS
10.0
SECTION A-A
A436700
9803/9090 Issue 1
4-8 4-8
Solid Spacer Setting Kits

892/00918 Solid Spacer Setting Tool Kit Powershift PS760-2004,
1 892/00918 Setting Tool Kit

1a 892/01164 Adaptor PS760 - 2004
1b 892/01165 Sleeve PS760 - 2004
1c 892/01163 Support Bracket PS760 - 2004
2 993/70111 Breakback Torque Wrench
1 3 823/10547 Spacer Kit - PS760 - 2004
Comprises of:
Spacer Spacer
thickness thickness
mm mm
829/30946 13.850 829/30953 13.675
829/30947 13.825 829/30954 13.650
829/30948 13.800 829/30955 13.625
829/30949 13.775 829/30956 13.600
829/30950 13.750 829/30957 13.575
829/30951 13.725 829/30958 13.550
829/30952 13.700
1a
1b
Note: After using a spacer, obtain a replacement to keep the
set complete.
1c
A396950
9803/9090 Issue 1
5-1 5-1
Sealing and Retaining Compounds
Loctite 574 or A medium strength sealant suitable for all

Permabond A136 sizes of gasket flanges, and for hydraulic fittings
of 25-65 mm diameter. † 4102/1212
Loctite 275 or For all sizes of flange where the strength

Permabond A140 of the joint is important. 4102/0552
Loctite 932 or For all retaining parts which are likely to

Permabond A137 be dismantled. 4101/0451
Loctite 242 or A medium strength locking fluid for sealing

Permabond A113 and retaining nuts, bolts, and screws up to
50mm diameter, and for hydraulic fittings
up to 25 mm diameter. † 4101/0251
Loctite 243 A medium strength fluid similar to Loctite 242 but

with greater resistance to thread contamination. 4101/0250
Loctite 648 or Permabond A118 For retaining parts which are unlikely to be
dismantled. 4101/0651
Loctite 577 A medium strength thread sealing compound. 4102/1951
Loctite Activator A cleaning primer which speeds the curing

rate of anaerobic products. † 4104/0251 Aerosol
† 4104/0253 Bottle
Cleaner/Degreaser For degreasing components prior to use of

anaerobic adhesives and sealants. 4104/1557 Aerosol
Loctite 509 Flange sealant, medium strength
Note: The above list is the range of Sealants and Retaining Compounds available. Items marked † are those referred to within
the sections.
9803/9090 Issue 1
Section 2 Care & Safety Section 2
i i
Contents Page No.
Safety Notices 1-1
General Safety 2-1
Operating Safety 3-1
Maintenance Safety 4-1
9803/9090 Issue 1
1-1 1-1
Safety Notices
In this publication and on the machine, there are safety notices. Each notice starts with a
signal word. The signal word meanings are given below.
! DANGER
Denotes an extreme hazard exists. If proper precautions are not taken, it is highly
probable that the operator (or others) could be killed or seriously injured.
INT-1-2-1
! WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator (or others)
could be killed or seriously injured.
INT-1-2-2
! CAUTION
Denotes a reminder of safety practices. Failure to follow these safety practices could
result in injury to the operator (or others) and possible damage to the machine.
INT-1-2-3
9803/9090 Issue 1
2-1 2-1
All machinery, whether mobile or static, can be hazardous.

When equipment is correctly operated and properly
maintained it can be safe to work with. But when it is
carelessly operated or poorly maintained it can become a
danger.
Do not work with any equipment until you are sure that it is
serviceable, that you know how to control it and be aware of
all relevant safety requirements.
If the equipment covered by this manual forms part of a

larger product (eg. a vehicle) be sure to observe the safety
requirements which relate to the product as a whole, as well
as those given in this manual.
On this and the following pages and throughout this manual,

you will find safety messages. Please read and understand
these safety messages before using and working on the
equipment covered in this manual.
Make sure you also read and understand all other safety
messages contained in operator handbooks and service
manuals concerned with the product of which this
equipment forms part.
Remember
BE CAREFUL
BE ALERT
BE SAFE
General Safety
! WARNING
Decals ! WARNING
This equipment may include safety decals Lifting Equipment
You can be injured if you do not obey decal safety You can be injured if you use faulty lifting equipment. Make
instructions. Keep decals clean. Replace unreadable or sure that lifting equipment is in good condition. Make sure
missing decals with new ones before operating the that lifting tackle complies with all local regulations and is
equipment. Make sure replacement parts include warning suitable for the job. Make sure that lifting equipment is
decals where necessary. strong enough for the job.
INT-1-3-7
! WARNING
Clothing ! WARNING
You can be injured if you do not wear the proper clothing. Raised Attachments
Loose clothing can get caught in the equipment. Wear Raised attachments on certain kinds of equipment can fall
protective clothing to suit the job. Examples of protective and injure you. Do not walk or work under raised
clothing are: a hard hat, safety shoes, safety glasses, a well attachments unless they are safely blocked.
fitting overall, ear-protectors and industrial gloves. Keep INT-1-3-8
cuffs fastened. Do not wear a necktie or scarf. Keep long

hair restrained.
! WARNING
! WARNING Care and Alertness
Alcohol and Drugs All the time you are working with or on the equipment, take
It is extremely dangerous to operate machinery when under care and stay alert. Always be careful. Always be alert for
the influence of alcohol or drugs. Do not consume alcoholic hazards.
drinks or take drugs before or whilst operating the machine
or attachments. Be aware of medicines which can cause
drowsiness.
INT-1-3-9
9803/9090 Issue 1
3-1 3-1
Operating Safety
! WARNING ! WARNING
Equipment Condition Communications
Defective equipment can injure you or others. Do not Bad communications can cause accidents. Keep people
operate equipment which is defective or has missing parts. around you informed of what you will be doing. If you will be
Make sure all maintenance procedures are completed working with other people, make sure any hand signals that
before using the equipment. may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands.
INT-2-2-3
! WARNING
Controls ! WARNING
You or others can be killed or seriously injured if you operate The transmission can be in 4 wheel drive until de-selected
machine control levers from outside the cab. Operate the by hydraulic pressure to 2 wheel drive. If the machine is to
control levers only when you are correctly seated inside the be raised and the engine/transmission run, make sure all
cab. four wheels are off the ground and supported by axle
stands. If only the rear wheels are raised, the machine could
still drive through the front axle.
! WARNING
Equipment Limits
Operating equipment beyond its design limits can damage ! WARNING
the equipment, it can also be dangerous. Do not operate the Powershift Transmission
equipment outside its limits. Do not try to upgrade the Do not change from a high gear to a low gear (for instance,
equipment performance with unapproved modifications. 4th to 1st) in one sudden movement whilst the machine is
moving. Otherwise the machine will rapidly decelerate, you
or others could be killed or seriously injured. When selecting
! WARNING lower gears, allow the engine speed to drop before each
Engine/Steering Failure gear change.
2-1-1-9/1
If the engine or steering on the ‘parent’ machine fails, stop
the machine as quickly as possible. Do not operate the
machine until the fault has been corrected.
! WARNING
! WARNING Do not dismount a moving machine.
3-2-3-12
Engine
The engine on the ‘parent’ machine has rotating parts. Do
not open the engine cover while the engine is running. Do If you have any queries concerning this test procedure or
not use the machine with the cover open. parking brake adjustment, consult your local distributor.
! DANGER ! WARNING
Sparks Do not use a machine with a faulty parking brake.
Explosions and fire can be caused by sparks from the 3-2-3-10
exhaust or the electrical system. Do not use the machine in

closed areas where there is flammable material, vapour or
dust.
INT-2-2-10 ! CAUTION
Non approved modifications to axle ratios, machine weight
or wheel and tyre sizes may adversely affect the
! WARNING performance of the parking brake.
3-2-3-11
Exhaust Gases
Breathing the ’parent’ machine exhaust gases can harm and
possibly kill you. Do not operate the machine in closed
spaces without making sure there is good ventilation. If
possible, fit an exhaust extension. If you begin to feel
drowsy, stop the machine at once. Get out of the cab into
fresh air.
9803/9090 Issue 1
4-1 4-1
Maintenance Safety
! WARNING ! DANGER
Repairs Hydraulic Pressure
Do not try to do repairs or any other type of maintenance Hydraulic fluid at system pressure can injure you. Before
work you do not understand. To avoid injury and/or damage disconnecting or connecting hydraulic hoses, stop the
get the work done by a specialist engineer. engine and operate the controls to release pressure trapped
GEN-1-5
in the hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11/1
! WARNING
Modifications and Welding
Non-approved modifications can cause injury and damage. ! WARNING
Welds on cast iron can weaken the structure and break. Do Oil
not weld cast iron. Contact your distributor for advice before Oil is toxic. If you swallow any oil, do not induce vomiting,
modifying the equipment. seek medical advice. Used engine oil contains harmful
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier
! WARNING cream or wear gloves to prevent skin contact. Wash skin
Metal Splinters contaminated with oil thoroughly in warm soapy water. Do
You can be injured by flying metal splinters when driving not use petrol, diesel fuel or paraffin to clean your skin.
INT-3-2-3
metal pins in or out. Use a soft faced hammer or drift to
remove and fit metal pins. Always wear safety glasses.
INT-3-1-3
! WARNING
Soft Ground
! WARNING A machine can sink into soft ground. Never work under a
Electrical Circuits machine on soft ground.
INT-3-2-4
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong connection
can cause injury and/or damage.
INT-3-1-4 ! WARNING
Always wear safety glasses when dismantling assemblies
containing components under pressure from springs. This
! WARNING will protect against eye injury from components accidently
Battery Gases flying out.
GEN 6-2
Batteries give off explosive gases. Keep flames and sparks
away from the vehicle battery. Do not smoke close to the
battery. Make sure there is good ventilation in closed areas
where batteries are being used or charged. Do not check the ! CAUTION
battery charge by shorting the terminals with metal; use a Cleaning
hydrometer or voltmeter. Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents and
solvents.
INT-3-2-11
! WARNING
Hydraulic Fluid ! CAUTION
Fine jets of hydraulic fluid at high pressure can penetrate the
'O' rings, Seals and Gaskets
skin. Do not use your fingers to check for hydraulic fluid
Badly fitted, damaged or rotted 'O' rings, seals and gaskets
leaks. Do not put your face close to suspected leaks. Hold a
can cause leakages and possible accidents. Renew
piece of cardboard close to suspected leaks and then
whenever disturbed unless otherwise instructed. Do not use
inspect the cardboard for signs of hydraulic fluid. If hydraulic
Triochloroethane or paint thinners near 'O' rings and seals.
fluid penetrates your skin, get medical help immediately. INT-3-2-12
INT-3-1-10/1
9803/9090 Issue 1
4-2 4-2
Maintenance Safety (cont'd)
! WARNING ! WARNING
Fires Fluoroelastomeric Materials
Do not use water to put out an equipment fire, you could Certain seals and gaskets (e.g. transmission oil seals) may
spread an oil fire or get a shock from an elecrical fire. Use contain fluoroelastomeric materials such as Viton, Fluorel
carbon dioxide, dry chemical or foam extinguishers. Contact and Technoflon. Fluoroelastomeric materials subjected to
your nearest fire department as quickly as possible. high temperatures can produce highly corrosive hydrofluoric
Firefighters should use self-contained breathing apparatus. acid. THIS ACID CAN SEVERELY BURN.
New fluoroelastomeric components at ambient temperature

require no special safety precautions.
! WARNING
Jacking Used fluoroelastomeric components whose temperatures
A machine can roll off jacks and crush you unless the wheels have not exceeded 300°C require no special safety
have been chocked. Always chock the wheels at the precautions. If evidence of decomposition (e.g. charring) is
opposite end of the machine that is to be jacked. Do not found, refer to the next paragraph for safety instructions DO
work underneath a machine supported only by jacks. Always NOT TOUCH COMPONENT OR SURROUNDING AREA.
support a jacked-up machine on axle stands before working
underneath it. Used fluoroelastomeric components subjected to
INT-3-2-8 temperatures greater than 300°C (e.g. engine fire) must be
treated using the following safety procedure. Make sure that
! WARNING heavy duty gloves and special safety glasses are worn:
Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the 1 Ensure that components have cooled then remove and
hoses regularly for: place material into plastic bags.
- Damaged end fittings
- Chafed outer covers 2 Thoroughly wash contaminated area with 10% calcium
- Ballooned outer covers hydroxide or other suitable alkali solution, if necessary
- Kinked or crushed hoses use wire wool to remove burnt remains.
- Embedded armouring in outer covers
- Displaced end fittings. 3 Thoroughly wash contaminated area with detergent and
INT-3-3-2
water.
! WARNING 4 Contain all removed material, gloves etc. used in this

Make the machine safe before working underneath it. Park operation in sealed plastic bags and dispose of in
the machine on level ground. Apply the parking brake, put accordance with Local Authority Regulations.
the transmission in neutral and stop the engine. Chock both
sides of all four wheels. DO NOT BURN FLUOROELASTOMERIC MATERIALS.
Disconnect the battery, to prevent the engine being started If contamination of skin or eyes occurs, wash the affected
while you are beneath the machine. area with a continuous supply of clean water or with calcium
GEN-1-2/IT hydroxide solution for 15-60 minutes. Get medical attention
immediately.
INT-3-3-5/1/IT
! WARNING
To avoid burning, wear protective gloves when handling hot
components. To protect your eyes, wear goggles when using
! CAUTION
a wire brush to clean components. When the strainer is removed, oil will gush out. Keep to one
HYD 1-3 side when you remove the strainer.
2-3-4-1
! WARNING
Some lubricants contain lead. The repeated swallowing of
! WARNING
very small quantities can cause chronic lead poisoning. Do Protect you eyes when grinding metal. Wear safety glasses
not smoke or touch food while handling this lubricant. or goggles. Remove or protect any combustible materials
Dispose of waste (rags etc.) in accordance with local from the area which could be ignited by sparks.
GEN-1-12
regulations.
2-1-1-8/IT
9803/9090 Issue 1
Section 3 Routine Maintenance Section 3
i i
Contents Page No.
Lubricants & Capacities 1-1
Lubricants - Health and Safety 1-3
Service Schedules 2-1
Powershift Transmission
- Checking the Oil Level 4-1
- Changing the Oil and Filter 4-2
Propshafts
- Removal and Replacement 5-1
9803/9090 Issue 1
1-1 1-1
Lubricants & Capacities
ITEM CAPACITY 3 FLUID/LUBRICANT INTERNATIONAL

Litres UK Gal SPECIFICATION
Powershift 6 speed 16 3.5 Dry T04, Q8 EL4117 SAE 10W

11.5 2.5 Wet Q8 EL4118 SAE 30
Powershift 4 speed 15.5 3.4 Dry T04, Q8 EL4117 SAE 10W

11 2.4 Wet Q8 EL4118 SAE 30
Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system.
3 Note: Capacity figures are only intended as a guide. Use the dipstick on all occasions when filling.
Note: EL4117 (SAE 10W) - This product is for use in Transmissions where the ambient temperature range is - 32 °C to 40 °C
(- 25 °F to 104 °F).
EL4118 (SAE 30) - This product is for use in Transmissions where the ambient temperature range is -5 °C to 46 °C (23 °F to
115 °F).
For further information refer to JCB Drivetrain Bulletin GX061.
9803/9090 Issue 1
1-2 Lubricants - Health and Safety 1-2
Hygiene
Lubricants are not a health risk when used properly for their 2 Apply a barrier cream to the skin before handling used
intended purposes. oil.
However, excessive or prolonged skin contact can remove 3 Note the following when removing oil from skin:
the natural fats from your skin, causing dryness and
irritation. a Wash your skin thoroughly with soap and water.
Low viscosity oils are more likely to do this, so take special b Using a nail brush will help.
care when handling used oils, which might be diluted with
fuel contamination. c Use special hand cleansers to help clean dirty
hands.
Whenever you are handling oil products you should maintain
good standards of care and personal and plant hygiene. For d Never use petrol, diesel fuel, or paraffin for washing.
details of these precautions we advise you to read the
relevant publications issued by your local health authority, 4 Avoid skin contact with oil soaked clothing.
plus the following.
5 Don't keep oily rags in pockets.
Storage
6 Wash dirty clothing before re-use.
Always keep lubricants out of the reach of children.
7 Throw away oil-soaked shoes.
Never store lubricants in open or unlabelled containers.
First Aid - Oil
Waste Disposal
Eyes
All waste products should be disposed of in accordance In the case of eye contact, flush with water for 15 minutes. If
with all the relevant regulations. irritation persists, get medical attention.
The collection and disposal of used oil should be in Swallowing

accordance with any local regulations. Never pour used oil If oil is swallowed do not induce vomiting. Get medical
into sewers, drains or on the ground. advice.
Skin
Handling In the case of excessive skin contact, wash with soap and
water.
New Oil
There are no special precautions needed for the handling or

Spillage
use of new oil, beside the normal care and hygiene
practices. Absorb on sand or a locally approved brand of absorbent
granules. Scrape up and remove to a chemical disposal
Used Oil area.
Used lubricants contain harmful contaminants. Fires

Here are precautions to protect your health when handling Extinguish with carbon dioxide, dry chemical or foam. Fire-
used oil: fighters should use self-contained breathing apparatus.
1 Avoid prolonged, excessive or repeated skin contact

with used oils.
9803/9090 Issue 1
2-1 2-1
Service Schedules
A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular
maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working
condition.
Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter
readings to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure any defects found
during the regular maintenance checks are rectified immediately.
Calendar equivalents:
10 Hours = Daily
50 Hours = Weekly
500 Hours = Six Months
1000 Hours = Yearly
2000 Hours = 2 Years
Service checks should be carried out as in the table at whichever time occurs first.
Pre-start Cold Checks Operation 10 50 †100 500 1000 2000

Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr
TRANSMISSION
Transmission Oil Level - Check O O
Transmission Oil - Change O O
Transmission Filter - Change O O O O
Transmission Strainer - Clean O O
Drive Shafts - Security/Grease O O O
Functional Test Operation 10 50 †100 500 1000 2000

and Final Inspection
TRANSMISSION
2WD/4WD Selection - Check O O O
Forward/Reverse and Gear Change - Operation - Check O O O O
Transmission Main Line Pressure †† - Check O O O
Clutch Disconnect - Check O O O O
Neutral Start Operation - Check O O O O
Clutch Pack Pressures †† - Check O O O O
† First 100 Hours Service only, to be completed by your Distributor.
†† Indicates jobs which should only be done by a specialist.
9803/9090 Issue 1
4-1 4-1
Transmission
Checking the Oil Level - for Interval see Service
Schedule
1 Make the machine safe and ensure the park brake is

engaged and the transmission set to neutral. Raise the
loader arms and fit the safety strut. Lower the backhoe
to the ground (if applicable), switch OFF the engine and
remove the starter key.
2 Gain access to the dipstick A and check that the oil

level is between the two marks on the dipstick. Refer
to Operator Manual for procedures for access.
3 Start and run the engine slowly for a period not

exceeding five minutes. This allows the oil to fill filter,
pump, torque converter, oil cooler and hoses.
4 Switch OFF the engine and remove the starter key, wait
approximately 20 seconds. Check the oil level and if
required, fill to the maximum mark on the dipstick.
715600
9803/9090 Issue 1
4-2 4-2
Transmission
Changing the Oil and Filter - for Interval see Service
Schedule
When draining JCB Drivetrain 760 Series Powershift

gearboxes it is recommended that the oil is drained through
the correct aperture as shown. This will ensure that any
debris collected in the transmission sump is flushed out.
Draining oil through the sump plug will filter oil through the
strainer and not flush out the debris.
Draining the Oil
1 Park the machine on firm level ground, apply the

parking brake. Switch OFF the engine and remove the
starter key.
2 Disconnect the battery.
3 Place a container of suitable size beneath the

transmission to catch the oil. Drain the oil as follows:
4 Remove bolts A. Pull out the strainer B and its gasket

C, allow the oil to drain into the container. Be aware
that the oil may be hot.
Note: When the strainer is removed oil will gush out. Keep to
one side when you remove the strainer.
5 Clean the strainer with a suitable solvent. Follow the

solvent manufacturer’s instructions on safety.
C
6 Fit the strainer B and a new gasket C. Apply Loctite 242
to bolts A before fitting them. Torque tighten the bolts
to 10 Nm (7.4 lbf ft.).
Renewing the Filter

B
1 Unscrew and remove the filter D. Fit the new filter:
a Smear seal E with transmission oil.

E
b Screw the filter on until it just contacts the filter
A
head.
c Turn the filter at least another 3/4 of a turn.

*2004 Gearbox:
2 Fill the system with new oil through the dipstick/filler.
Do not fill past the top mark on the dipstick.
IMPORTANT NOTE: Check the oil level as described in
Checking the Oil Level.
3 On completion check for oil leaks.
Note: Fit only a genuine JCB Drivetrain filter, otherwise

D
damage to the system may be incurred through
contamination.
9803/9090 Issue 4
5-1 5-1
Propshafts
Removing and Replacing
When Removing
Before removing propshafts always mark both companion

flanges and also mark the sliding joints prior to removal.
When Replacing
Upon reassembly, after lubricating sliding joints with Mobil

HP222 Grease, align the shafts against identification marks
previously made or, in the case of a shaft being renewed,
use the manufacturer's alignment markings.
Apply Loctite 242 to threads of all flange bolts.
Retaining straps C stretch with use, therefore these straps

must always be replaced with new ones.
The propshaft must have both ends exactly on the same

plane as shown at X. The yokes must not be at right angles
as at Y or at an intermediate angle as at Z.
Torque Settings B
A
Item Nm kgf m lbf ft
A 75 - 85 7.7 - 8.7 55 - 63
B 118 12 87
A396840
X C
A
S232350
Z A
S189610
S157500
9803/9090 Issue 1
Section 4 Basic Operation Section 4
i i
Contents Page No.
Technical Data - Powershift Gearbox - 6 Speed - 2004 1-1
Technical Data - Powershift Gearbox - 4 Speed - 2004 1-2
Component Identification 2-1
Principle of Operation 2-2
Hydraulic and Electrical Operation 2-3
ShiftMaster Operation Characteristics 2-5
Powershift Gearbox
Drivepaths - 4 Speed - 2004 3-1
Drivepaths - 6 Speed - 2004 3-5
Clutch Operation - Forward, Reverse 4-1
Clutch Operation - 2/4 Wheel Drive 4-3
Torque Converter
Principle of Operation 5-1
9803/9090 Issue 2
1-1 Technical Data 1-1
Powershift Gearbox - 6 Speed - 2004
Description Full electro-hydraulic transmission unit with torque converter, input,

reverse, layshaft, mainshaft, 6 speed shaft and 4 wheel drive clutch
packs giving 6 forward and 4 reverse speeds.
Designation PS7646 (4 wheel drive)

2WD Gearbox N/A
4WD Gearbox 280 kg (750 lb)
Gear Ratios
1st 8.17:1
2nd 4.90:1
3rd 3.62:1
4th 2.25:1
5th 1.35:1
6th 1.00:1
Torque Converter
Dia. 310 mm (12.2 in)
Part No. 04/600580 04.600581
Torque Multiplication at Stall 2.52:1 3.01:1
Converter Pressure (in neutral) bar kgf/cm2 lbf/in2

Converter in @ 50 ºC 1000 rev/min 1.4 - 2.2 1.4 - 2.2 20.3 - 31.9
2000 rev/min 5.8 - 6.9 5.9 - 7.0 84.1 - 100.0
2000 rev/min 2.5 - 3.5 2.5 - 3.7 36.2 - 50.8
Converter out @ 50 ºC 1000 rev/min 0.6 - 1.6 0.6 - 1.6 8.7 - 23.2
2000 rev/min 2.8 - 3.8 2.9 - 3.9 40.6 - 55.1
2000 rev/min 1.0 - 1.9 1.0 - 1.9 14.5 - 27.6
Cover Inlet Relief Pressure (max) 7.1 7.2 103.0
Lubrication Pressure (in neutral) bar kgf/cm2 lbf/in2

Oil @ 50 ºC 1000 rev/min 0.2 - 0.9 0.2 - 0.9 2.9 - 13.1
2000 rev/min 1.1 - 2.1 1.1 - 2.1 16.0 - 30.5
Oil @ 100 ºC 1000 rev/min 0.1 - 0.4 0.1 - 0.4 1.5 - 5.8
2000 rev/min 0.4 - 1.4 0.4 - 1.4 5.8 - 20.3
Mainline Pressure (in neutral) bar kgf/cm2 lbf/in2

Oil @ 50 ºC 1000 rev/min 11.0 - 13.0 11.2 - 13.3 159.5 - 188.5
2000 rev/min 13.0 - 15.2 13.3 - 15.5 188.5 - 220.5
Oil @ 100 ºC 1000 rev/min 10.2 - 12.2 10.4 - 12.4 147.9 - 176.9
2000 rev/min 11.4 - 14.5 11.6 - 14.8 165.3 - 210.3
Clutch Pressure All clutch pressures should be the same as mainline pressure to within
0.7 bar (10 lbf/in2)
[4WD clutch pressure within 1.4 bar (20 lbf/in2)]
Flow Rates (in neutral) l/min US gal/min UK gal/min

Cooler Oil Flow @ 50 ºC 1000 rev/min 8.5 - 11.0 2.1 - 2.9 1.9 - 2.4
2000 rev/min 17.0 - 25.1 4.5 - 6.6 3.7 - 5.5
2000 rev/min 15.0 - 19.5 4.0 - 5.2 3.3 - 3.4
Pump Oil Flow @ 50 ºC 1000 rev/min 11.5 - 15.6 3.0 - 4.1 2.5 - 3.4
2000 rev/min 24.0 - 33.0 6.3 - 8.7 5.3 - 7.3
Control Solenoid Valves 3 way, 2 position, normally closed, integral suppression diode
Initial Coil current draw 1.68 amps @ 12 volts @ 20 ºC
9803/9090 Issue 1
Powershift Gearbox - 4 Speed - 2004
Description Full electro-hydraulic transmission unit with torque converter, input,

reverse, layshaft, mainshaft, and 4 wheel drive clutch packs giving 4
forward and 4 reverse speeds.
Designation PS7644 (4 wheel drive)

2WD Gearbox N/A
4WD Gearbox 253 kg (678 lb)
Gear Ratios XtraLow Ratio (XLR) StdRatio (STD)

1st 7.97:1 6.17:1
2nd 4.29:1 3.32:1
3rd 1.86:1 1.86:1
4th 1.00:1 1.00:1
Torque Converter
Dia. 310 mm (12.2 in)
Part No. 04/600580 04.600581
Torque Multiplication at Stall 2.52:1 3.01:1
Converter Pressure (in neutral) bar kgf/cm2 lbf/in2

2000 rev/min 5.8 - 6.9 5.9 - 7.0 84.1 - 100.0
2000 rev/min 2.5 - 3.5 2.5 - 3.7 36.2 - 50.8
2000 rev/min 2.8 - 3.8 2.9 - 3.9 40.6 - 55.1
2000 rev/min 1.0 - 1.9 1.0 - 1.9 14.5 - 27.6
Cover Inlet Relief Pressure (max) 7.1 7.2 103.0
Lubrication Pressure (in neutral) bar kgf/cm2 lbf/in2

Oil @ 50 ºC 1000 rev/min 0.2 - 0.9 0.2 - 0.9 2.9 - 13.1
2000 rev/min 1.1 - 2.1 1.1 - 2.1 16.0 - 30.5
Oil @ 100 ºC 1000 rev/min 0.1 - 0.4 0.1 - 0.4 1.5 - 5.8
2000 rev/min 0.4 - 1.4 0.4 - 1.4 5.8 - 20.3
Mainline Pressure (in neutral) bar kgf/cm2 lbf/in2

Oil @ 50 ºC 1000 rev/min 11.0 - 13.0 11.2 - 13.3 159.5 - 188.5
2000 rev/min 13.0 - 15.2 13.3 - 15.5 188.5 - 220.5
Oil @ 100 ºC 1000 rev/min 10.2 - 12.2 10.4 - 12.4 147.9 - 176.9
2000 rev/min 11.4 - 14.5 11.6 - 14.8 165.3 - 210.3
Clutch Pressure All clutch pressures should be the same as mainline pressure to
within 0.7 bar (10 lbf/in2)
[4WD clutch pressure within 1.4 bar (20 lbf/in2)]
Flow Rates (in neutral) l/min US gal/min UK gal/min

2000 rev/min 17.0 - 25.1 4.5 - 6.6 3.7 - 5.5
2000 rev/min 15.0 - 19.5 4.0 - 5.2 3.3 - 3.4
Pump Oil Flow @ 50 ºC 1000 rev/min 11.5 - 15.6 3.0 - 4.1 2.5 - 3.4
2000 rev/min 24.0 - 33.0 6.3 - 8.7 5.3 - 7.3
Control Solenoid Valves 3 way, 2 position, normally closed, integral suppression diode
Initial Coil current draw 1.68 amps @ 12 volts @ 20 ºC
9803/9090 Issue 1
2-1 Component Identification 2-1
746950
G
1
M
N
K
H
3
5
C
Q2
A439080
F
E
A
J 2
B
C
D
9803/9090 Issue 1
Powershift Gearbox
2-2
Component Identification Principle of Operation
9803/9090
A Torque converter The Powershift gearbox is an electro-hydraulic
Section 4
B Forward/input clutch assembly transmission unit. Gear shifting and direction

C Reverse clutch assembly selection are controlled using multi-disc clutch
D Mainshaft assembly packs.
E Layshaft assembly
F 2/4 wheel drive clutch assembly Electrically operated solenoid valves 5 divert
G Torque converter relief valve pressurised oil (provided by pump J) to the
H Oil pressure maintenance valve selected clutch packs.
J Transmission oil pump
K 6 speed assembly (if fitted) A combined lever/swivel switch 4 on the steering
L 4WD output yoke column actuates both gear ratio and direction
M Hose connection - to oil cooler solenoids.
N Hose connection - from oil cooler
P Oil strainer The Powershift unit consists of a torque converter
Q Oil filter A, forward clutch assembly B, reverse clutch
R Driveshaft (drives machine main hydraulic assembly C, layshaft assembly E, mainshaft
pump) assembly D, 2/4 wheel drive clutch assembly F.
6 speed gearboxes incorporate a ‘6 speed’ shaft
1 Speed sensor and clutch assembly K.
2 Gear drive to reverse unit clutch assembly
3 Transmission oil pressure switch The forward clutch assembly B is driven by the
4 Steering column mounted gear selection switch torque converter A. The reverse clutch assembly C
5 Solenoid control valves is permanently driven via constant meshing of spur
gears 2. On 6 speed gearboxes the 6 speed
Basic Operation
Principle of Operation
assembly is also driven via meshing gears 2.
Driveshaft R is permanently driven by the engine

4 and runs through the hollow forward/reverse unit
1 shaft to the back of the gearbox. The shaft (R)
2 F drives the gearbox mounted machine main
3 N hydraulic pump.
A R
Strainer P and filter Q are used to prevent potential
system contamination by filtering dirt particles.
Gearbox oil is cooled by an air blast cooler 6. The

cooler is part of the front mounted machine ‘cooling
pack’.
Issue 1
2-2
Section 4
2-3 2-3
Hydraulic and Electrical Operation
H
G
K
2 1
3
2 3
Xs
5 1
C
Q
A
Us
J
Ts
Ss
1
B R M
Ws 6
Vs
D
Ys
L
E
Zs
P
N
F
747560
9803/9090 Issue 1
2-4 2-4
Hydraulic and Electrical Operation

Oil pump J is directly driven by the engine via the torque The 2/4 wheel drive unit F also has a single clutch S. When
4WD is selected, pressurised oil is directed via solenoid
converter.
valve Ss to the 4WD clutch. When 2WD is selected a Key
connection from the clutch to the transmission sump is 4 Speed Powershift
Oil from the pump J is fed through an internal passage via
made. For a full description of 2/4 wheel drive clutch Gear Clutches engaged A Torque converter
the filter Q to the pressure maintenance valve H, which
operation see Systems Description, 2/4WD Clutch B Forward clutch assembly
maintains pressure to the solenoid valve block for clutch Forward Reverse
Operation C Reverse clutch assembly
selection. Excess oil from the maintainance valve flows
1st T,Z W,Z D Mainshaft assembly
back through the casing to the torque converter A.
When a gear is selected via the control switch in the cab, 2 E Layshaft assembly
Pressure in the converter is controlled by a relief valve G
clutches are always engaged. By selecting different pairs of 2nd U,Z V,Z F 2/4 wheel drive clutch assembly
which dumps oil from the converter line back to the sump.
clutches different gear ratios are engaged. On 4 speed G Torque converter relief valve
gearboxes the solenoids are electrically controlled using 3rd T,Y W,Y H Oil pressure maintenance valve
Oil from the torque converter A flows out of the gearbox at
position M to the external oil cooler 6, returning to the relays. On 6 speed gearboxes the solenoids are controlled J Transmission oil pump
by an electronic control unit (ECU). Speed sensor 1 is used 4th U,Y V,Y K 6 speed assembly (if fitted)
solenoid valve manifold block 5 at position N. The oil then
flows through internal oilways providing lubrication for to enable the gear selection to be managed automatically L 4WD output yoke
clutches and bearings before returning to the gearbox as required. M Hose connection - to oil cooler
6 Speed Powershift
sump. N Hose connection - from oil cooler
Example - 2nd gear forward 4WD (6 speed gearbox) Gear Clutches engaged P Oil strainer
The torque converter A is a fluid coupling bolted to a drive Forward Reverse Q Oil filter
plate which in turn is bolted to the engine flywheel. As the In the schematic, the gearbox is shown with 2nd gear R Driveshaft (drives machine main hydraulic
1st X,Z W,Z
engine starts to rotate, the converter gives smooth power forward engaged. 2nd gear forward requires the forward pump)
take off gradually increasing the torque transmitted. This low clutch T and layshaft clutch Z to be engaged. When 2nd T,Z V,Z S 2/4WD clutch
torque is transferred from the converter assembly to the the gear selection switch is moved to 2nd gear forward, the Ss 2/4WD clutch solenoid
clutch/gear assemblies via input shaft on the forward electrical control system energises solenoid valves Ts and 3rd U,Z W,Y T Forward low ratio clutch
clutch assembly B. Zs. Pressurised oil is diverted to the back of pistons in Ts Forward low ratio clutch solenoid
both clutches to engage the drive. At the same time all 4th X,Y V,Y U Forward high ratio clutch
Forward clutch assembly B contains two hydraulically other solenoids are de-energised, diverting oil from the Us Forward high ratio clutch solenoid
operated clutches; one clutch (T) provides a forward low back of the other clutch pistons to the gearbox sump. 4WD 5th T,Y - V Reverse high ratio clutch
ratio drive and the other (U) a forward high ratio drive. Each clutch S is also energised to give 4 wheel drive. Vs Reverse high ratio clutch solenoid
clutch is controlled by a 2-position solenoid valve. When 6th U,Y - W Reverse low ratio clutch
the applicable solenoid is energised, pressurised oil is The tables show which clutches and solenoids are Ws Reverse low ratio clutch solenoid
directed to either the forward low (solenoid Ts) or forward engaged for each gear selection. X 6 speed clutch (6 speed gearbox only)
high (solenoid Us) clutch. Xs 6 speed clutch solenoid (6 speed gearbox only)
Note: Solenoid valve Xs controls clutch X, solenoid valve Y Mainshaft clutch
The reverse clutch assembly C is similar to the forward Ys Mainshaft clutch solenoid
Zs controls clutch Z and so on.
clutch assembly. It contains two hydraulically operated Z Layshaft clutch
clutches; one clutch (W) provides a reverse low ratio drive Zs Layshaft clutch solenoid
and the other (V) a reverse high ratio drive. 2-position
solenoid valves when energised, direct pressurised oil to Ts Us
Ws 1 Speed sensor
either the reverse low (solenoid Ws), or reverse high Vs 5 Solenoid valve manifold block
(solenoid Vs) clutch. 6 Gearbox oil cooler
Both the mainshaft and the layshaft assemblies have a

single clutch each. Solenoid valve Zs, when energised,
directs pressurised oil to the layshaft clutch Z. Solenoid
valve Ys, when energised, directs pressurised oil to the
mainshaft clutch Y.
On 6 speed gearboxes, the 6 speed clutch X is controlled

via solenoid valve Xs. Ss
Note: The 6 speed clutch assembly is so called as it is Ys
fitted to 6 speed, and not 4 speed gearboxes. However,
5
Zs
the clutch is NOT engaged when 6th gear is selected. See Xs
the adjacent table.
Note: All the clutches work on the same principle. For a full
description of operation see Clutch Operation.
9803/9090 Issue 1
2- 5 2-5
ShiftMaster Typical Operation Characteristics
Powershift Gearbox - 6 Speed Transmission dump

When the operator presses the dump switch the ECU selects
Central to the system is the ShiftMaster ECU (Electronic neutral by de-energising one clutch only. This enables
Control Unit) A. The unit receives ‘inputs’ from electrical smooth re-engagement of gears when the dump button is
devices such as the gear select switch B. Depending on the released.
input signals the ECU ‘outputs’ energise electrical devices
such as gearbox solenoid control valves C. For a full Load Modes - ECU 2.2 only
description of how the ShiftMaster electrical system works The operator can change to a different mode using a cab
see Section 7 - Electrics mounted switch. When the ECU detects a mode change
input, a different set of data is used from the ECU setup file.
Start up In this way shift parameters are altered to suit different
When the starter switch is set to the ON position the ECU operating applications. ECU 2.2 can select upto 3 modes.
performs a series of self checks. If the checks are valid three See Section 7 - ShiftMaster Setup - User Guide.
beeps sound. After the checks the ECU selects neutral even
if forward or reverse is selected on the column lever. To Warning Alarms
select forward or reverse the operator must cycle the lever The ShiftMaster ECU features and output for driving an
through neutral. audible and visual alarm. Alarms are available in response to
faults and certain gearbox operating parameters. For a full
‘Manual’ gear select list of warning alarms see Section 7 - Fault Finding.
The operator can ‘manually’ select 1st, 2nd and 3rd gears
using the column switch. When down shifting (say from 3rd
to 2nd) the ECU checks to see if the machine road speed is
suitable before down shifting the gearbox. If the road speed
is too high a repeating double beep is sounded. When the
road speed reduces to a pre-set value the ECU down shifts
the gearbox and the beeps will stop.
Kick down operation

A kickdown switch enables the operator to down shift to the
next lowest gear. The ECU checks to see if the machine road
speed is suitable before down shifting the gearbox. If the
1 B
2 F
road speed is too high a single double beep is sounded. 3 N
Pressing the kick down switch a second time causes the A R
ECU to select the previous gear.
‘Automatic’ gear selection

When A (auto) and F (forward) are selected on the column
switch, the ECU selects 4th, 5th or 6th gears, mainly
according to road speed †. The gearbox will automatically up A
shift and down shift. 2WD†† will also be selected.
To enable up shifts the accelerator pedal must be pressed,
this prevents up shifting when coasting down hill for
example, thus ensuring maximum machine control.
Note that the ECU does not automatically shift gears in
response to engine load.
When A (auto) and R (reverse) are selected the ECU selects
4th gear and 2WD††. There is no automatic gear shifting in
reverse.
† Typical auto selection. The ECU can be configured to
perform different automatic shifts if required. See Section 7
- ShiftMaster Setup - User Guide.
†† On machines with 4WB (4 wheel brake), if the operator
has selected 4WB the ECU will automatically select 4WD (4
wheel drive) when the brake pedal is pressed.
Park brake ON
When the park brake is on, the ECU will hold the gearbox in
neutral even if forward or reverse are selected. A continuous
tone is sounded.
C
714940
9803/9090 Issue 2
3-1 3-1
Powershift Gearbox
Drivepaths - 4 Speed - 2004
1F
1st GEAR FORWARD (4 wheel drive)
Clutches Engaged Solenoids Energised
T Forward Low Ts Ts Us
Z Layshaft Zs Ws
Vs
S 2/4 Wheel Drive Ss
2F
2nd GEAR FORWARD (4 wheel drive)
U Forward High Us
Z Layshaft Zs
3F
3rd GEAR FORWARD (4 wheel drive) Ss
Clutches Engaged Solenoids Energised Ys
T Forward Low Ts Zs
Y Mainshaft Ys
4F A396740
4th GEAR FORWARD (4 wheel drive)
U Forward High Us
Y Mainshaft Ys
9803/9090 Issue 1
3-2 3-2
Powershift Gearbox
Drivepaths - 4 Speed - 2004 (cont’d)
1F W V 2F W V
T U T U
Y Y
Z Z
S S
3F 4F
W V W V
T U T U
Y Y
Z Z
S S
714950
9803/9090 Issue 1
3-3 3-3
Powershift Gearbox
1R 2R
W V W V
T U T U
Y Y
Z Z
S S
3R 4R
W V W V
T U T U
Y Y
Z Z
S S
714960
9803/9090 Issue 1
3-4 3-4
Powershift Gearbox
1R
1st GEAR REVERSE (4 wheel drive)
Ts Us
W Reverse Low Ws
Ws
Z Layshaft Zs Vs
2R
2nd GEAR REVERSE (4 wheel drive)
V Reverse High Vs
Z Layshaft Zs
3R
3rd GEAR REVERSE (4 wheel drive) Ss
Clutches Engaged Solenoids Energised Ys
W Reverse Low Ws Zs
Y Mainshaft Ys
A396740
4R
4th GEAR REVERSE (4 wheel drive)
V Reverse High Vs
Y Mainshaft Ys
9803/9090 Issue 1
3-5 3-5
Powershift Gearbox
Drivepaths - 6 Speed - 2004
1F
1st GEAR FORWARD (4 wheel drive)
X ‘6 Speed’ Xs
Z Layshaft Zs
2F Ts Us
Ws
2nd GEAR FORWARD (4 wheel drive) Vs
T Forward Low Ts
Z Layshaft Zs
3F
3rd GEAR FORWARD (4 wheel drive)
U Forward High Us
Ss
Z Layshaft Zs
S 2/4 Wheel Drive Ss Ys
Zs
4F Xs
X ‘6 Speed’ Xs
Y Mainshaft Ys
5F
T Forward Low Ts
Y Mainshaft Ys
6F
U Forward High Us
Y Mainshaft Ys
9803/9090 Issue 1
3-6 3-6
Powershift Gearbox
1F 2F
X X
W V W V
T U T U
Y Y
Z Z
S S
3F 4F
X X
W V W V
T U T U
Y Y
Z Z
S S
5F X
6F X
W V W V
T U T U
Y Y
Z Z
S S
714970
9803/9090 Issue 1
3-7 3-7
Powershift Gearbox
1R 2R
X X
W V W V
T U T U
Y Y
Z Z
S S
3R 4R
X X
W V W V
T U T U
Y Y
Z Z
S S
714980
9803/9090 Issue 1
3-8 3-8
Powershift Gearbox
1R
1st GEAR REVERSE (4 wheel drive)
W Reverse Low Ws
Z Layshaft Zs
2R Ts Us
2nd GEAR REVERSE (4 wheel drive) Ws
Clutches Engaged Solenoids Energised Vs
V Reverse High Vs
Z Layshaft Zs
3R
3rd GEAR REVERSE (4 wheel drive)
W Reverse Low Ws
Y Mainshaft Ys Ss
S 2/4 Wheel Drive Ss Ys
Zs
4R Xs
4th GEAR REVERSE (4 wheel drive)
V Reverse High Vs
Y Mainshaft Ys
9803/9090 Issue 1
Clutch Operation - Forward, Reverse
4-1
The forward and reverse clutch units are very similar in † The valve E is shown using symbols.
9803/9090
design and operate in the same way. The following
description refers to one unit and can be applied to either
Section 4
the forward or reverse clutch units. Clutch Operation - Mainshaft, Layshaft, 6 Speed
The clutch 1 transfers drive from the input shaft A3 to either The mainshaft, layshaft and 6 speed units all incorporate
gear G1 or gear G2 depending on which of the two clutches one clutch and not two, as in the forward and reverse units.
(A1 or A2) is engaged, transferring drive to the mainshaft. The operation of the single clutches is the same as for one
When neither clutch is engaged, neutral is selected. clutch in the forward or reverse units.
The clutches are of the wet, multi-plate type.
The clutch housings and input shaft are a one piece

assembly A3. The assembly is permanently driven by the
engine via the torque converter. Clutch counter plates 3 are
also permanenty driven via meshing teeth inside the clutch
housings.
Clutch friction plates 4 are meshed with the gear/plate
carriers (G1 and G2).
In the diagram, clutch A1 is engaged. The counter plates 3

and friction plates 4 are pressed together by hydraulically
actuated piston 5. Drive is then transmitted from the input
shaft to the gear G1.
Clutch A2 is disengaged and no drive is transmitted to
gear/plate carrier G2. The gear is also free to rotate on the
Basic Operation
input shaft assembly.
Actuation of the hydraulic pistons 10 and 5 is controlled via

two position solenoid valves E1 and E2†.
When neutral is selected, solenoids E1 and E2 are
deactivated and the flow of pressurised oil to the clutches is
blocked. Springs 8 and 9 move the pistons away from the
clutch plates and oil from both pistons is vented to the
sump.
When for example clutch A1 is selected to be engaged,
solenoid valve E1 is energised and solenoid valve E2 is de-
energised. Pressurised oil is diverted via cross drillings
inside the input shaft A3 to the clutch piston 5. Pressure
from clutch A2 is vented to the sump via the solenoid valve
spool E2. Oil is prevented from leaking by seals 6 on the
pistons and ring seals 7 on the input shaft A3.
Issue 1
4-1
Section 4
Clutch Operation - Forward, Reverse
4-2
9803/9090
Section 4
E1
1
A3 G1 A1 6 5 6 10 A2 G2
E2
Basic Operation
8 9
4 3
A396830
Issue 1
4-2
Section 4
Clutch Operation - 2/4 Wheel Drive
- Pressure ON/Spring OFF Type 4-3
9803/9090
4 Wheel Drive Operation
Section 4
This clutch is of the 'Pressure-ON (4WD)/Spring- Pressurised oil is directed to piston C via ports 3
OFF (2WD)' type. The clutch is engaged and and 2. The piston moves, against spring D, to press
disengaged by introducing or dumping pressurised the friction/counter plates of clutch pack B
oil behind piston C via a solenoid valve A. The together, thus driving the output yoke E.
solenoid valve is operated by a switch in the cab.
When the switch is in the 4 wheel drive position,

solenoid valve A is energised. The energised
solenoid A1 causes the valve spool to move and
form a connection between ports 3 and 2.
Basic Operation
A406200
Issue 1
4-3
Section 4
Clutch Operation - 2/4 Wheel Drive
- Pressure ON/Spring OFF Type (cont’d) 4-4
9803/9090
2 Wheel Drive Operation
Section 4
When the switch is in the 2 wheel drive position, Because there is no pressure behind piston C, the
solenoid valve A is de-energised. With the solenoid friction/counter plates of clutch pack B now freely
A1 de-energised, the valve spool moves under the rotate on the output shaft, thus disengaging drive
force of the spring A2. The oil supply to the piston to the front axle.
C is blocked (shown at port 3). At the same time oil
vents from the back of piston C to the sump via
ports 1 and 2.
Basic Operation
A406210
Issue 1
4-4
Section 4
5-1 5-1
Torque Converter
Component Identification
A Impeller
B Turbine
C Reaction member
D E
D Drive plate
E Engine flywheel
F Drive to gearbox input shaft
G Spline location for reaction member
H Direct drive from the engine to the gearbox oil pump
J Direction of oil flow
Principle of Operation
A
The torque converter is similar to a fluid coupling, which
B
utilises the centrifugal force exerted in the transmission oil to
transmit power from the engine to the gearbox. It multiplies
the torque from the engine and functions as a combined
clutch and infinitely variable reduction gearbox
The torque converter is enclosed in a casing and consists of

C
three basic parts, the impeller A, reaction member C, and
turbine B. H
Impeller A is driven by the engine.
Reaction member C does not rotate. Its hub engages with a

G F
splined tube on the gearbox oil pump and is held stationary.
Turbine B is engaged with the splined end of the gearbox

input shaft.
The impeller A, driven by the engine, forms one set of

shaped blades, it can be likened to a centrifugal pump
imparting energy to the transmission oil. This energy is
transferred to another set of shaped blades, which form the
J
turbine B The turbine is connected to the gearbox and
converts the energy back to a mechanical torque.
When the impeller A is rotating faster than the turbine B, the

fixed reaction member C causes some of the energy in the
oil to be transferred back to the impeller A. This has the
effect of multiplying the torque available.
When the impeller A (input) is running much faster than the

turbine B (output) there is a substantial circulation of
transmission oil around the blades. The oil circulation is
maximum when the turbine (output) is stalled, and is almost
zero when the impeller and turbine speeds are equal i.e. the A401340
ratio is near 1:1. If the turbine (output) is stalled whilst the
impeller (input) is revolving, all the power is dissipated as
heat.
Because of the absence of a direct mechanical connection

between the engine and the gearbox therefore, the flexibility
of the torque converter drive greatly reduces wear on the
transmission, absorbing shocks and torsional vibration from
the engine. The engine cannot be stalled due to overload, as
the fluid coupling slips.
9803/9090 Issue 1
Section 5 Fault Finding Section 5
i i
Contents Page No.
Introduction 1-1
Fault Finding Charts 1-1
Gearbox Oil Contaminated with Water 1 - 10
9803/9090 Issue 1
1-1 1-1
Introduction Further Fault Finding Information

Gearbox Oil Contaminated with Water
The fault finding procedures are given in the form of flow
charts. There are a number of charts, each one dedicated to
a particular fault. The charts are designed to identify
possible causes by performing checks and where
applicable, specific tests on the gearbox. Having identified a
cause the suggested remedy is given. The charts are
designed to identify causes through a process of elimination,
starting with the simplest, most easily rectified faults.
Gearbox faults may be caused by faulty electrical

connectors or components as indicated in the fault finding
charts. Full explanations of the relevant electrical systems
for both 4 speed and 6 speed (ShiftMaster) gearboxes are
given in Electrics Section 7.
Due to the time and effort involved in removing, dismantling,

assembling and replacing a gearbox, it is recommended that
fault finding procedures are carried out until a fault can be
identified with a good degree of certainty.
Full details of the test procedures referred to in the charts

are given in Service Procedures Section 6.
Technical Data Check List
To assist in the correct fault identification it is advisable to

record test results. A blank checklist is included in this
section and can be printed or copied as required. Correct
completion of the check list will assist the engineer in
diagnosing gearbox abnormalities. Should any further
assistance be required the form can be forwarded to the
Transmissions Technical Service Team via email.
Fault Finding Charts:
Chart A - Machine drives but lacks power in all gears.

Gearbox oil may also be overheating.
Chart B - Machine does not drive in any gear.
Chart C - Some gears fail to engage or lack power. 4WD

fails to engage.
Chart D - (6 speed gearbox only) ShiftMaster fails to

function normally - fails to autoshift - shifts at
incorrect road speed.
Note: 4th, 5th and 6th gears utilise clutches used for 1st,
2nd and 3rd gears. If 4th, 5th or 6th gears fail to engage,
check that the lower 3 gears function correctly before
investigating a possible ShiftMaster fault. See Fault Finding
Chart C.
Chart E - Gearbox oil overheats.
Chart F - External oil leakage.
Chart G- Noisy operation.
9803/9090 Issue 2
1-2 1-2
9803/9090 Issue 1
9803/9090
Powershift Gearbox
1-3
Section 5
Chart A - Machine drives but lacks power in all gears. Gearbox oil may also be overheating.
START Top up oil level
Is gearbox oil level low? YES
YES
Check reason for contamination.

Rectify as applicable Drain and flush
the oil.
NO
Is gearbox oil the correct type and Check the operation of the parking
YES Repair the engine as applicable.
free from contamination? and service brakes.
YES NO NO
Fault Finding
Torque converter reaction member
Carry out a Torque Converter Stall Test Is the engine performance normal?
Are all the stall speeds too low? YES clutch slipping. Remove the gearbox
in all gears. Are all the stall speeds YES
See Checking the Engine Power. YES
and renew the torque converter.
outside specifications?
NO
Carry out Mainline Oil Pressure Test Carry out Torque Converter In Check condition of torque
YES Pressure Test. Is torque converter in NO
Is mainline oil pressure correct? converter relief valve.
pressure correct? Clean or renew as applicable.
NO
YES
Check condition of pressure

maintenance
valve. Clean or renew as applicable.
Check for signs of excessive external Too high?
Cooler lines restricted or blocked. Oil
oil leakage. YES
cooler blocked.
Carry out Torque Converter Out

Pressure Test. Is torque converter out NO
Carry out Mainline Oil Pressure and pressure correct?

Flow Tests YES Cooler lines or cooler leaking. Internal
Is mainline oil pressure /flow correct? Too low? leakage. Remove the gearbox, torque
YES
YES converter housing and pump, check
NO
all sealing faces for damage.
It may be that another fault may have
Section 5
Remove and dismantle gearbox. been overlooked. Go back to the start
Check condition of pump, casings for of the fault finding and re-check.
internal/external leakage. The clutches
will have been slipping due to low oil
pressure - dismantle all clutches and
715610
Issue 1
1-3
renew as required.
9803/9090
Powershift Gearbox
1-4
Section 5
Chart B - Machine does not drive in any gear.
START
Is gearbox oil level low? YES Top up oil level.
NO
Are the park brake and transmission NO Renew switch or repair wiring as
dump switches working correctly? applicable.
YES
Is the gear selection column switch

working correctly. See Powershift NO Renew switch or repair wiring as
applicable.
Fault Finding
Electrical System Tests.
NO
YES Carry out Torque Converter In Check condition of torque

Carry out Mainline Oil Pressure Test Pressure Test
Is mainline oil pressure correct? NO converter relief valve.
Is torque converter in pressure Clean or renew as applicable.
correct?
NO
YES
Check condition of pressure

Are the clutch control solenoids
maintenance
working? Check control valve
valve. Clean or renew as applicable.
solenoids for correct resistance Renew solenoid or repair wiring as
Check for signs of excessive external NO
and wiring continuity - check applicable.
oil leakage.
forward and reverse solenoids
first.
Carry out Mainline Oil Pressure and

Flow Tests YES YES
Is mainline oil pressure /flow correct?
6 Speed - Is the gearbox ECU connected
correctly?
NO Clean connectors and fit securely.
4 Speed - Are the Powershift relays NO
connected correctly?
Remove and dismantle gearbox.
YES
Check condition of pump, casings for
internal/external leakage. Check
Section 5
pump drive dogs on torque converter 6 Speed - Renew the ECU.
are undamaged. 4 Speed - Renew the relays as
applicable. A396290
Issue 1
1-4
9803/9090
Powershift Gearbox
1-5
Section 5
Chart C - Some gears fail to engage or lack power. 4WD fails to engage.
Fault Finding Chart C - Some gears fail to engage or lack power. 4WD fails to engage.
START
Are the gear selection column/4WD

switches working correctly. See Renew applicable switch or repair
NO
Powershift Electrical System Tests. wiring as applicable.
YES
Are the relevant the clutch solenoids Are the solenoids or associated Renew applicable solenoid or repair
YES
working? Identify the applicable
NO wiring faulty. wiring as applicable.
solenoids and check for correct
Fault Finding
resistance and wiring continuity. NO
6 Speed - Is the gearbox ECU connected

correctly? NO Clean connectors and fit securely.
YES 4 Speed - Are the Powershift relays
connected correctly?
YES
6 Speed - Renew the ECU.

4 Speed - Renew the relays as
applicable.
Carry out Individual Clutch Pressure Clutch failure, jammed pistons or

Tests. Are the relevant clutch YES blocked oil ways: Remove and
pressures correct? dismantle gearbox. Clear oilways,
renew clutches as applicable.
NO
Are the oilways clear at the control Clear debris from ports. Replace valve
valve manifold and casing? - manifold. If fault is cleared, flush
NO
Remove the manifold and check. See gearbox oil.
Removing the Control Valves.
YES
Section 5
Clutch Leakage: Remove and
dismantle gearbox. Check condition
of clutch piston seals, ball valves and
housings. Check shaft sealing rings
for wear or damage.
Issue 1
1-5
715620
9803/9090
Powershift Gearbox
1-6
Section 5
Chart D - (6 speed gearbox only) ShiftMaster fails to function normally - fails to autoshift - shifts at incorrect road speed.
Note: 4th, 5th and 6th gears utilise clutches used for 1st, 2nd and 3rd gears. If 4th, 5th or
START 6th gears fail to engage, check that the lower 3 gears function correctly before investigating
a possible ShiftMaster fault. See Fault Finding Chart C.
* The simplest and best way to fault find the 6 speed gearbox electrical system, (including the
Are the gear selection column
switches, kickdown and throttle NO
Renew the switch or repair wiring as ECU) is by using ShiftMaster Diagnostics software and a laptop PC. See Diagnostics User
applicable.
switches working correctly? Guide Section 6 This diagnostics system enables the engineer to quickly identify faults with
specific electrical circuits or devices. The devices electrical connections, locations and wire
YES
identifications are given in Electrics Section 7.
* Is the speed sensor operating?
See Service Procedures - Powershift NO
Renew sensor or repair wiring as Warning Alarms In response to some combinations of inputs the ShiftMaster ECU can
applicable.
Gearbox, Speed Sensor. provide audible and visible alarms (if the alarm output is connected to suitable devices) The
ECu will also inhibit some gearbox functions. For a full list of warning alarms see Section 7 -
YES
Fault Finding.
Is the gearbox ECU connected NO
*
correctly? Clean connectors and fit securely.
Fault Finding
Use ShiftMaster Diagnostics software
to check ECU inputs and outputs. See
YES
Service Procedures, Powershift
Gearbox, Diagnostics User Guide.
*
Renew the ECU.
See Service Procedures,
Powershift Gearbox, Electronic A396310
Control Unit.
Section 5
Issue 2
1-6
9803/9090
Powershift Gearbox
1-7
Section 5
Chart E - Gearbox oil overheats
Fault Finding Chart E - Gearbox Oil Overheats.
START
Clean the matrix.

Is the gearbox oil cooler heat
exchanger matrix clogged with YES
dirt/chaff?
Adjust oil to correct level.
Is gearbox oil level incorrect (too low YES

or too high)?
NO Rectify as applicable. Drain and flush
oil.
Is gearbox oil the correct type and
Fault Finding
free from contamination, especially YES
water contamination?
Rectify routing/renew hoses as

NO
applicable
Are the cooler lines kinked, or

trapped? YES
Educate operator.
NO
Is the machine being operated NO

correctly - in the correct gear range?
YES
Carry out Torque Converter Out Check condition of torque

NO
Pressure/Flow Test. Is the pressure converter relief valve.
correct? Clean or renew as applicable.
YES
YES
Is oil flow correct? NO

Is the cooling circuit restricted or Rectify as applicable.
YES
blocked internally? Remove cooler,
check lines and cooler for internal
YES blockages.
Section 5
NO
Remove gearbox. Check condition of
pump, casings for internal/external
leakage. Inspect clutches for signs of
jammed pistons. Repair clutches as
715630
Issue 1
applicable.
1-7
9803/9090
Powershift Gearbox
1-8
Section 5
Chart F - External oil leakage
START
Is the oil leaking from the gearbox or

from another source? Remember that
the main machine hydraulic pump Rectify as applicable.
YES
may be mounted on the gearbox. Oil
leakage from inside the torque
converter housing may be engine oil.
NO
Drain oil to correct level.

Is gearbox oil level too high? YES Check oil for water contamination.
NO
Fault Finding
Is oil leaking from external, plugs,
adaptors, filter, pipes and hoses on YES Rectify as applicable.
the gearbox and cooling circuit?
NO
Remove valve manifold, check sealing

Is oil leaking from the solenoid control faces for damage. Renew gaskets,
valve manifold/solenoid valve stem? YES
solenoids and components as
applicable.
NO
Remove gearbox. Remove the torque

converter housing. Check the sealing
Is oil leaking between the torque faces for signs of damage. Rectify as
converter housing to front case joint? YES
applicable. Re-seal casings, See
Powershift Gearbox - Assembly step 10.
NO
Carefully check casings for signs of

damage. If damage is evident, remove
the gearbox and renew components
as required.
A396330
Section 5
Issue 1
1-8
9803/9090
Powershift Gearbox
1-9
Section 5
Chart G - Noisy operation
START
Is gearbox oil level low? YES Top up oil level.
NO

Is gearbox oil the correct type and
NO Rectify as applicable Drain and flush
free from contamination?
oil.
Fault Finding
NO
Carry out a Lubrication Pressure

Test. Carry out Torque Converter Out
YES
Is the pressure low? Pressure Test. Is the pressure correct?
NO NO YES
Check the condition of the torque

converter relief valve. Make sure that
the cooler lines are not restricted.
Rectify as applicable.
Remove and dismantle gearbox.

Check all components for signs of
wear or damage, especially shaft
seals and bearings. Rectify as
applicable.
715640
Section 5
Issue 1
1-9
1 - 10 1 - 10
Gearbox Oil Contaminated with Water

Carefully inspect the gearbox oil for signs of water contamination. Contaminated oil will contain water droplets or be visibly
emulsified. Water droplets may be visible on the dipstick or inside the filler tube. For oil analysis purposes, the maximum
permissible water content of the oil is 0.10%.
If the gearbox oil has been contaminated with water, faults or damage to the gearbox may be apparent as a result. Before
remedying, thoroughly investigate and rectify the cause of the water contamination.
Note: The correct gearbox oil is given in Section 3, Lubricants and Capacities.
Possible Cause Remedy

1 Water ingress during filling/topping up. Carry out flushing procedure.
Refill with the correct oil, see Section 3.
2 Missing/incorrect dipstick, damaged filler tube. Renew missing/incorrect/damaged components.

Carry out flushing procedure.
3 Machine operated in deep water. Carry out flushing procedure.

4 Gearbox casings damaged. Inspect, renew damaged components.

5 Gearbox oil circuit pipes/hoses damaged. Inspect, renew damaged components.

Gearbox faults caused typically by water contamination and other factors related to the gearbox oil:
Fault Possible Cause Remedy

1 Pressurisation of gearbox Water in oil combined with heat Replace/renew dipstick.
casing - Dipstick blows out/oil from torque converter causes Carry out flushing procedure.
leaking from dipstick tube. steam. Refill with the correct oil, see Section 3.
Gearbox over filled with oil. Drain the oil level to the correct level,
see Routine Maintenance - Checking
Transmission Oil Level.
2 Clutch Failure - Friction Lining Water ingress. Renew friction plates.

Separation. Carry out flushing procedure.
Overheating transmission oil. See Fault Finding - Overheating.
3 Badly worn/noisy bearings. Water ingress. Fit new bearings.

Insufficient lubrication. Refill with the correct oil, see Section 3.
9803/9090 Issue 1
Section 6 Service Procedures Section 6
i i
Contents Page No.
Torque Converter Stall Test 1-1

Powershift Gearbox - 2004
Pressure and Flow Testing 1-3
Pressure Testing Clutches 1 - 10
Speed Sensor 2-1
Powershift Gearbox - 6 Speed (ShiftMaster) - 2004

Electronic Control Unit 3-1
Pressure Testing the 2/4WD Clutch 4-1
9803/9090 Issue 1
1-1 1-1
Torque Converter Stall Test
The purpose of the stall test is to check the performance of Note: When fully engaged, the parking brake electrically
the transmission by ‘stalling’ the torque converter. This is the disconnects the transmission drive; this prevents the
point at which, due to torque applied by the engine the machine from being driven with the parkbrake on. Therefore,
torque converter stops transmitting drive to the gearbox. so that we can complete the test, move the parkbrake lever
The engine speed at which ‘stalling’ occurs is compared to fractionally forward until the warning light is just
speeds recorded for a machine in normal condition (see the extinguished; hold the lever in this position for the duration
engine manufactures technical data). Abnormal stall speed of the test. DO NOT move the lever too far forward,
results can be used to identify a number of possible faults otherwise the parkbrake will not be fully operational.
with the transmission, typically gearbox hydraulic and clutch Alternatively, disconnect the switch at the park brake.
faults.
3 Select 1st speed forward drive and open throttle fully.
Note: DO NOT stall the converter for longer than 10 seconds Record the engine speed from the tachometer. Repeat
or the transmission fluid will overheat. Make sure that the oil the test for 2nd and 3rd speed forward and record the
level is correct and at normal operating temperature. readings.
Before completing the following test, remove the 4 Repeat step 3 except this time select 1st, 2nd and 3rd
transmission dipstick. If there is any sign of smoke emitting gear reverse drive respectively. Record the readings.
from the dipstick tube STOP THE TEST IMMEDIATELY and
dismantle the transmission for servicing. 5 All recorded readings should be as specified in the
machine manufactures technical data.
By performing the tests in the first 3 gears in forward and
reverse we can see from the tables below that all the Key to Clutches
clutches in the gearbox will be engaged, ensuring faults will T - Forward low ratio clutch pressure
be easy to identify. make a copy of the Transmission U - Forward high ratio clutch pressure
Technical Data Check List and fill in the test results, see V - Reverse high ratio clutch pressure
Fault Finding. Alternatively draw a table as shown so that W - Reverse low ratio clutch pressure
you can record the results. X - 6 speed clutch pressure (6 speed gearbox only)
Y - Mainshaft clutch pressure
Stall Test Results - 6 Speed Powershift Z - Layshaft clutch pressure
Gear Clutches engaged
Forward Rev/min Reverse Rev/min
1st X,Z W,Z
2nd T,Z V,Z
3rd U,Z W,Y
Stall Test Results - 4 Speed Powershift

1st T,Z W,Z
2nd U,Z V,Z
3rd T,Y W,Y
1 Ensure that the engine and transmission are at normal

working temperature (the transmission oil must be
above 50°C). Run engine at maximum speed and check
the No Load Speed (see the engine manufactures
technical data), adjust if necessary.
2 Apply parking brake and footbrake firmly. If necessary,

set the machine against a fixed obstruction.
9803/9090 Issue 2
1-2 1-2
Torque Converter Stall Test (cont’d)
Interpreting the Test Results
If all the engine speeds are below the stated figures either
the engine is losing power and should be
serviced/overhauled or the torque converter reaction
member clutch is slipping. To check the engine, select
Neutral, open throttle fully and operate an excavator service
to 'blow off' the main relief valve. Engine speed should fall to
slightly below the Maximum Governed Speed (see the
engine manufactures technical data). If engine speed is
correct the torque converter reaction member clutch is
slipping.
If all the engine speeds are higher than the stated figures in
all gears the torque converter safety relief valve may be
faulty. Alternatively there may be internal oil leakage.
If engine speeds are higher than the stated figures in some

gears, check the transmission for clutch slippage or internal
leakage. Look at the example below and see how the results
can be used to isolate a suspect clutch.
Stall Test Results - 6 Speed Powershift

1st X,Z 1990 W,Z 1980
2nd T,Z 2060 V,Z 1975
3rd U,Z 1985 W,Y 1990
In the example shown, we can see that the engine speed is

abnormally high when 2nd gear forward drive is selected,
indicating a slipping clutch, possibly T or Z. We can now use
the results to determine which clutch is at fault.
From the table we can see that there is no problem with

clutch Z since it is engaged in other gears, the stall speeds
for those gears are normal. This indicates that clutch T is
slipping.
Clutches may be slip for several reasons. Hydraulic leakage

is possible and this can be confirmed by carring out a
pressure test, see Pressure Testing - Individual Clutches.
9803/9090 Issue 1
1-3 1-3

Pressure and Flow Testing
B1
V M
U
J
S
S
Z
Y
X
C004190-C1
9803/9090 Issue 2
1-4 1-4

Pressure and Flow Testing (cont’d)
Test Points:
Before completing any of the transmission pressure/flow A - Mainline pressure
tests, make sure that the oil level is correct and at normal B - Converter inlet and converter relief valve
operating temperature (not less than 50°C). pressure
B1 - Converter inlet and converter relief valve
All gauges etc used in the following pressure/flow tests are pressure - Lock up torque converter variant
shown in Service Tools - Section 1. C - Converter outlet pressure
F - Pump flow (remove filter and fit adapters)
J - Lubrication pressure
! WARNING
Fine jets of hydraulic oil at high pressure can penetrate Clutches:
the skin. Do not use your fingers to check for hydraulic S - 2 and 4 wheel drive clutch pressure
oil leaks. Do not put your face close to suspected leaks.
T - Forward low ratio clutch pressure
Hold a piece of cardboard close to suspected leaks and
then inspect the cardboard for signs of hydraulic oil. If U - Forward high ratio clutch pressure
hydraulic oil penetrates your skin, get medical help V - Reverse high ratio clutch pressure
immediately. W - Reverse low ratio clutch pressure
HYD 1-1
X - 6 speed clutch pressure (6 speed gearbox only)
! WARNING Y - Mainshaft clutch pressure
Take care when disconnecting hydraulic hoses and Z - Layshaft clutch pressure
fittings as the oil will be HOT.
Trans 1-2
Other Items:
! WARNING L - Torque converter relief valve
DO NOT go underneath the machine with the engine M - Pressure maintenance valve
running. Switch off the engine, apply the parking brake
and chock both sides of all wheels before going
underneath the machine. Test Procedures:
Trans 2-1 Pump Flow
Mainline Pressure
! WARNING
Converter in Pressure
If a 4 wheel drive machine is to be raised and the
engine/transmission run, make sure all four wheels are Converter Relief (Safety) Valve Pressure
off the ground and supported by axle stands. If only one Converter Out Pressure and Oil Cooler Flow Rate
pair of wheels is raised, the machine could still drive
Lubrication Pressure
through the other axle.
Trans 2-2/2 Clutches:-
Isolating a Suspect Clutch
! WARNING Individual Clutch Leakage Test
Under no circumstances must the engine be run with the
transmission in gear and only one driving wheel jacked Record the test results carefully. Make a copy of the
clear of the ground, since the wheel on the ground will Transmission Technical Data Check List and fill in the test
move the machine. results, see Fault Finding. Correct completion of the
INT-3-1-16
checklist will assist the engineer in diagnosing gearbox
abnormalities. Alternatively the check list can be emailed to
the Transmission Service Technical Service Team should
and further assistance be required.
9803/9090 Issue 2
1-5 1-5

B1
B
C004210-C1
9803/9090 Issue 2
1-6 1-6

Pressure and Flow Testing, (cont’d)
Pump Flow Mainline Pressure
1 Stop engine, remove the gearbox oil filter and fit 1 Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure
adapter X (460/15708) into the gearbox casing. gauge to test connector A.
Connect flowmeter W (892/00268).
2 Start engine and run at 1000 rev/min. With the
2 Start engine and run at 1000 rev/min. With the transmission in neutral the pressure gauge will show
transmission in neutral the flowmeter will show the the Main Line Pressure which should be as shown in
Pump Flow which should be as shown in Technical Technical Data - Section 4. A low reading can be
Data - Section 4. A low reading indicates a worn pump caused by either a faulty pressure maintenance valve or
or blocked suction strainer. a worn pump. A high or low reading may indicate a
faulty pressure maintenance valve.
3 Repeat step 2 and note gauge readings with engine
running at 2000 rev/min. 3 Repeat step 2, with engine running at 2000 rev/min
note gauge readings which should be as shown in
4 Stop engine and remove test adapters, refit filter. Technical Data - Section 4.
4 Stop engine and remove test gauge.
Converter In Pressure
Note that the converter in pressure is affected by the torque

converter relief valve operation. Before carrying out tests
check the operation of the relief valve (see Converter Relief
(Safety) Valve Pressure).
1 Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure

gauge to test point B or B1 as applicable.
Note: A pressure test kit (998/10650) is available to enable

easier pressure gauge connection, refer to Service Tools -
Section 1.
2 Start the engine and run at 1000 rev/min. With the

W transmission in neutral the pressure gauge will show
Converter In Pressure which should be as shown in
Technical Data - Section 4. A high or low reading
could indicate a faulty converter relief valve.
3 Stop engine and remove pressure test gauge.
717890
9803/9090 Issue 2
1-7 1-7

B1
C004230-C1
9803/9090 Issue 2
1-8 1-8

Converter Relief (Safety) Valve Pressure
The purpose of the torque converter relief valve is to protect Converter Out Pressure/Oil Cooler Flow Rate
the torque converter from excessive oil pressure. Excessive
oil pressure can be generated when the transmission oil Note that the converter out pressure and oil cooler flow rate
temperature is below 50°C and/or the engine is run at over are affected by the torque converter relief valve operation.
2000 rev/min. In this event the relief valve opens and returns Before carrying out tests check the operation of the relief
oil directly to the transmission sump, bypassing the torque valve (see Converter Relief (Safety) Valve Pressure.
converter, cooler and clutch lubrication circuits, protecting
against damage due to excessive pressure. For this reason 1 Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure
it is essential that the transmission oil is above 50°C and gauge and flowmeter into the converter out line as
the engine is run between idle and 1000 rev/min when shown at C and K respectively.
testing the relief valve.
2 Run the engine at 1000 rev/min with transmission in
1 Connect a 0-20 bar (0-300 lbf/in2) pressure gauge to neutral. The pressure gauge indicates the Converter
test point B or B1 as applicable. Out Pressure and the flowmeter indicates the Oil
Cooler Flow Rate, both readings should be as
Note: A pressure test kit (998/10650) is available to enable specified in Technical Data - Section 4. A high
easier pressure gauge connection, refer to Service Tools - pressure together with low flow could be caused by a
Section 1. blocked oil cooler or internal leakage.
2 Fit a load valve P into the converter out line. 3 Repeat step 2, with engine running at 2000 rev/min
note gauge readings which should be as shown in
! CAUTION Technical Data - Section 4.
Make sure the load valve is in the OPEN position, (the
4 Stop engine, remove test gauges and refit hoses to
adjusting knob screwed fully OUT), before starting the
original position.
following pressure test. Failure to do this could damage
the pump.
Lubrication Pressure
HYD 4-4/1
Note that the lubrication pressure is affected by the torque

DO NOT allow the pressure to exceed 8.3 bar (120 lbf/in2) or
converter relief valve operation. Before carrying out tests
damage to the converter seals will be caused.
check the operation of the relief valve (see Converter Relief
(Safety) Valve Pressure.
transmission in neutral, slowly screw down the load
1 Stop engine, connect a suitable pressure gauge into
valve P whilst observing the gauge reading which
the return line from the oil cooler to the transmission as
should rise to the Converter Relief (Safety) Valve
shown at J.
setting as specified in Technical Data - Section 4.
Note that the gauge pressure will fall once the valve has
transmission in neutral the pressure gauge will indicate
opened. This is normal relief valve operation and does not
the Lubrication Pressure which should be as specified
indicate a fault. If necessary reset the load valve P and
in Technical Data - Section 4.
perform the test again, watching the pressure gauge
carefully.
3 Repeat step 2 and note gauge readings with engine
running at 2000 rev/min. If the pressure is high the oil
4 If the converter relief valve opens at a pressure higher
cooler may be blocked, (see Converter Out
than specified then the valve is faulty. A low opening
Pressure/Oil Cooler Flow Rate).
pressure indicates a leaking pump to casing seal or a
faulty converter relief valve.
4 Stop engine and remove pressure gauge.
5 Stop engine, remove test gauges and load valve. Refit
hoses to original position.
9803/9090 Issue 2
1-9 1-9

W
V
T U
Z
Y
X
C004240-T1
9803/9090 Issue 2
1 - 10 1 - 10

Pressure Testing - Clutches
Isolating a Suspect Clutch
By performing the tests in the first 3 gears in forward and 3 Start engine and run at 1000 rev/min, engage 1st gear
reverse all the clutches in the gearbox will be engaged, forward. Record the pressure reading. Repeat the test
ensuring any clutch leakage will be easy to identify. Draw a for 2nd and 3rd gears forward and 1st, 2nd and 3rd
table as shown so that you can record the results. gears reverse. Record the pressure readings as shown
in the example below:
Clutch Pressure Test Results - 6 Speed Powershift Clutch Pressure Test Results - 4 Speed Powershift
Gear Clutches engaged Gear Clutches engaged
Forward bar lbf/in2 Reverse bar lbf/in2 Forward bar lbf/in2 Reverse bar lbf/in2
1st X,Z W,Z 1st T,Z 13.4 194 W,Z 13.4 194
2nd T,Z V,Z 2nd U,Z 12.0 175 V,Z 13.6 197
3rd U,Y W,Y 3rd T,Y 13.5 195 W,Y 13.5 195
Readings should not vary between clutches by more than

Clutch Pressure Test Results - 4 Speed Powershift 0.7 bar (10 lbf/in2). In the example shown, we can see that
Gear Clutches engaged pressure is low when 2nd gear forward is selected,
Forward bar lbf/in2 Reverse bar lbf/in2 indicating clutch leakage.
1st T,Z W,Z From the table we can see that the layshaft clutch Z is
working normally (1st gear forward, 1st and 2nd gears
2nd U,Z V,Z reverse all show normal operating pressure). We can
assume that the forward high clutch U is leaking.
3rd T,Y W,Y
By carring out ‘Individual Clutch Leakage Tests', (see next
page) we can confirm that the forward high clutch U is
leaking.
1 Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure
gauge to test connector A (mainline pressure test
point).
2 Make sure that both sides of all four wheels are

chocked. Apply the footbrake and parking brake.
Note: When fully engaged, the parking brake electrically

disconnects the transmission drive; this prevents the
machine from being driven with the parkbrake on. Therefore,
so that we can complete the test, move the parkbrake lever
fractionally forward until the warning light is just
extinguished; hold the lever in this position for the duration
of the test. DO NOT move the lever too far forward,
otherwise the parkbrake will not be fully operational.
Alternatively, disconnect the switch at the park brake.
9803/9090 Issue 2
1 - 11 1 - 11
Pressure Testing - Clutches (cont’d)
W
V
T U
Z
Y
X
C004240-T1
9803/9090 Issue 2
1 - 12 1 - 12
Pressure Testing - Clutches (cont’d)

Individual Clutch Leakage Test
When testing individual clutch pressures it is necessary to In the following procedures the forward low clutch T is
isolate the clutch being tested. So for instance, on a 6 speed tested on a 4 speed gearbox, therefore in step 2 a pressure
gearbox, to check the forward low clutch T we must select gauge is connected to the forward low clutch test point.
2nd gear forward - this would energise the forward low (T)
and layshaft (Z) clutches. Because we only want to check When testing other suspect clutches connect a gauge to the
the forward low (T) clutch pressure and not the layshaft (Z) relevant suspect clutch test point. Because the forward low
clutch pressure, remove the electrical connector to the 6 clutch is suspect, a gear must be selected that will use the
speed clutch solenoid Xs BEFORE selecting 2nd gear. forward low clutch, in this instance 2nd gear forward on a 4
speed gearbox.
On a 4 speed gearbox, to check the forward high clutch (U)
we must select 2nd gear forward - this would energise the Note: When testing the 2/4WD clutch remove the feed pipe
forward high (U) and layshaft (Z) clutches. Because we R and fit service tool. This pipe incorporates a test point.
only want to check the forward high (U) clutch pressure and Replace the original pipe when testing is complete.
not the layshaft (Z) clutch pressure, remove the electrical
connector to the layshaft clutch solenoid Zs BEFORE 1 Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure
selecting 2nd gear. gauge to test connector A, (mainline pressure test
point).
Use the table below to determine which solenoid electrical
connectors should be removed when pressure testing
2 Connect a 0-20 bar (0-300 lbf/in2) pressure gauge to
individual clutches. Note that as the first 3 forward and
test connector T (forward low ratio clutch test point).
reverse gears utilise all clutches, there is no need to select
other gears when testing for leakage.
3 Remove the layshaft clutch solenoid feed connector Zs,
6 Speed Gearbox at the solenoid control valve. This ensures that only the
Gear Clutches Engaged (Solenoids Energised) forward low clutch T is energised when 2nd gear
Selected forward is selected.
1st Forward 6 Speed & Layshaft - X,Z (Xs,Zs)
4 Make sure that both sides of all four wheels are
2nd Forward Forward Low & Layshaft - T,Z (Ts,Zs)
chocked. Apply the footbrake and parking brake.
3rd Forward Forward High & Layshaft - U,Z (Us,sZ)
Note: When fully engaged, the parking brake electrically
1st Reverse Reverse Low & Layshaft - W,Z (Ws,Zs)
disconnects the transmission drive; this prevents the
2nd Reverse Reverse High & Layshaft - V,Z (Vs,Zs)
machine from being driven with the parkbrake on. Therefore,
3rd Reverse Reverse Low & Mainshaft - W,Y (Ws,Ys)
so that we can complete the test, move the parkbrake lever
4 Speed Gearbox fractionally forward until the warning light is just
Gear Clutches Engaged (Solenoids Energised) extinguished; hold the lever in this position for the duration
Selected of the test. DO NOT move the lever too far forward,
otherwise the parkbrake will not be fully operational.
1st Forward Forward Low & Layshaft - T,Z (Ts,Zs ) Alternatively, disconnect the switch at the park brake.
2nd Forward Forward High & Layshaft - U,Z (Us,Zs)
3rd Forward Forward Low & Mainshaft - T,Y (Ts,Ys) 5 Start engine and run at 1000 rev/min, select 2nd gear
forward. Note the pressure readings on both gauges,
1st Reverse Reverse Low & Layshaft - W,Z (Ws,Zs) which should not vary by more than 0.7 bar (10 lbf/in2).
2nd Reverse Reverse High & Layshaft - V,Z (Vs,Zs) If the difference on the gauges is greater than 0.7 bar
3rd Reverse Reverse Low & Mainshaft - W,Y (Ws,Ys) (10 lbf/in2) do the following:
a Stop the engine and interchange the gauges.

Ts Us
Ws b Start the engine and run at 1000 rev/min, select
Vs
2nd gear forward. If the difference on the gauges is
still greater than 0.7 bar (10 lbf/in2) dismantle the
forward low clutch for servicing.
c If after interchanging the gauges, the readings are

different than at step 5, have the gauges calibrated
and repeat the testing procedure.
Ss
Ys Note:
Zs No Xs on 4
Xs Speed Box.
9803/9090 Issue 2
2-1 2-1
Speed Sensors
The gearbox electronic control system incorporates a

gearbox speed sensor.
Gearbox Speed Sensor
The speed sensor detects the speed of rotation of the

gearbox output shaft and relays this information to the ECU.
The sensor detects the passing of the gear teeth on the

output gear. When adjacent to the top of a gear tooth the
sensor electrical output turns ON, when adjacent to a gap
between the teeth the sensor output turns OFF. In this way
the frequency of the electrical signal changes according to
the speed of gear rotation and therefore machine road
speed.
The gearbox ECU uses the input from the speed sensor to
determine gear shift points. Failure of the speed sensor or
D
its wiring will enable an ECU warning alarm. See Fault
Finding.
Testing
The speed sensor can be tested in situ without removing it

by means of service test harness 892/01096 .
1 Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral.
Lower the loader arms to the ground. Switch OFF the
E
engine and remove the starter key.
2 Connect the test harness E as shown. Tie back and

secure the wires clear of the driveshaft and other
moving components, in a position where the light
emitting diode (LED) can be seen while operating the
machine.
3 Turn the engine ON and drive the machine forward B A
approximately 2 m (6 ft), make sure it is clear in front.

C
Alternatively raise the wheels off the ground. If the
sensor is operating correctly the LED will illuminate as
the gear teeth pass the sensor, when the speed Key:
increases the LED will flash at a greater frequency until
becoming continuously illuminated at higher speeds. A Ground
B +V
4 If the LED fails to illuminate carefully check the relevant C Output
wires and connectors for damage. Repair as required
and re-test the sensor as described above. It should be 717960
noted that the speed sensor is normally a reliable

component and a fault is more likely attributed to
damaged wires or electrical connectors, see Electrics
Section 7.
9803/9090 Issue 2
3-1 3-1
Powershift Gearbox - 6 Speed (ShiftMaster) - 2004
Electronic Control Unit
The PS766 6 speed gearbox is controlled by an Electronic Renewing The ECU

Control Unit (ShiftMaster ECU).shown at A. Before renewing the ECU note the following:
Note: See Electrics, Section 7 for further details. The ShiftMaster ECU is a non serviceable part. Any units
returned under warranty found to have been tampered with
The ECU is housed in a rugged case protected from ingress will invalidate any claim.
of dirt and moisture. Gearbox faults are more likely to be
caused by faulty or damaged wiring, electrical components ECU’s are configured at the factory for each transmission
or hydraulic faults than by failure of the ShiftMaster ECU. variant and are not interchangeable between transmissions.
Although the part numbers may be the same, the internal
Fault Finding software may not be. DO NOT interchange ECU’s
When fault finding note the following: between transmissions.
Make sure you understand the normal operation Before renewing the ECU carry out all the relevant fault
characteristics of the 6 speed gearbox. Some characteristics finding and diagnostics to confirm ECU failure. Units
may be interpreted as faults by some operators. See returned under warranty found not to be faulty will invalidate
ShiftMaster Operation Characteristics, Section 4. any claim.
The ShiftMaster ECU incorporates ‘Limp Modes’. These
modes can operate in response to other gearbox faults.
Make sure you understand the characteristics of the ‘Limp
Modes’, see Fault Finding, Section 5.
The simplest and best way to fault find the 6 speed gearbox
electrical system, (including the ECU) is by using ShiftMaster
Diagnostics software and a laptop PC. This diagnostics
system enables the engineer to quickly identify faults with
specific electrical circuits or devices. The devices electrical
connections are given in Electrics, Section 7.
If the facilities to use the ShiftMaster Diagnostics software

system are not available, the gearbox and ECU can still be
checked using a conventional multimeter.
714990
9803/9090 Issue 1
4-1 4-1
Pressure Testing the 2/4WD Clutch

1 Assemble the 2/4 wheel drive clutch, as described in
‘Assembly’.
2 Check the clutch pack end float and adjust as required

(see Assembly - Section 8).
3 Using special tool 993/59300, insert the adaptor A into

the oil gallery in the end of the 2/4 wheel drive clutch
shaft as shown. Hold the adaptor in position with
clamp B.
4 Use a hand pump to pressurise the clutch assembly

until gear, item 5 can be turned by hand. Note the
pressure gauge reading - DO NOT EXCEED 200 lb/in2
(13.8 bar).
5 If the pressure gauge reading is between 125 - 135

lbf/in 2 (8.6 - 9.3 bar) then the clutch is operating
correctly and can be fitted in the transmission.
6 If however the pressure gauge reading is above 135

lbf/in 2 (9.3 bar) then check the clutch for assembly
defects, especially the clutch pack end float (the shim
may not be to the correct thickness). -test after
checking for (and rectifying) assembly defects.
B
A
S185720
9803/9090 Issue 1
Section 7 Electrics Section 7
i i
Contents Page No.
Solenoid Technical Data

Clutch Control Cartridge Valve 1-1
Hydraulic Lock Up Control Spool Valve 1-3
Solenoid Gear Pairing Selections 1-4
* Gearbox Electrical Components

Parking Brake Switch 2-1
Low Pressure Switch 2-2
Oil Temperature Switch 2-2
Transmission Speed Sensor 2-3
Gearbox Electrical Component Locations 2-3
4 and 6 Speed Column Control lever

Column Control Lever 4 and 6 Speed 3-1
Connector Mounting Details 3-3
4 Speed Standard PS760 Gearbox Relay Control

4 Speed Standard PS760 Gearbox Electrical
Circuit Drawing 4-1
2 Wheel Braking and All Wheel Steer Circuit
Drawing 4-2
4 Speed Standard PS760 Gearbox Harness
Drawing 721/10939 4-3
6 Speed Standard and LUC PS760 Gearbox Electronic

Control Unit 2
General Description ECU 2 5-1
Software Summary 5-2
ECU 2 Input and Output Block Diagram 5-3
Typical Wiring Installation 5-4
6 Speed Standard PS760 Gearbox Harness Drawing
721/10941 5-7
4 and 6 Speed LUC PS760 Gearbox Harness
721/11654 5-8
Gearbox and Harness Connection Kits 5-9
ECU Connection Kits 5 - 10
Communication Leads 5 - 11
Throttle Switch 5 - 12
ShiftMasters Diagnostics
ShiftMaster Diagnostics Software User Guide 6-1
ShiftMaster SetUp
ShiftMaster Setup Software User Guide 7-1
ShiftMaster Flash Programmer

ShiftMaster Flash Programmer User Guide 8-1
PS760 Gearbox Electrical Fault Diagnosis 9-1
9803/9090 Issue 3*
1-1 Solenoid Technical Data 1-1
Clutch Control Cartridge Valve

- JCB Drivetrain 25/220994
Type 3 Way 2 Position
Operating Flow 30 l/min (maximum)
Operating Pressure (nominal) 13.8 Bar
Maximum Operating Pressure 30 Bar
Leakage 0.75 l/min at 71CST viscosity
Fluid Type Oil Grade 10W (JCB Drivetrain Standard 4000/2500)
Oil Grade SAE30W (JCB Drivetrain Standard 4000/2600)
Fluid Cleanliness JCB Standard 9993/0005 Class A
Seals Viton
Waterproof Specification IP6K9K
Coil Operating Specification Nominal 14Vdc (9 - 16Vdc)
Operating Temperature Range
Air -30 ºC to +115 ºC
Oil -40 ºC to +120 ºC
Diode Protection Standard Diode Installed
Deutsch Connector Side Socket 1 is Positive, Socket 2 is Negative
9803/9090 Issue 4
Solenoid Location Diagram for 4 and 6

Speed Valve Blocks
4 Speed PS760 Valve Block
T U W V
4 Sand 6 Speed Letter Designations

T Forward Low
U Forward High
S Y Z
W Reverse Low
V Reverse High
S 4 Wheel Drive
Y Mainshaft
Z Layshaft
X 6th Speed
T U W V

S Y Z X
9803/9090 Issue 1
Hydraulic Lock Up Control Spool Valve -

JCB Drivetrain 25/221760 (if applicable)
Hydraulic Lock Up Clutch Valve
Hydraulic Solenoid Valve 25/221760

Type 5 Way 2 Position
Operating Flow 30 l/min
Operating Pressure (nominal) 13.8 Bar
Maximum Operating Pressure 30 Bar
Leakage 0.75 l/min at 71 CST
Fluid Type Oil Grade 10W (JCB Drivetrain Standard 4000/2500)
Oil Grade SAE30W (JCB Drivetrain Standard 4000/2600)
Fluid Cleanliness JCB Standard 9993/0005 Class A
Seals Viton
Waterproof Specification IP67
Coil Operating Specification Nominal 14Vdc (9 - 16Vdc)
Operating Temperature Range
Air -30 ºC to +115 ºC
Oil -40 ºC to +120 ºC
Diode Protection Standard Diode Installed
Deutsch Connector Side Socket 1 is Positive, Socket 2 is Negative
Solenoid Location Diagram for PS760 Lock Up Clutch

Valve
LUC Solenoid Valve
9803/9090 Issue 4
Solenoid Location Diagram for 4 and 6

Speed Valve Blocks
* Note:In order to select a gear, two clutches must operate

via two solenoids on the PS760 gearbox, gear pairings are
shown below for 4 and 6 speed boxes.
T U W V
4 Speed Power Shift

Clutches Engaged
Gear Forward Reverse
1 T and Z W and Z
2 U and Z V and Z
3 T and Y W and Y
4 U and Y V and Y
S Y Z
4 Speed Power Shift

T U W V
Clutches Engaged
Gear Forward Reverse
1 X and Z W and Z
2 T and Z V and Z
3 U and Z W and Y
4 X and Y V and Y
5 T and Y
6 U and Y
S Y Z X
9803/9090 Issue 2*
2-1 * Gearbox Electrical Components 2-1
* Park Brake Switch

The park brake is an essential safety component and forms
part of ECU 2 park brake interlock circuit. This allows ECU 2
software ShiftMaster Flash programmer and ShiftMaster
SetUp to perform downloads when the machine is in a safe
state. The interlock also provides added protection by
dumping the gearbox into neutral whilst the handbrake is
'on' and alarming if a forward or reverse direction is
selected. A typical installation showing two sensor mounting
positions is shown below and demonstrates that the sensor
is 'made' when the handbrake is applied.
Hand Brake Sensor Example Position 1
Hand Brake Sensor Example Position 2
9803/9090 Issue 2*
2-2 *Gearbox Electrical Components 2-2
Low pressure Switch 701/80459

The gearbox has a low pressure switch which is normally
closed below 40psi to indicate loss of transmission
pressure. The switch contacts are not suitable for driving
ECU 2 inputs directly and normally are connected to the
machines alarm circuits through relays, which require more
current than the ECU input.
Oil Temperature Switch 701/80394

The oil temperature switch mounted on the gearbox is a
normally open type which closes at 110 °C to indicate
gearbox overheating. The switch is usually wired into the
machine's alarm circuits.
9803/9090 Issue 2*
2-3 *Gearbox Electrical Components 2-3
Transmission Speed Sensor 716/30123

The transmission speed sensor monitors the gearbox output
speed and outputs a frequency proportional to transmission
speed. The biasing of the output signal causes the voltage
to float between 2 and 10Vdc. The speed sensor has simple
on board diagnostics which permit the ECU to generate
alarms when fault conditions arise.
Note: 4 speed standard PS760 gearboxes do not normally

have the speed sensor installed.
Gearbox Electrical Component Locations
Oil Temperature Switch

Low Pressure Switch
Speed Sensor
9803/9090 Issue 2*
3-1 4 and 6 Column Control Lever 3-1
Column Control Lever 4 and 6 Speed

The same column lever is used for both 4 and 6 speed
PS760 gearboxes. The 4 speed is usually manually
selectable for each of the four gears. The six speed is
normally programmed to have manual gears in 1st, 2nd and
3rd. Therefore the 4th position usually has automatic
operation for 4th, 5th and 6th gears.
9803/9090 Issue 1
Column Control Lever 4 and 6 Speed

(cont’d)
The diagrams opposite show both a gear switch A and a
multi-function switch B. Item A incorporates a locating pin X
which engages with a drilled hole in the column to ensure
correct location and prevents rotation of the switch
mounting. The two switches are clamped onto the shaft
using two screws D. If item B is not required, mounting
clamp C should be used instead.
The gear switch incorporates a rotary selector for gears 1, 2,

3, 4 and a horn button (or kickdown button).
Forward/Reverse selection is made by lifting the lever out of
its neutral (detent) position and moving it forward (for
forward direction) or back (for reverse direction).
Note: Late versions of the gear selector switch have a 12 pin

plug which provides an explicit neutral signal to the ECU.
Gear Switch Connections Y
12 Pin Plug
1 1st gear
2 2nd gear
3 3rd gear
4 4th gear
6 Horn (for kickdown)
7 Reverse
9 Forward
11 Neutral
12 Feed
Multi-function Switch Connections Z

1 Flasher mode
2 Washer feed
3 High beam
4 Headlamp feed
5 Low beam
6 Wiper park
7 Wash/Wipe load
8 Wiper feed
9 Left turn
10 Right turn
11 Turn signal feed
Deutsche Mating Connector Requirements
Item Deutsche Part No. JCB Part No. Qty.

12 Pin Plug
Housing (12 way) DT06-12S 460/34901 1

Terminal Socket 1062-16-0122
Contact (female) 0462-210-16141 460/34702
Locking Wedge W12S 460/34902 1
Seal Plug 114017 460/34903 6
9803/9090 Issue 4
Connector Mounting Details
A281920
12-Pin Plug Kit

Female Connector (460/34901)
A281950
Sealing Plug 114017 (460/34903)

Plugs are used to seal unused terminal holes
9803/9090 Issue 1
4 Speed Standard PS760 Gearbox Current gearbox economics dictate that the 4 speed
Electrical Circuit Drawing PS760 standard gearbox is controlled by relay logic, 4-1
though this may change in the near future. The
9803/9090
circuit below shows a typical application of the
Guidance only - Typical Circuit Diagram
column lever control using relay logic to drive
Section 7
gearbox solenoids.
Electrics
Section 7
Issue 1
4-1
2 Wheel Braking and All Wheel Steer
Circuit Drawing 4-2
9803/9090
Guidance only - Typical Circuit Diagram The electrical circuit diagram below shows typical
Section 7
4WD electrical diagrams controlled by relay logic for

two modes of operation 2 Wheel Steer (2WS) and All
Wheel Steer (AWS).
Electrics
Section 7
Issue 1
4-2
4-3 4 Speed Standard PS760 Gearbox Relay Control 4-3
4 Speed Standard PS760 Gearbox
Harness Drawing 721/10939
9803/9090 Issue 1
5-1 6 Speed Standard and LUC PS760 Gearbox Electronic Control Unit 2 5-1
General Description ECU 2

The Electronic Control Unit 2 (ECU 2) is used for The following components are required for software testing
microprocessor gearbox control of the 6 speed standard, 4 of ECU 2s:
speed Lock Up Clutch (LUC) and the 6 speed LUC range of
Power Shift gearboxes. ECU control allows features and l Personnel computer / laptop.
parameters setting which are not achievable through l Communications periphery consisting of JCB Drivetrain
conventional relay logic. The primary objectives are; ServiceMaster kit 892/01174.
* l ShiftMaster Diagnostics Software
1 Control the selection of gears and direction. l ShiftMaster SetUp Software
2 Protection of the gear box from damage. * l ShiftMaster Flash Programmer Software
The unit receives signals from the FNR (Forward Neutral
Software distribution is by JCB Drivetrain CD ROM.
Reverse) lever and other cab switches and operates the
corresponding gear solenoid sequences. Software design
prevents potentially damaging gear selections. The control
features provided by the ECU software are listed below.
1 Manual Downshift Inhibit - prevents too low a gear

being selected for a given speed.
2 Automatic Up and Down Gear Shifts - Manufacturer

programmable automatic up and down gear shift limits
or can be programmed as a combination of both
manual and automatic gear shifts.
3 Kickdown - operated by a switch in the cab and

changes down a gear (from 2nd, 3rd or 4th) for a time
period of 1 to 254 seconds, programmed by the
supplier, before reverting to the selected gear.
4 Reversal Inhibit - prevents directional changes if the

speed is too high.
5 Transmission Dump - temporary selection of neutral,

irrespective of gear selection.
6 Control of 4WD - automatic control of 4WD solenoid to

provide 4 wheel braking (when in 2WD) and to switch
out of 4WD at high road speeds to prevent drive line
'wind up' through the use of direct and indirect 4WD
ECU inputs.
7 Control of LUC - automatic control of LUC, when

fitted.
8 Load Mode - ECU 2.2 only - Facilitates operator

selectable shift parameters. When a machine is
operated in high and light load situations the operator
can switch to the most applicable mode. Upto three
sets of shift parameter data can be selected.
8 PC Based Fault Diagnostic Tool - ShiftMaster

Diagnostics is a Windows based fault finding tool.
Machine transmission status can be observed.
Informative graphics allow easy diagnosis of faults.
9 PC Based Setup Tool - Allows uploading /

downloading of pre-configured SetUp files and
observation of parameter settings.
10 PC Based Flash Programmer - ShiftMaster Flash

Programmer is a windows based flash programmer that
permits field uploading of ECU 2 application programs.
9803/9090 Issue 4
5-2 6 Speed Standard and LUC PS760 Gearbox Electronic Control Unit 2 5-2
The microprocessor controlled unit should preferably be ShiftMaster Diagnostics

mounted in the cab area. Connections are made to the ECU
through a Deutsch DRC 24 and 40 way connections. The 40 The main software used for 'in field' gearbox diagnostic
way connection referred to as 'terminal A' which is shown activities for all levels use including OEMs and Service.
below connects to predominately switch inputs including Further details are given in the section on ShiftMaster
FNR lever, kickdown, etc. The 24 way referred to as Diagnostics.
'terminal B' connects to solenoids, gear box oil pressure
switch, and a speed sensor. Note, the ECU connection ShiftMaster SetUp
letter designations are clearly marked on the ECU's casing.
This predominately an OEM tool for observing gearbox
! CAUTION parameters but allowing new setup files to be up and
downloaded as part of the development process with JCB
Each ECU type is factory configured to a specific
Drivetrain prior to the production release process. Further
customer's requirements and may not be transferable
details are given in the section on ShiftMaster SetUp.
between gear boxes. Always consult the OEM or JCB
Drivetrain before transferring ECUs from one machine to
ShiftMaster Flash Programmer
another.
An OEM PC tool with one main objective to download
Software Summary
different versions of the ECU 2 application code under JCB
Drivetrain authorisation. Further details are given in the
The 6 speed standard and LUC PS760 are ECU 2 controlled
section on ShiftMaster Flash Programmer.
gearboxes. For the purposes of this document the software
resident on ECU 2 can be divided into two distinct
programs. The first is the main core application code,
carrying the file extension 'vsf', and defines and maps all the
relationships between the input and output functions of ECU
2. This is core program which should not need to be
changed unless advised by JCB Drivetrain. The second
program is the SetUp file, which carries the file extension
'ets' and may need to be changed during the customer
development process This tailors the application code for
customer machine applications. Once production released
then this file should not be changed unless advised by JCB
Drivetrain. The following three PC Tools software interact
with application code and customer Setup file to give the
user useful data on the gearbox parameters and diagnostics.
TERMINAL A TERMINAL B
9803/9090 Issue 4
ECU 2 Input and Output Block Diagram
5-3
Guidance only - Please refer to OEM Electrical Schematics Note: Kickdown Indicator 5B and Gearshift Load Switch 12A
9803/9090
and 22A is intended for future use.
Section 7
Electrics
6 Speed Standard and LUC PS760 Gearbox Electronic Control Unit 2
Section 7
Issue 1
5-3
Typical Wiring Installation - ECU2 Power
and Relays Terminal A 5-4
9803/9090
Guidance only - Please refer to OEM Electrical Schematics
Section 7
Electrics
Section 7
Issue 1
5-4
and Relays Terminal A 5-5
9803/9090
Section 7
Electrics
Section 7
Issue 2
5-5
and Relays Terminal B 5-6
9803/9090
Section 7
Electrics
Section 7
Issue 2
5-6
Typical Wiring Installation - ECU 2.2 Power
5-7
and Relays Terminal A
9803/9090
Section 7
Electrics
Section 7
Issue 2
5-7
5-8
and Relays Terminal A
9803/9090
Section 7
Electrics
Section 7
Issue 2
5-8
5-9
and Relays Terminal B
9803/9090
Section 7
Electrics
Section 7
Issue 2
5-9
5 - 10 6 Speed Standard and LUC PS760 Gearbox Electronic Control Unit 2 5 - 10
6 Speed Standard PS760 Gearbox Harness Drawing 721/10941
Gearbox Harness Kit 460/90013
9803/9090 Issue 1
4 and 6 Speed Standard PS760 LUC Gearbox Harness Drawing 721/11654
9803/9090 Issue 1
Gearbox and Harness Connection Kits

Note: Drawings are representative and do not show total
quantities of connection kits
Gearbox Speed Sensor
Three Socket Connector Kit 460/90012 - Recommended

Crimping Hand Tool Deutsch HDT-48-00
Item 1 = Housing
Item 2 = Solid Sockets
Item 3 = Retainer
Pressure Switch and Solenoid
Two Socket Connection Kit 460/90011 - Recommended

Crimping Hand Tool Deutsch HDT-48-00
Item 1 = Housing
Item 2 = Solid Sockets
Item 3 = Retainer
Harness 721/10941 and 711/10939
12 Pin Connection Kit 460/90013 - Recommended Crimping

Hand Tool Deutsch HDT-48-00
12 Way DT Plug Blanking Plug

Retainer
Important Note: Pin Connector 1.0 - 2.0 mm2

Pin Connector 0.5 - 1.00 mm2
is used for the ‘common return’ (negative) on
terminal 1 of harness 721/10939 and
721/10941
9803/9090 Issue 1
ECU Connection Kits

1 ECU 24 Way Connector Kit 460/90015 - Recommended
Crimping Hand Tool Deutsch DDT-20-00
Extraction Tool Blanking Plug
DT Sockets
0.5 - 1.00 mm2
24 Way
DT Plug
2 ECU 40 Way Connector Kit 460/90016- Recommended

Crimping Hand Tool Deutsch DDT-20-00
Blanking Plug
Extraction Tool
DT Sockets
0.5 - 1.00 mm2
40 Way
DT Plug
3 ECU Diagnostic Connector Kit 460/90014 -

Recommended Crimping Hand Tool Deutsch HDT-48-00
9 Way HD Plug
Connector Cover
Extraction Tool
Blanking Plug
Pin - 0.5 - 1.00 m2
9803/9090 Issue 1
Communications Leads
In order to communicate with ECU 2 the following separate
components are necessary:
JCB Drivetrain Service Master Kit 892/01174
This consists of a Data Link Adapter (DLA) and three

communications leads, serial PC's ports 9 way D-type
connector, PC USB connector and DLA to Diagnostics
connector.
OEM Harness Connector
In order to connect with the above diagnostic J1939 lead

(ITEM 4) the OEM harness must terminate with the following
Deutsch components
Note: The JCB Drivetrain part number for this kit, of parts
listed below is 460/90014.
Quantities Deutsch Part Number Description
1 HD10-9-1939PE 9 Way HD10 Connector with Flange
5 0460-202-16141 Pins
6 114017 Cavity Blank Seal
1 0411-204-1605 Extraction Tool
1 HDC16-9 HD Protective Cover
Important Note: The OEM must fit two 120 Ohms resistors
at both extremes of the wiring which form the two
communication wires, see electrical installation drawings.
One resistor should be near to the ECU2 connections across
terminals 6A and 16A and the other close to the diagnostics
connection across terminals D and C. Problems with
establishing communications will result without resistors. A
typical OEM arrangement is to fit the resistors into a plug to
give a level of physical protection, see diagram.
9803/9090 Issue 4
Throttle Switch 701/15400

A throttle switch is required to be installed if ECU 2 auto
gear shifting function is to be utilised on six speed
gearboxes. The throttle switch prevents unintentional
automatic up shifts if the machine, for example, is travelling
down hill.
9803/9090 Issue 1
6-1 ShiftMaster Diagnostics 2.2 - User Guide 6 - 1
Shiftmaster Diagnostics - User Guide
Introduction Care and Safety
The ShiftMaster Diagnostics software tool is part of the

JCB Service Master software suite. The diagnostics
!MWARNING
software is designed to be an easy to use fault finding tool Be sure to read and follow any on screen instructions.
for PS760 electronically controlled gearboxes. Failure to follow correct procedure could result in
death or injury.
Shiftmaster Diagnostics employs the graphical strengths 2-4-5-5
of the Microsoft Windows operating environment to
simplify electrical fault finding within the gearbox ECU
control system.
Shiftmaster Diagnostics is only intended for use with

ECU 2 and ECU 2.2 controlled PS760 gearboxes. The
system is not compatible with relay controlled gearboxes.
Older versions of Powershift Controllers used on the
PS750 series gearboxes are not supported.
This software is intended for use on IBM Compatible

Personal Computers (PCs) running Windows 9x,
Windows2000 and WindowsXP operating systems but is
not compatible with either earlier versions of Windows 3.x.
Ideally the computer should be a laptop type.
Fig 1.
9803/9090 Issue 4
Installing Shiftmaster Diagnostics
The Shiftmaster Diagnostics tool is fully integrated within

JCB ServiceMaster. To use ShiftMaster diagnostics you
must install JCB Service Master onto a suitable laptop
computer.
For full instructions on how to install JCB Service Master

software please refer to the documentation which
accompanies JCB Service Master.
9803/9090 Issue 4
Connecting Shiftmaster Diagnostics 1 Connect either the 'Serial PC Cable' 2B (718/20236)

or the 'USB PC Cable' 2A (718/20235) between the
To use ShiftMaster Diagnostics your laptop computer must DLA 2C and a free port on your laptop computer.
be connected to the machine transmission ECU
diagnostics connector K Fig 3. ( T 6-3). Connection is a The 'Serial PC cable' has a 9-way D-type
made using Diagnostic Link Adapter (DLA) 2C and the connector on one end and a 25-Way D-type
applicable cables. connector on the other. Plug the 25-way male
connector into the DLA and the other connector
into a free port on your laptop PC, remembering to
tighten any thumb-screws appropriately.
A
D
C025170
Fig 3.
2 Connect the 'Machine Cable' 2D between the DLA

and the machines' Diagnostic Connector 3A. The
C 'Machine Cable' has a 15-way D-type connector on
one end and a 9-way CAN connector on the other.
Plug the 15-way connector into the DLA and tighten
the thumb-screws, then connect the 9-way CAN
connector into the machines' Diagnostics Connector
3A and twist the lock-ring to secure it.
A B
Fig 2.
Table 1. Component Key

Kit Includes items A,B,C and D 892/01174
A USB PC Cable 718/20235
B Serial PC Cable 718/20236
C USB DLA 728/26500
D Machine Cable 718/20237
9803/9090 Issue 2
Starting Shiftmaster Diagnostics
1 Turn ON the machine ignition and additionally start

the engine if required (taking normal precautions).
2 Start JCB Service Master on the laptop computer.

Fig 6.
5 Warning message appears K Fig 7. ( T 6-4). Read

and understand the Warning message. If you can
comply with the requirements press the ‘Accept’
button.
Fig 4.
3 Make sure that the correct DLA is selected in the

chooser. Click on ‘Utilities’, DLA Setup. The DLA
Chooser window opens. Check the button to match to
the Current Device. Click ‘Apply’ K Fig 5. ( T 6-4).
Fig 7.
6 The Shiftmaster Diagnostics tool will then open up

displaying the main window K Fig 8. ( T 6-4).
Fig 5.
4 Select ‘PS760’ from the drop down list K Fig

4. ( T 6-4) and then start the diagnostics tool running
by clicking on the ShiftMaster Diagnostics icon
K Fig 6. ( T 6-4).
Fig 8.
9803/9090 Issue 2
Shiftmaster Diagnostics Overview
There are several key elements to the Diagnostics tool.

These can be seen labelled below. Each element is
explained in detail in later sections.
Fig 9.
Key:
1 Menu Bar K ( T 6-6) 8 Solenoid Test Mode Page K ( T 6-17)
2 Start and Stop Buttons K ( T 6-9) 9 Solenoid Identification Page K ( T 6-18)
3 Main Window 10 ECU Block Diagram Page K ( T 6-18)
4 ECU Setup Page K ( T 6-11) 11 Page List(1)
5 Dashboard Page K ( T 6-12) 12 LED Status Key K ( T 6-13)

6 ECU Status Page K ( T 6-13) 13 Page Display Area
7 LUC Page(2) K ( T 6-15) 14 Status Bar K ( T 6-10)
(1) The page list is differs depending on the type of ECU connected (ECU 2 or ECU 2.2)
(2) Lock up torque converter page. Some gearboxes are not fitted with a lock up torque converter. The diagnostics
software always displays the page even if it is not applicable.
9803/9090 Issue 2
Navigating within Shiftmaster Diagnostics Menu Bar - File Menu
Navigation is designed to be via a mouse. On Laptop PCs The File Menu contains an Exit option to close down the
this may take the form of a small joystick or touch sensitive program K Fig 10. ( T 6-6).
pad and some buttons, usually located near to the
keyboard.
As with most Windows based programs, it is possible to

navigate the Shiftmaster Diagnostics software using the
keyboard by pressing certain combinations of keys.
Note: This can be particularly useful for certain Laptop

computers where the mouse/joystick can be over-
sensitive. Try out the following, it may come in useful one
day.
There are two main methods of navigation described

below;
– Pressing the ALT key will cause the File option on the
Menu Bar to be highlighted. You can then use the Fig 10.
arrow keys to navigate the menus.
– Notice that all the menu items on the Menu Bar have On exiting the program communications with both ECU
a letter that is underlined (e.g. the 'F' in File). Holding and DLA are shut down.
down the ALT key and pressing the required letter key
will activate that option (i.e. either open the menu or
execute a function). For example, if you wish to open
the Preferences Dialogue this can be done by
pressing ALT + O (to open the Options menu) then
ALT + P (to execute the Preferences option).
9803/9090 Issue 2
Menu Bar - Options Menu
Fig 11.
– Start Diagnostics to commence communications
Fig 13.
with the ShiftMaster ECU K Fig 11. ( T 6-7).
– Preferences option opens up the Preference
– Stop Diagnostics to cease communications K Fig
Dialogue K Fig 13. ( T 6-7).
11. ( T 6-7).
Fig 14.
Fig 12.
– From the Preferences Dialogue there is support for
– Road Speed Settings (ECU 2.2 only) Opens up the multiple languages. Use the drop-down menu and
Road Speed Settings window K Fig 12. ( T 6-7). scroll bar to chose the required language K Fig
– Press the ‘Load’ button to upload the data from the 14. ( T 6-7). Languages presently on offer are
ECU – English (Canada)
– If the rolling radius of the wheel has been changed – English (United Kingdom)
(due to a tyre fitment change for example) input the
– French (France)
rolling radius and the associated axle ratio.
– German (Germany)
– To change the speed units displayed by the
diagnostics software check the required button on – Italian (Italy)
The Display Units panel. – Portuguese (Portugal)
– Press the ‘OK’ button to save the settings and close – Spanish (International Sort)
the window.
Note: The language option only effects text within the Main
Window (e.g. Page List, LED Status Key, etc). Language
9803/9090 Issue 2
support is not available for the text within the page Menu Bar - Window Menu
displays.
K Fig 16. ( T 6-8)
.
Fig 15.
– The Preferences Dialogue also offers the ability to
change the background colour of the Page displays.
Select the required background colour using the radio
buttons K Fig 15. ( T 6-8).
Note: When using a laptop PC it can often be difficult to Fig 16.

see the screen in bright sunlight. Changing the
background colour can help improve the contrast Like most other Windows based programs where there are
(especially with the different LED colours) and so make multiple sub-windows or Pages used, there are usually
viewing the screen easier. options to organise how they are laid-out. ShiftMaster
Diagnostics software is no different and offers the following
Once your preferences have been selected either: options;
Click on the OK button to apply them or click on the Cancel – Cascade

button to leave them unchanged. – Tile Horizontally
– Tile Vertically
9803/9090 Issue 2
Menu Bar - Help Menu Start and Stop Buttons
K Fig 17. ( T 6-9) These offer the same function as the Start Diagnostics
and Stop Diagnostics options within the Options Menu.To
start the Diagnostics tool communicating with the
gearbox ECU simply click on the Start Button (large green
LED) at the top of the Main Window.Similarly, click on the
Stop Button (large red LED) to cease communications
K Fig 19. ( T 6-9).
Fig 17.
– About: Opens a window showing the part number Fig 19.
and the version number of the installed copy of the
Diagnostics software K Fig 18. ( T 6-9).
Fig 18.
9803/9090 Issue 2
6 - 10 ShiftMaster Diagnostics 2.2 - User Guide 6 - 10
Page List Status bar
In the top left corner of the main window is displayed a list There are 2 items of interest displayed on the Status Bar,
of pages which can be displayed K Fig 20. ( T 6-10). which is located along the bottom of the Diagnostics main
window.
Note: The page list is differs depending on the type of ECU
connected (ECU 2 or ECU 2.2). Connected ECU: The type of ECU connected to the
Diagnostics tool is indicated on the far left side of the
Status bar K Fig 21. ( T 6-10).
Fig 21.
CAN communications: Two small LEDs indicate data

being transmitted (red) and received (green) over the CAN
communications link K Fig 22. ( T 6-10).
Fig 22.
Fig 20. These LEDs can be seen to be flashing rapidly as data is

transported. This can be another useful aid to determining
Clicking in the box next to the required page will make that the state of any established communications.
page appear in the main window display area. (A tick will
also appear in the box to show it is being displayed.) At any
time the user may swap between displayed pages simply
by clicking in the check box of the required page in the
page list. The function keys, F2, F3 etc. can also be used
to select pages as required.
9803/9090 Issue 2
ECU Setup Page Hardware Version: This hardware version is a reference

to the build level of the electronics. Future developments
This page displays crucial information about the ECU may mean that hardware upgrades are required. This may
configuration K Fig 23. ( T 6-11). effect which software can be used.
Software Version: The software version refers to the

issue level of the ECU operating software. Again, future
developments may require software revisions.
Fig 23.
It is always useful to confirm that this is the correct

configuration for the machine before commencing any fault
finding.
The ECU Setup Page displays the following information;
ECU Setup Description: As well as its' operating

software, the gearbox ECU also stores a group of Setup
Data (or Settings). This Setup Data is used to tailor how a
certain ECU part number functions. The Setup Data is
loaded during the manufacturing process and has been
approved for use in the intended application.
Contained as part of the Setup Data is a Description. This

Description is what is displayed here. The engineer can
use this description to verify that the correct Setup Data is
being used.
The ShiftMaster Setup software tool is designed to view

current setup data. In certain circumstances the tool can
also be used to up load ,or down load, a setup file from and
to the ECU. See ShiftMaster Setup 2.2, User Guide.
Application Code Part Number: During normal

operation the application code is displayed. If there are
communications errors present then this will contain either:
a). 'NO DLA COMMS' if there are problems

communication with the DLA, or
b). 'NO ECU COMMS' if the DLA is working but the

ShiftMaster ECU is not responding.
Note: If communications problems are suspected then

please consult the accompanying Troubleshooting Guide
for further information.
9803/9090 Issue 2
Dashboard Page
K Fig 24. ( T 6-12)
Fig 24.
– Requested Gear: This is the demand from the
opertor.
– Selected Gear: This is the actual gear being selected
by the ECU.
Note: The driver Request Gear is not always the same as

the Selected Gear, e.g. when the ECU blocks shifts when
offering protection.
– Transmission Speed: This is the current

transmission output speed which is directly related to
the road speed (through axle ratio and tyre size). The
transmission speed sensor is located next to the
output gear and detects the passing of the gear teeth.
The sensor has a fixed installation, no adjustment is
necessary. This signal is used by the ECU to
determine gear-shifting and protection strategies.
– ECU 2.2 only. The speed may be displayed as a
frequency value or, alternatively, road speed in MPH
or KPH. Use the Options Menu, Road speed Settings
to select the required units. K Menu Bar - Options
Menu ( T 6-7).
9803/9090 Issue 2
ECU Status Page Gears
This page gives a detailed picture of how the ECU is – Inputs: The items on the left show the signal lines
operating. connected to the gear selection lever. This lever if the
left hand half of the control lever assembly mounted
on the steering column. The input status is indicated
by a coloured LED, grey - input OFF, green - input
ON.
– Outputs: The items on the right are the power
outputs to the transmission solenoid valves. The
output status is indicated by a coloured LED, grey -
output OFF, red - output ON (solenoid energised).
The ECU and Diagnostics software proactively scans
the solenoids for electrical open and short circuits. In
the event of a circuit problem the corresponding
solenoid output LED will be coloured yellow when
ON, or blue when OFF.
Note: During certain gear-shifts the gearbox ECU will

perform electrical Modulation to improve gear-shift
quality. The ECU does this by adding delays to off-going
and/or on-coming clutches and so overlapping energised
outputs. These delays are in the order of a few hundred
milli-seconds but it is sometimes long enough to be
observed on the status LEDs. Thus, during certain shifts it
Fig 25. is quite normal to observe more than 2 outputs ON at any
one time.
Information in this display is constantly updated in real-
time. The status of the ECU electrical inputs and outputs is 4WD
displayed using simulated LED’s. The LED’s change
colour depending on the status of the inputs and outputs. – Direct 4WD: An ECU input which is usually derived
A key in the bottom left corner of the main window explains from the machine footbrake switch (which also
the colours. controls the brake lights). Whenever this signal is
present the 4WD Solenoid output is energised.
– Indirect 4WD: An ECU input which is usually derived
from a command from a console mounted '4WD
selector' switch. (However, this switch arrangement
may change between machines.)
– 4WD Solenoid (Bank 2): An ECU output to the
transmission 4WD solenoid. The output status is
indicated by a coloured LED, grey - output OFF, red -
output ON (solenoid energised). The ECU and
Diagnostics software proactively scans the solenoids
for electrical open and short circuits. In the event of a
Fig 26. circuit problem the corresponding solenoid output
LED will be coloured yellow when ON, or blue when
The following is a brief explanation of each feature. OFF.
– 4WD Configuration: Depending on the type of 4WD
Transmission Speed clutch fitted 4wheel drive OR 2 wheel drive may be
selected when the ‘4WD’ solenoid is energised. The
This is exactly the same signal as explained in the previous
section.
9803/9090 Issue 2
clutch may be a ‘Spring Applied’ or ‘Pressure – Bit 0: An ECU input signal derived from a mode
Applied’ type. selection switch.
– 4WD Status: Indicates if 4WD is ‘Engaged’ or – Bit 1: An ECU input signal derived from a mode
‘Disengaged’. selection switch.
– Set #: Indicates the transmission shift pattern data
Misc Inputs sets selected. There can be upto three different data
set combinations selected by the ECU depending on
These inputs are derived from the remaining driver the combination of inputs at Bit 0 and Bit 1.
controls. The input status is indicated by a coloured LED,
grey - input OFF, green - input ON. Note: The shift pattern data sets can be viewed using the
ShiftMaster Setup software tool. See ShiftMaster Setup
– Handbrake Switch: Signal derived from the 2.2, User Guide
Parkbrake switch. Used to hold the transmission in
Neutral if the parkbrake is applied.These inputs are
derived from the remaining driver controls.
– Handbrake Switch: Signal derived from the
Parkbrake switch. Used to hold the transmission in
Neutral if the parkbrake is applied.
– Dump Switch: (or Transmission Disconnect) Signal
usually derived from a momentary switch.
Temporarily selects Neutral when pressed (usually to
divert engine power to hydraulics).
– Throttle Switch: Signal derived from a switch fitted
to the machine throttle pedal. Used to interact with the
Automatic Mode of gear-shifting.
– Pressure Switch: Signal derived from the
transmission mounted Low Oil Pressure Switch.
– Kickdown Switch: Signal derived from a momentary
button used to temporarily select the next lowest
gear.
Misc Outputs
These are the additional ECU outputs, generally used to

control cab instrumentation such as a Driver Indicator
(lamp and buzzer where fitted), low Oil Pressure Lamp
and Kickdown Indicator. The output status is indicated by
a coloured LED, grey - output OFF, red - output ON.
Load Mode (ECU 2.2 only)
The transmission can be configured to change shift

patterns depending on a machine mode of operation. For
example the machine may be operated towing a laden or
unladen trailer. For optimum performance the operator
selects a the appropriate transmission mode using a cab
mounted switch.
9803/9090 Issue 2
Torque Converter Lock Up (TCLU) Page
The TCLU control page displays information relating to the

torque converter lock up operation K Fig 27. ( T 6-15).
3 8
11
10
9
2
12 13 4 14
Fig 27.
Key 8 Lock up clutch solenoid valve symbol
1 Engine speed sensor 9 Engine speed - lock up clutch ÒFF' value
2 Engine speed r.p.m. (real time) 10 Engine speed - lock up clutch ÒN' value
3 Engine speed sensor input status LED 11 Lock up clutch system àctive' or ìnactive'
4 Transmission output speed sensor 12 Reference value - engine, transmission speed
differential
5 Transmission speed r.p.m. (real time)
13 Engine, transmission speed differential (real time)
6 Transmission speed sensor input status LED
14 Current gear selected
7 Lock up clutch solenoid status LED
9803/9090 Issue 2
For operation of the lock up clutch two speed references
are required by the E.C.U. 2 4 3
Engine speed (n/min) is read from the input side of the
transmission. The engine speed input is connected to the
E.C.U. (pin 31A) and a green input LED 27-3 indicates the
signal satus.
Fig 28.
Transmission output speed is taken from the same signal

source described in Dashboard K Dashboard
Page ( T 6-12). The transmission output speed is
connected to the E.C.U. (pin 03B) and a green input LED
27-6 indicates the signal status. 1
Two padlock symbols can be seen above the engine speed Fig 30.
display. The locked padlock indicates the speed at which
the lock up clutch (LUC) is switched ÒN' and the unlocked The central graphic 27-8 attached to E.C.U. output 01B
padlock indicates when the LUC is switched ÒFF'. depicts the lock up clutch solenoid. The red LED 27-7
indicates its status. Reference in brackets 27-11 displays
as (active) if the gear selected is valid for LUC operation,
or (inactive) if gear selected is not valid. The current gear
selected is shown under the label `Gear'.
A maximum differential speed reference value 27-12 is

indicated next to a padlock symbol. If all the other
Fig 29. interlocks are observed and the differential speed 27-13 is
below that of the reference value, in this case 360 then the
The circular graphic represents the torque converter and LUC is enabled.
its elements K Fig 30. ( T 6-16).
1 Stator
2 Turbine
3 Impellar
4 Lock up clutch
Real time engine and transmission output speed are also

displayed on the graphic K Fig 27. ( T 6-15).
9803/9090 Issue 2
Solenoid Test Mode Page (ECU 2.2 only)
Fig 31.
The Solenoid Test Mode page allows testing of each with the test mode the Start/Stop button is disabled
transmission solenoid individually. Since gear selection and ‘NOT ALLOWED’ is displayed.
always requires two solenoid valves to be energised the – To test a solenoid: If tests are being carried out with
tests can be carried out with the transmission in neutral. the engine running, make sure that the drive shafts
For electrical tests the engine does not have to be running. are disconnected at the gearbox. Click the
For hydraulic clutch pressure testing the engine must be appropriate button using the mouse. The ECU is
running, before using the Test Mode facility disconnect the ‘forced’ to output power to the selected solenoid. The
drive shafts at the gearbox. output status is indicated by a coloured LED, grey -
output OFF, red - output ON (solenoid energised).
Important: It is possible that the gearbox may have The ECU and Diagnostics software proactively scans
developed a fault causing a clutch to be permanently the solenoids for electrical open and short circuits. In
engaged. If a second clutch is engaged ( by using the Test the event of a circuit problem the corresponding
Mode facility for instance) the gearbox will engage a gear solenoid output LED will be coloured yellow when
unexpectantly. Before using the Test Mode facility ON, or blue when OFF.
disconnect the drive shafts at the gearbox.
– To test the Driver Indicator: Click the appropriate
button using the mouse. While the button is held
– Initial Conditions: To enable the test mode the
down the ECU is ‘forced’ to output power to the
handbrake must be ON, the FNR lever set to
indicator and or warning divices. The output status is
NEUTRAL and the road speed must be ZERO. The
indicated by a coloured LED, grey - output OFF, red -
conditions are displayed in the Initial Conditions
output ON. If the devices are working they will
panel.
illuminate and, or sound, as applicable.
– Start/Stop Button: Press the button to toggle the test
mode either on or off as required. ‘TEST MODE Note: If the test mode is not enabled make sure that the
READY’ or ‘TEST MODE ACTIVE’ is displayed as START button is pressed (large green ‘LED’ at the top left
applicable. If the initial conditions are not compatible corner of the screen).
9803/9090 Issue 2
Solenoid Identification Page (ECU 2.2 only) ECU Block Diagram Page (ECU 2.2 only)
The solenoid identification page is for reference only K Fig The solenoid identification page is for reference only K Fig
32. ( T 6-18). 33. ( T 6-18).
Fig 33.
Fig 32.
9803/9090 Issue 2
Connection Problems
In general, whenever there are problems communicating

with the DLA there will be an error message displayed.The
following section although not exhaustive attempts to
identify the more common of ECU communication
problems.
ShiftMaster PC Service Tools must use the authorised Fig 35.

Data Link Adaptor (DLA) contained in the Electronic
Service Tool Kit. The latest versions of both the hardware The second is generated when no communications can be
and software can be obtained through authorised established with the DLA and the ECU usually through a
suppliers. ShiftMaster software has been designed to run hardware problem. No power supply from the vehicle
on the Windows 9.X, Windows 2000 and Windows XP indicated by the DLA’s power LED will display the ’NO ECU
operating systems. COMMS’ message. K Fig 36. ( T 6-19). Another source
could be related to resistance of the two data
A number of reasons can generate software problems and communication wires making up the machine’s harness for
assistance from an Information Technology engineer is the ECU’s CAN connection to the Deutsch 9 way round
advised. In particular, laptop PCs can suffer serial diagnostic connector. The wiring must have two 120 Ohm
communications conflicts were the PC hardware does not resistors fitted to either end of this run of cable to give a 60
allow the Diagnostic software access to the Ohm impedance. If the impedance is incorrect then ‘No
communication ports. In the majority of cases conflicts are ECU Comms message will displayed. K Fig 36. ( T 6-19)
caused by either software already running on the PC, or by
certain 'driver' files not releasing the COM port(s).
The PC Service Tools for example ShiftMaster Diagnostics

indicate the existence of an ECU communication problem
that can reside in two areas indicated in the type of
displayed error message. The first message is generated
when the problem exists between the PC and DLA then the
‘Error Connecting to DLA’ will be displayed. K Fig
34. ( T 6-19) Fig 36.
Note: The ECU must be powered for communications to

work, i.e. the machine ignition must be ON (but the engine
need not be running).
If a problem is experienced it can take one of three forms,

a constant failure to establish communications, drop out
Fig 34. during communications or intermittent communication
connection. However, the source has a tendency to be of
Confirmation of this error can be found in the ‘ECU Setup the ‘No DLA Comms’ type and thus related to the user’s
Page’ with ’NO DLA COMMS’ being displayed in the PC. Contributory factors to communication errors could be
‘Application Code Part Number’ box. K Fig 35. ( T 6-19) related to the following items:
– DLA Drivers. The DLA and PC are programmed with

software ‘drivers’ which handle communications.
Ensuring the latest drivers are installed on the PC and
DLA contained on the latest version of ServiceMaster
– PC Power Management. Previous experiences have
shown that some laptops’ Power Management
software can disrupt the COM ports. Turning of the
9803/9090 Issue 2
power management software may resolve the General Information
problem.
– IR Drivers. If the PC has an InfraRed (IR) For all enquiries about the Shiftmaster Diagnostics tool
communications port then disabling the driver may please follow your normal channels of enquiry. This
help. ensures that useful information can filter through to JCB
Drivetrain personnel at all levels.
– Modem Drivers. Modem drivers could cause
communication conflicts and temporary disabling to
establish if the software is conflicting with the port
may establish this source.
If the aforementioned information fails to resolve the

situation then the following contacts may be able to provide
further assistance;
– Information Technology (IT) engineer.

– Authorised machine dealer or agent.
– Machine OEM. The Original Equipment Manufacturer
(OEM) will make the relevant enquires.
9803/9090 Issue 4
7-1 ShiftMaster Setup 2.2 - User Guide 7 - 1
Shiftmaster Setup 2.2 - User Guide
Introduction – Download a Setup data file (.ets) from a transmission

ECU to a laptop computer and view the data.
The ShiftMaster Setup software tool is part of the JCB – Open a Setup data file (.ets) stored on a computer
Service Master software suite. and view the data.
– Upload a Setup data file (.ets) to the flash memory of
Shiftmaster Setup employs the graphical strengths of the
a transmission ECU.
Microsoft Windows operating environment to
communicate with the gearbox ECU control system used – View a Setup file description.
on Powershift PS760 series gearboxes.
For service engineers it can be useful to view setup file
ShiftMaster 2 transmission ECU features 2 programs data when fault finding. From time to time a new setup file
stored stored in a flash memory. may be made available to improve machine performance.
ShiftMaster Setup enables loading of the new file to the
– The first is the main core application code and carries ECU.
the file extension .vsf. This file defines and maps all
the relationships between ihe input and output For OEM (original equipment manufacturers) the data
functions of the ECU. During normal service this file pages enable development engineers to analyise the shift
does not need to be changed. combinations and request revised settings to suit a given
transmission application.
– The second program is the Setup file and carries the
extension .ets. The Setup file is used to tailor variable
Shiftmaster Setup is only intended for use with ECU 2
parameters in the application code to configure
and ECU 2.2 controlled PS760 gearboxes. The system is
gearbox shift parameters for use in different
not compatible with relay controlled gearboxes. Older
machines.
versions of Powershift Controllers used on the PS750
series gearboxes are not supported.
Shiftmaster Setup software is a service tool designed to
enable the following:
9803/9090 Issue 4
The software is intended for use on IBM Compatible Care and Safety
Personal Computers (PCs) running Windows 9x,
Windows2000 and WindowsXP operating systems but is
not compatible with either earlier versions of Windows 3.x. !MWARNING
Ideally the computer should be a laptop type. Be sure to read and follow any on screen instructions.
Failure to follow correct procedure could result in
death or injury.
2-4-5-5
Fig 1.
9803/9090 Issue 2
Installing Shiftmaster Setup
The Shiftmaster Setup tool is fully integrated within JCB

ServiceMaster. To use ShiftMaster Setup you must install
JCB Service Master onto a suitable laptop computer.
For full instructions on how to install JCB Service Master

software please refer to the documentation which
accompanies JCB Service Master.
9803/9090 Issue 4
Connecting Shiftmaster Setup 1 Connect either the 'Serial PC Cable' 2B (718/20236)

or the 'USB PC Cable' 2A (718/20235) between the
To use ShiftMaster Setup your laptop computer must be DLA 2C and a free port on your laptop computer.
connected to the machine transmission ECU diagnostics
connector K Fig 3. ( T 7-4). Connection is made using a The 'Serial PC cable' has a 9-way D-type
Diagnostic Link Adapter (DLA) 2C and the applicable connector on one end and a 25-Way D-type
cables. connector on the other.Plug the 25-way male
connector into the DLA and the other connector
into a free port on your laptop PC, remembering to
tighten any thumb-screws appropriately.
A
D
C025170
Fig 3.
2 Connect the 'Machine Cable' 2D between the DLA

and the machines' Diagnostic Connector 3A. The
C 'Machine Cable' has a 15-way D-type connector on
one end and a 9-way CAN connector on the other.
Plug the 15-way connector into the DLA and tighten
the thumb-screws, then connect the 9-way CAN
connector into the machines' Diagnostics Connector
3A and twist the lock-ring to secure it.
A B
Fig 2.
Table 1. Component Key

Kit Includes items A,B,C and D 892/01174
A USB PC Cable 718/20235
B Serial PC Cable 718/20236
C USB DLA 728/26500
D Machine Cable 718/20237
9803/9090 Issue 2
Starting Shiftmaster Setup
1 Turn ON the machine ignition.
2 Start JCB Service Master on the laptop computer.

Fig 6.
5 Warning message appears K Fig 7. ( T 7-5). Read

and understand the warning message. If you can
comply with the requirements press the ‘Accept’
button.
Fig 4.
3 Make sure that the correct DLA is selected in the

chooser. Click on ‘Utilities’, DLA Setup. The DLA
Chooser window opens. Check the button to match to
the Current Device. Click ‘Apply’ K Fig 5. ( T 7-5).
Fig 7.
6 The Shiftmaster Setup tool will then open up

displaying the main window K Fig 8. ( T 7-6).
Note: No setup file is displayed until a setup file is

uploaded to the setup software. The file can be uploaded
from a transmission ECU or from a remote computer
location.
Fig 5.
4 Select ‘PS760’ from the drop down list K Fig

4. ( T 7-5) and then start the software tool running by
clicking on the ShiftMaster Setup icon K Fig
6. ( T 7-5).
9803/9090 Issue 4
Fig 8.
If ShiftMaster Setup cannot be started successfully see

K Connection Problems ( T 7-28).
9803/9090 Issue 2
Shiftmaster Setup Overview
The setup main window allows the user to view setup file
data for each parameter by clicking on the applicable page
tab.
2
1
3
4
5
Fig 9.
Key:
1 Menu Bar
2 Title Bar
3 Page Tabs
4 Page Details
5 Progress Indicator
9803/9090 Issue 2
Menu Bar - File
K Fig 10. ( T 7-8).
Fig 10.
– Open : Opens a setup data file. K Open a Setup
File ( T 7-13).
– Save : Saves the current setup data as a setup data
file.
– Save As : Saves the currently open data file as
another file.
– Exit : To close down the program.
9803/9090 Issue 2
Menu Bar - Tools Click on the OK button to apply them or click on the Cancel
button to leave them unchanged.
Fig 11.
– Upload Setup Data to ECU : Used to copy the
opened setup file into the ECU flash memory.
K Upload Setup Data to ECU ( T 7-12).
– Download Setup Data from ECU : Used to retrieve
setup data from an ECU. K Download Setup Data
from ECU ( T 7-11).
Fig 12.
– Preferences option opens up the Preference
Dialogue K Fig 12. ( T 7-9).
– Select Language : Use the drop-down menu and
scroll bar to select the required language.
– English (Canada)
– English (United Kingdom)
– French (France)
– German (Germany)
– Italian (Italy)
– Portuguese (Portugal)
– Spanish (International Sort)
Once your preferences have been selected either:
9803/9090 Issue 2
7 - 10 ShiftMaster Setup 2.2 - User Guide 7 - 10
Menu Bar - Help
– Opens a window showing the part number and the

version number of the installed copy of the
ShiftMaster Setup software.
Fig 13.
9803/9090 Issue 2
Download Setup Data from ECU
Before ECU setup data can be viewed the set up file must
be downloaded to the connected PC using the ShiftMaster
Setup software.
1 Turn ON the machine ignition. Do not start the engine.
Fig 17.
6 The setup file data can now be viewed.
7 If required save a copy of the setup file to a computer

location. This enables viewing of the data at a later
date without the need to connect to the transmission
Fig 14. ECU. Use the Save As option from the file menu. A
setup file with the extension .ets is created.
2 Select Tools from the menu bar followed by
Download Setup Data from ECU. K Fig Note: The dowload function does not remove the setup file
14. ( T 7-11) from the ECU. The setup file data is copied to the Setup
software.
If Setup Data cannot be downloaded successfully see

Fig 15.
3 If a setup file has been loaded previously a confirm

message is displayed. Click Yes to overwrite the
current data. K Fig 15. ( T 7-11)
4 ShiftMaster Setup will down load the setup file. The

progress bar appears at the bottom of the window.
K Fig 16. ( T 6-8)
Fig 16.
5 If the download was successful a message is

displayed. Click OK to continue. K Fig 17. ( T 7-11)
9803/9090 Issue 2
Upload Setup Data to ECU
Note: When a new setup file is uploaded to the ECU the

original file is erased. If necessary download the existing
data and make a copy setup file before uploading a new
file. K Download Setup Data from ECU ( T 7-11)
2 Apply the machine parkbrake. Set the FNR lever to

neutral.
Fig 20.
6 A confirmation message appears. Read and

understand the message. If you can comply click the
OK button to proceed. K Fig 21. ( T 7-12)
Fig 18.
3 Open the required setup file. Select File and Open

from the menu bar. The Open window appears.
Navigate to the location of the required setup file Fig 21.
(.ets). Double click on the file to open it into
Shiftmaster Setup. K Fig 18. ( T 7-12) 7 ShiftMaster Setup will now upload the setup file to the
ECU. The progress bar appears at the bottom of the
window. K Fig 22. ( T 7-12)
Fig 22.
Fig 19.
8 When the upload is complete a message is displayed.
4 Shiftmaster Setup software is now ready to upload Click OK. K Fig 23. ( T 7-12)
the setup file to the ECU. Select Tools and Upload
Setup Data to ECU from the menu bar. K Fig
19. ( T 7-12)
5 A warning message appears. Read and understand

the warning. If you can comply click the Accept button
to proceed. K Fig 20. ( T 7-12)
Fig 23.
If Setup Data cannot be uploaded successfully see

9803/9090 Issue 2
Open a Setup File Setup File Description
You can open and view setup files (.ets) stored on a In certain circumstances service personnel will require
computer using ShiftMaster Setup software. The PC does information about the Setup file loaded on the transmission
not need to be connected to a transmission ECU. ECU.
Note: The Setup file description can also be accessed

using the ShiftMaster Diagnostics software. Shiftmaster
Diagnostics - User Guide, ECU Setup Page.
1 Connect the PC to the ECU and start the Shiftmaster

Setup software.
3 Download Setup data from the ECU. K Download

Setup Data from ECU ( T 7-11).
Fig 24.
4 The description appears on the Machine Setup page
1 Open the required setup file. Select File and Open
in the Setup Description window K Fig 25. ( T 7-13).
from the menu bar. The Open window appears. You can copy and paste the description using your PC
Navigate to the location of the required setup file or alternatively, copy by hand. The Set-up Description
(ets). Double click on the file to open it into contains part numbers and codes. K Machine
Shiftmaster Setup. K Fig 24. ( T 7-13) Setup ( T 7-15)
2 The setup file data can now be viewed.
Fig 25.
9803/9090 Issue 2
Data Pages
The data pages display all the parameters in the loaded

setup file. The parameters determine the gearbox shift
characteristics. The relevant data page is displayed by
clicking on its tab.
For service engineers the data pages can assist in fault

finding. Shift combinations can be seen for all operating
parameters. By analysing the data it is possible to confirm
gearbox shift characteristics as valid or faulty.
For OEM (original equipment manufacturers) the data

pages enable development engineers to analyise the shift
combinations and request revised settings to suit a given
transmission application.
Data is displayed on pages as follows:
K Machine Setup ( T 7-15)

K Gear Ratios ( T 7-17)
K Allowable Shifts ( T 7-18)
K Shift Timing ( T 7-19)
K Speed Limits ( T 7-20)
K TCLU Limits ( T 7-22)
K Gear Lever ( T 7-24)
K Other ( T 7-26)
K ECU Details ( T 7-27)
9803/9090 Issue 2
Machine Setup
Fig 26.
The Machine Setup page appears by default when loaded. The description line is usually formatted as
ShiftMaster Setup software is started. The page shows the follows:
general feature options which are enabled by the loaded
Setup Data. It is normal for the check boxes and labels in ECU part number, example E728/80044
the inputs and outputs list to be shown as greyed-out.
Values are still displayed correctly (i.e. a tick when Setup File part number, example S728/90187
enabled). The text fields will contain no information if no
setup file has been loaded K Fig 26. ( T 7-15). OEM indentifiction code, example LDL P42
1 Setup Description: Contains information related to Type of gearbox, lock up torque converter (LUC) or
the machine application. By checking this description standard (std)
field you can verify that the correct setup file is
Setup file software version, example
(SM4.08,ETS2v23.0)
9803/9090 Issue 2
2 4/6 Speed Select : Shows gearbox supported, 6
Speed or 4 Speed.
3 Inputs : Lists inputs expected.
4 Outputs : Lists outputs expected.
9803/9090 Issue 2
Gear Ratios
Fig 27.
The Gear Ratios page shows the transmission ratio for

each gear, forward and reverse. These values are used by
the ECU for internal calculations and are dictated by the
type of gearbox being controlled. K Fig 27. ( T 7-17)
9803/9090 Issue 2
Allowable Shifts
Fig 28.
The Allowable Shifts page contains a list of all gear shifts

which the ECU can enable. The ECU uses this data to
prevent the selection a potentially harmful shift.
Note: double-clicking on a particular shift will jump the

application to the ‘Shift Timing’ page. The selected shift
timing is displayed K Shift Timing ( T 7-19)
9803/9090 Issue 2
Shift Timing
Fig 29.
During gear shifts the clutch solenoids on and off timing 3 OFF-going Delay: Displays the time delays for the off
relationships are set to achieve the smoothest possible going clutches. Example: U and Z (F3). Delay for U =
gear shift. This ensures miniumum transmission wear and 10 and Z = 10.
maximum operator comfort.
4 Engaging: The range of clutches always engaging.
1 Shift: Use the drop down list to select the required Example, 2nd gear requires clutches T and Z to be
shift. Example: F3-F4. engaged, 3rd gear requires U and Z. T and U are
‘engaging’ clutches.
2 ON-coming Delay: Displays the time delays for the
on coming clutches. Example: X and Y (clutches 5 Holding: The range of clutches usually holding.
required to select F4). Delay for X = 0 and Y = 100. Example, 2nd gear requires clutches T and Z to be
engaged, 3rd gear requires U and Z. Z is a ‘holding’
clutch.
9803/9090 Issue 2
Speed Limits
Fig 30.
The ShiftMaster ECU prevents downshifts to a lower gear 1 Data Set : (ECU 2.2 only) Use the drop down list to
if the machine is travelling too fast. This ensures select the required Data Set. Some applications
miniumum transmission wear and maximum operator utilise transmission ‘modes’. The operator can
comfort. change to a different mode using a cab mounted
switch. When the ECU detects a mode change input
All speed values are quoted in Hertz (Hz), or pulses per a different Speed Limits data set is selected. Upto
second. The gearbox speed sensor detects the passing of three data sets are available.
gear teeth on the gearbox output gear. Hence speed
values are effectively measures in teeth per second. The 2 Manual Downshift : Displays the maximum speed at
actual road speed value is dependant on the ratio of the which the gear will be engaged. If the speed is higher
axle and size of tyres fitted. K Fig 30. ( T 7-20) that the set value the ECU will prevent selection until
the speed falls to the set value. Example: F1 will not
9803/9090 Issue 2
be selected unless the speed is less than or equal to
390 Hz.
3 Reversals, Rev Zero : Fixed value for all

applications.
4 Reversals, Reversal : Displays the maximum speed

at which the ECU will select F to R or R to F. If the
speed is higher that the set value the ECU will prevent
selection until the speed falls to the set value.
5 Auto Upshift : Displays the speed at which the gear

will be engaged. Example: The ECU will perform an
automatic upshift from F1 to F2 when the speed
reaches 197 Hz.
6 Auto Downshift : Displays the speed at which the

gear will be engaged. Example: The ECU will perform
an automatic downshift from F2 to F1 when the speed
falls to180 Hz.
7 Braked Compensation : Not used. (Value is always

zero.)
9803/9090 Issue 2
TCLU Limits
Fig 31.
This page defines the operation of the optional Torque speed is 1900 RPM or higher. Since the engine can
Converter Lock-Up (TCLU). K Fig 31. ( T 7-22) not reach 6000 RPM the clutch will not engage when
any other gear is selected.
1 Data Set : (ECU 2.2 only) Use the drop down list to
select the required Data Set. Some applications 3 Lock Up Clutch OFF : Displays the engine speed at
utilise transmission ‘modes’. The operator can which the lock up clutch disengages. Example: With
change to a different mode using a cab mounted F6 engaged the lock up clutch disengages when the
switch. When the ECU detects a mode change input engine speed falls to 1400 RPM.
a different TCLU Limits data set is selected. Upto
three data sets are available. 4 Max TC Speed Diff : Displays the maximum speed
difference between the engine and the transmission
2 Lock Up Clutch ON : Displays the engine speed at in RPM. The value represents torque converter
which the lock up clutch engages. Example: With F6 slippage. Example: With F6 selected the lockup
engaged the lock up clutch engages when the engine clutch will only engage if the speed difference is less
9803/9090 Issue 2
than or equal to 360 RPM. This condition is true even
if the engine speed is 1900 RPM or above, see Lock
Up Clutch ON.
5 TCLU Cut-off Ratio : Maximum gear ratio at which

clutch will operate. Example, 2. K Gear
Ratios ( T 7-17)
6 TCLU In Reverse : Enabled, clutch can operate

when reverse gears are engaged within the set limits.
Disabled, clutch does not operate when any reverse
gear is engaged.
7 TCLU Shift Drop-Out Time : Clutch operating time

delay to ensure smooth operation.
8 TCLU Shift Drop-Out 4-5 : Clutch operating time

delay to ensure smooth operation.
9803/9090 Issue 2
Gear Lever
Fig 32.
This page shows gear lever information and defines how positions). Example: Automatic Pos 1, Start F1, End
the ECU interacts with the machine’s gear-shift lever. F1. Gear lever position 1 operates in ‘manual’ mode.
K Fig 32. ( T 7-24) No automatic gear shifts are enabled. Example:
Automatic Pos 4, Start F4, End F6. Gear lever
1 Data Set : (ECU 2.2 only) Use the drop down list to position 4 enables automatic gear shifts between F4,
select the required Data Set. Some applications F5 and F6.
utilise transmission ‘modes’. The operator can
change to a different mode using a cab mounted 3 Reverse : Displays the automatic reverse gear
switch. When the ECU detects a mode change input selection range in the same way as the Forward
a different Gear Lever data set is selected. Upto data.
three data sets are available.
4 Gear Lever Codes : Displays the code for each gear
2 Forward : Displays the automatic gear selection lever position (maximum of six positions). The codes
range for each gear lever position (maximum of six
9803/9090 Issue 2
represent binary numbers dependant on the type of
gear selection switch used.
5 Neutral Sense Delay : Displays the time delay factor

when the gear lever is set to N. This value is set to
prevent flase inputs from spurious signals. Values are
also shown for FR Sense Delay and Gear to Gear
Delay.
9803/9090 Issue 2
Other
Fig 33.
This page contains all the miscellaneous setup data which

cannot be categorised into any of the above pages. Data
includes information used for rpm calculation, kickdown
operation, setting up of transmission and engine speed
inputs and reversal limits. K Fig 33. ( T 7-26)
9803/9090 Issue 2
ECU Details
Fig 34.
This page displays the details of the connected ShiftMaster

ECU. These values are NOT part of the setup files and are
only included for the completeness of this document.
K Fig 34. ( T 7-27)
9803/9090 Issue 2
Connection Problems
In general, whenever there are problems communicating

with the DLA there will be an error message displayed.The
following section although not exhaustive attempts to
identify the more common of ECU communication
problems.
ShiftMaster PC Service Tools must use the authorised Fig 36.

Data Link Adaptor (DLA) contained in the Electronic
Service Tool Kit. The latest versions of both the hardware The second is generated when no communications can be
and software can be obtained through authorised established with the DLA and the ECU usually through a
suppliers. ShiftMaster software has been designed to run hardware problem. No power supply from the vehicle
on the Windows 9.X, Windows 2000 and Windows XP indicated by the DLA’s power LED will display the ’NO ECU
operating systems. COMMS’ message. K Fig 37. ( T 7-28). Another source
could be related to resistance of the two data
A number of reasons can generate software problems and communication wires making up the machine’s harness for
assistance from an Information Technology engineer is the ECU’s CAN connection to the Deutsch 9 way round
advised. In particular, laptop PCs can suffer serial diagnostic connector. The wiring must have two 120 Ohm
communications conflicts were the PC hardware does not resistors fitted to either end of this run of cable to give a 60
allow the Diagnostic software access to the Ohm impedance. If the impedance is incorrect then ‘No
communication ports. In the majority of cases conflicts are ECU Comms message will displayed. K Fig 37. ( T 7-28)
caused by either software already running on the PC, or by
certain 'driver' files not releasing the COM port(s).
The PC Service Tools for example ShiftMaster Diagnostics

indicate the existence of an ECU communication problem
that can reside in two areas indicated in the type of
displayed error message. The first message is generated
when the problem exists between the PC and DLA then the
‘Error Connecting to DLA’ will be displayed. K Fig
35. ( T 7-28) Fig 37.

If a problem is experienced it can take one of three forms,

a constant failure to establish communications, drop out
Fig 35. during communications or intermittent communication
connection. However, the source has a tendency to be of
Confirmation of this error can be found in the ‘ECU Setup the ‘No DLA Comms’ type and thus related to the user’s
Page’ with ’NO DLA COMMS’ being displayed in the PC. Contributory factors to communication errors could be
‘Application Code Part Number’ box. K Fig 36. ( T 7-28) related to the following items:
– DLA Drivers. The DLA and PC are programmed with

software ‘drivers’ which handle communications.
Ensuring the latest drivers are installed on the PC and
DLA contained on the latest version of ServiceMaster
– PC Power Management. Previous experiences have
shown that some laptops’ Power Management
software can disrupt the COM ports. Turning of the
9803/9090 Issue 2
power management software may resolve the General Information
problem.
– IR Drivers. If the PC has an InfraRed (IR) For all enquiries about the Shiftmaster Setup tool please
communications port then disabling the driver may follow your normal channels of enquiry. This ensures that
help. useful information can filter through to JCB personnel at all
levels.
– Modem Drivers. Modem drivers could cause
communication conflicts and temporary disabling to
establish if the software is conflicting with the port
may establish this source.
If the aforementioned information fails to resolve the

situation then the following contacts may be able to provide
further assistance;
– Information Technology (IT) engineer.

– Authorised machine dealer or agent.
– Machine OEM. The Original Equipment Manufacturer
(OEM) will make the relevant enquires.
9803/9090 Issue 4
8-1 ShiftMaster Flash Programmer 8-1
User Guide
ShiftMaster Flash Programmer is a PC based tool designed
to allow easy updating of ShiftMaster ECU operating
software. Flash Programmer is only intended for use with
the ShiftMaster ECU and does not support older versions of
Powershift Controllers used on the PS750 series
transmissions. This software is intended for use on IBM
Compatible Personal Computers (PCs) running Windows 9x
or Windows2000 operating systems but is not compatible
with either earlier versions of Windows 3.x. ECU
communications use the same arrangement as ShiftMaster
Diagnostics
Care & Safety
! WARNING
As well as following the guidelines in this document it is
essential that you also refer to any relevant Handbooks
and Service Manuals for guidance on fundamental safety
instructions. Failure to follow correct procedure could
result in death or injury.
! WARNING
Please also read and follow any on-screen instructions
issued by ShiftMaster Diagnostics. Failure to follow
correct procedure could result in death or injury.
Starting ShiftMaster Flash Programmer

1 Connect PC to ShiftMaster using the same sequence
highlighted in the section on ShiftMaster Diagnostic's
step 1 to 3.
2 Observe safety notices.
3 Start the diagnostics tool running by clicking on the

ShiftMaster Flash Programmer icon.
4 The ShiftMaster Flash Programmer tool will then open

up and display the main window as shown here.
The program will automatically scan for any ShiftMaster ECU

resident on the CAN connection.
9803/9090 Issue 1
Starting ShiftMaster Flash Programmer

1 Connection Problems
ShiftMaster Flash Programmer will start and can be

partly used even if connection problems exist.
In general, whenever there are problems

communicating with the DLA there will be an error
message displayed.
2 Non Communication with ECU
If communications with the ECU can not be established

then the various items on the main window will be
blank, as shown here. See troubleshooting section for
further information.

ShiftMaster Flash Programmer: Overview

There are several key elements to the ShiftMaster
Diagnostics tool and are labelled below. Each element is
explained in detail in later sections.
ECU Details
Menu Bar
ECU Description
Resident ECU
ECU List Software Version
Download Download File

Start/Stop Selection
Button
Download Progress
Indicator
9803/9090 Issue 1
ShiftMaster Flash Programmer: Overview

(cont’d)
1 File Menu
The Open option is used to locate and select the

required file.
Note: This functions in exactly the same way as the Browse

button.
The File Menu contains an Exit option to close down

the program.
On exiting the program communications with both ECU

and DLA are shut down.
2 ECU List
This area of the screen indicates if the ShiftMaster ECU

is connected then a JCB icon will appear in the ECU
list.
Note: If communications with a ShiftMaster ECU can not be

established then this area of the screen will be blank. See
the accompanying Troubleshooting Guide for help on fixing
communications problems.
3 ECU Details
Click on the icon displayed in the ECU List area and

you will notice that the ECU Details boxes will have
values inserted.
When a ShiftMaster ECU is interrogated by any

ShiftMaster Service Tool hardware and software
application data is transmitted. This information is
applicable to the Software Engineer and therefore is of
no use to the Service Engineer. Typically TransFlash
displays a number of text fields containing this
information including, a description (same as below
icon in ECU List), source address, function, identity. If
an operating code upgrade is necessary the most
useful piece of information is the version field. This
displays the current version of operating software
installed in the ECU. However, after clicking on the
icon, none of the fields contain data then this indicates
a communications problem may exist.
9803/9090 Issue 1
Download File Selection

This area of the screen allows the user to navigate and open
a file which contains ECU operating software (Flash File).
Click on the Browse button to bring up the standard

Open Dialog window.
Use the dialog window to navigate to the required file.

Clicking on the required file will select and it will become
highlighted.
Note: The ShiftMaster Flash Programmer tool supports 2 file

types (hex and vsf). All ShiftMaster ECU operating software
is distributed as vsf files, please make sure that the Flash
Files (*.vsf) type is selected when browsing for files. If not
the file will be invisible in the dialog box.
To open up the file into the ShiftMaster Flash Programmer

tool, select the file and click on
To abort file selection click on
After opening, ShiftMaster Flash Programmer's main

window details for the Download File Selection areas contain
data.
The white area will display the filename and path of the
selected file. The grey area displays the version and release
date for this file.
9803/9090 Issue 1
Downloading Software
Note: Before attempting to download any software to the
ShiftMaster ECU you should have a clear justification
and/or instruction for carrying out this activity. As with
any similar exercise there are always associated risks. If
you are not fully familiar with the software updating
process please do not attempt to update any software.
Ensure that the machine is in a safe condition with the

handbrake 'on' and forward, neutral and reverse lever in the
neutral position.
Once the required ECU operating software file (vsf file) has
been opened the reprogramming process can begin. Use
following process to update the ECU software;
1 To start the download process click on the

button.
Note: If the Flash File is selected but there is no ECU

communications then the Start button will appear 'greyed
out'.
2 The ShiftMaster Flash Programmer Tool will first start

by asking you to confirm if this is the correct file to load
into the connected ECU.
To confirm click the button.
To cancel the download process click on the

button.
3 Once you have confirmed to download the selected file,

ShiftMaster Flash Programmer Tool starts to send the
Flash File to the ECU. A progress indicator bar is
displayed to show download progress.
Please be patient while the Flash File is sent. The whole

download only takes a round 15 to 20 seconds.
Warning: DO NOT INTERRUPT THE

DOWNLOAD PROCESS BY CLICKING ON
THE BUTTON.
This button is provided purely to abort a download in

the unlikely event of communications being lost during
a download.
If this should happen please allow 5 to 10 minutes

before clicking on
9803/9090 Issue 1
Downloading Software (cont’d)

4 After the progress indicator bar has scrolled across the
box the ECU will reset. Three warning beeps will be
heard on the machine buzzer or an indication on the
lamp, if both are fitted, alerting the user that a power-
up has occurred. The ShiftMaster Flash Programmer
tool will pop-up an information box informing that the
download has completed.
The download process is completed by clicking on the

button.
9803/9090 Issue 1
9-1 PS760 Gear Box Electrical Fault Diagnostics 9-1
Fault Symptom Diagnosis
No Drive Problems - ECU Control
No Drive 1 FNR lever fault. 1 Check fuses and FNR lever. If no

outputs from FNR lever, ECU will
generate driver warning alarm. Use
diagnostics to check for signal
status.
2 No movement in selected gear. 2 Check for movement in other gears.
3 Handbrake ‘on’. 3 Check handbrake sensor and wiring

on ECU input connector terminals
when fitted. Use diagnostic
software. Note: audible alarm will
sound.
4 Incorrect ECU 2 SetUp file. 4 Use ShiftMaster SetUp and the

description line to read ECU details.
Contact JCB Drivetrain with part
number and settings.
5 ECU 2 connectors not engaged. 5 Check connectors are mating.
6 Faulty dump input. 6 Check dump switch and wiring. Use

diagnostic software to check ECU
status.
No drive and continuous alarm. 1 Attempting to select drive with 1 Release handbrake.
handbrake ‘on’.
No Drive Problems - Relay Control
No Drive. 1 FNR lever fault. 1 Electrically check fuses and FNR

lever.
2 No movement in selected gear. 2 Check for movement in other gears.
3 Handbrake ‘on’. 3 Check handbrake sensor, relays

and circuitry.
4 Faulty dump input. 4 Electrically check dump switch,

relays and wiring.
* Gear Shift Problems - ECU Control
No automatic top gears. 1 No speed sensor signal or throttle 1 Check speed sensor and wiring.
switch. Use diagnostic software to check
for display frequency.
2 Check throttle switch and use

diagnostics for switch status.
Lower gear not being selected. 1 Speed to high. 1 Allow vehicle to slow down.
Gearbox in lower gear than shown on 1 Kickdown engaged. 1 Cancel kickdown by depressing
gear lever. switch.
2 Wait for end of kickdown period.
9803/9090 Issue 4
* Gear Shift Problems - ECU Control

(cont’d)
Missing Gear. 1 Faulty solenoid(s). 1 Check solenoid(s), wiring and

relays. Check for voltage on
solenoid connectors. Use ECU 2
diagnostic software to check input
and output status.
2 Faulty gear lever. 2 Check switches and wiring. Use

diagnostic software to confirm ECU
status.
3 Low oil pressures. 3 Mechanical problem, follow clutch

pressure check procedures (see
Pressure Testing Clutches -
Section 6).
No dump. 1 Faulty dump input. 1 Check dump switch and wiring. Use
diagnostics to check switch status.
No 4WD (when fitted). 1 Electrical circuitry fault. 1 Check harness, connectors and
4WD switch. Use diagnostics to
check switch input and 4WD output
status.
2 Check 4WD solenoid voltage and

operational movement.
Intermittent 4WD. 1 Faulty 4WD input. 1 Check harness, connectors and

4WD switch. Use diagnostics to
check switch input and 4WD output
status.
2 4 Wheel braking mode operating. 2 False signal from footbrake switch

and wiring.
3 Normal indirect 4WD operation. 3 ECU inhibits 4WD above certain

gear ratios to prevent driveline wind
up.
No 4 Wheel braking (optional). 1 Faulty footbrake. 1 Check footbrake switch and wiring.
2 Check footbrake switch adjustment.
No downshift and audible alarm. 1 Speed too high for selected 1 Slow machine with brakes.
downshift.
2 De-select downshift.
Kickdown will not engage and and 1 Speed to high for reversal of 1 Slow machine and retry.
audible alarm sounds. direction.
Kickdown not operating. 1 Faulty kickdown input. 1 Check kickdown switch and wiring.
Machine will not perform a reversal and 1 Speed too high for reversal of 1 Slow machine with brakes.
an audible alarm sounds. direction.
2 De-select reversal.
9803/9090 Issue 2
* Gear Shift Problems - Relay Control
Missing Gear. 1 Faulty solenoid(s). 1 Check solenoid(s), wiring and

relays. Check for voltage on
solenoid connectors.
2 Faulty gear lever. 2 Check switches outputs and wiring.
3 Low oil pressures. 3 Mechanical problem, follow clutch

pressure check procedures (see
Pressure Testing Clutches -
Section 6).
No dump. 1 Faulty dump input. 1 Check dump switch and wiring.
No 4WD (when fitted) 1 Electrical circuitry fault. 1 Check harness, connectors, relays
and 4WD switch. Check 4WD
solenoid voltage and operational
movement.
9803/9090 Issue 2
Warning Alarms Continuous Tone
1 Disconnected FNR lever - The FNR lever outputs are

The ECU is capable of generating a number of alarms continually monitored and if no signal exists after ten
provided that the ECUs driver alarm output (pin 25A) is seconds then continuous alarm is sounded. This warns
connected to suitable warning system. If an audible alarm the operator that the FNR lever is disconnected or a
and warning lamp is fitted the system is capable of warning fuse supply may have blown.
the operator of the following conditions,
2 Hand Brake - The ECU will hold the transmission in
Double Tone Alarms neutral whenever the hand brake is applied. If the FNR
lever is not in neutral then a continuous tone will sound.
1 Manual Down Shift Protection - A double beep alarm
is given if the machine speed is above the Manual 3 Low Oil Pressure - The ECU monitors the status of the
Downshift limit.The ECU will inhibit the requested low oil pressure sensor. If the pressure sensor is below
downshift until the speed falls to the preset value. The 40psi for longer than 2 seconds then a continuous tone
speed values can be observed using ShiftMaster Setup is sounded.
software, see ShiftMaster Setup - User Guide .
2 Machine Reversal Protection - A double beep alarm is

given if the machine speed is above the Reversal
Limit.The ECU will inhibit the requested reversal until the
speed falls to the preset value. The speed values can be
observed using ShiftMaster Setup software, see
ShiftMaster Setup - User Guide .
3 Transmission speed sensor - If the transmission speed

sensor fails a repeated double tone will sound. The
speed sensors output can be confirmed by observing if
any frequency reading exists using ShiftMaster
Diagnostics. See ShiftMaster Diagnostics - User
Guide.
Note: For LUC applications the engine speed sensor is

not monitored but the sensor output can be verified by
checking for a frequency reading on the ShiftMaster
Diagnostics' LUC page. LUC will not operate with the
loss of the engine speed signal. See ShiftMaster
Diagnostics - User Guide.
4 Kickdown - If the machine speed is too high for

selection of the next lowest gear then a double tone will
be sounded.
Treble Tone Alarms
1 Power Up - A treble beep alarm is given when the ECU

is first powered up to indicate a healthy status.
9803/9090 Issue 1
Section 8 Gearbox Section 8
i i
Contents Page No.
Removal and Replacement 1-1
Dismantling 1-5
Inspection 2-1
Assembly 3-1
Forward/Input & Reverser Clutch - Dismantling 4-1

Forward/Input & Reverser Clutch - Assembly 4-3
Layshaft Clutch - Dismantling 5-1

Layshaft Clutch - Assembly 5-3
Mainshaft Clutch - Dismantling 6-1

Mainshaft Clutch - Assembly 6-3
6 Speed Clutch - Dismantling 7-1

6 Speed Clutch - Assembly 7-3
2/4WD Clutch (Pressure ON) - Dismantling 8-1

2/4WD Clutch (Pressure ON) - Assembly 8-3
2/4WD Clutch (Spring ON) - Dismantling 9-1

2/4WD Clutch (Spring ON) - Assembly 9-3
Piston Ring Seals - Fitting Procedure 10 - 1
Torque Converter - Removal and Replacement 11 - 1
Integral Park Brake (if fitted)

Check Park Brake Plate Wear 12 - 1
Dismantling 12 - 3
Inspection 12 - 5
Assembly 12 - 6
9803/9090 Issue 1
1-1 1-1
Removal and Replacement

Note: This illustration shows a typical machine.
J H H
K
R c
R
M
P N
S
L
a b
Y Z
D
B
C012150
9803/9090 Issue 1
1-2 1-2
Removal and Replacement (cont’d)
IMPORTANT: The gearbox is heavy. Unless it is safely

supported during removal and replacement it could fall and
cause injury. Make sure that you have access to suitable 7 Support the gearbox using a suitable trolley jack and
jacks and a gearbox locating ‘cradle’ before attempting to cradle. The gearbox must be securely located on the
remove the gearbox. cradle as shown at Y.
The following procedures do not relate to any specific 8 Make sure that the weight of the gearbox is supported
gearbox installation. For details of specific gearbox removal by the trolley jack and then remove the gearbox
and replacement procedures refer to the relevant vehicle mounting bolts H.
manufactures documentation.
9 Pull off the breather tube K. Undo the gearbox dipstick
! WARNING fixing nut L and then remove the dipstick tube.
A raised and badly supported machine can fall on you.
10 Label and then uncouple the solenoid control valve
Position the machine on a firm, level surface. Before
electrical connectors M, oil pressure sender N and
raising one end ensure the other end is securely
temperature sender P (if fitted). Uncouple the electrical
chocked. Do not rely solely on the machine hydraulics or
connector at the speed sensor S.
jacks to support the machine when working under it.
11 Disconnect the gearbox oil cooler hoses R.
Disconnect the battery, to prevent the engine being
started while you are beneath the machine.
12 Support the engine as required - see the machine
GEN 1-1
manufacturers documantation. Uno the torque
converter housing bolts J.
Removal
13 Manoeuvre the gearbox with the torque convertor clear
1 Park the machine on firm level ground. The gearbox is
of the engine housing.
heavy. If the ground is soft or uneven it will not be
possible to remove the gearbox safely.
14 Lower the trolley jack and pull the gearbox and torque
convertor clear of the machine.
2 Note that at least 800 mm clearance wil be required
between the ground and machine underside to allow
the gearbox to be pulled clear.
3 Remove the propshafts from the gearbox - see

Propshafts.
4 If the gearbox is fitted with a hydraulic pump, Drain the

hydraulic system and remove the pump. See the
machine manufacturers documantation.
5 Drain the gearbox oil, see Section 3, Routine

Maintenance.
6 Remove the access bung/plate at the bottom of the

torque converter housing. Through the access hole,
loosen and remove the torque converter to engine
flywheel retaining bolts D.
9803/9090 Issue 1
1-3 1-3

Note: This illustration shows a typical machine.
J H H
K
R c
R
M
P N
S
L
a b
Y Z
D
B
C012150
9803/9090 Issue 1
1-4 1-4
Replacement
Replacement is a reversal of the removal procedure but note

the following:
1 Before replacing the gearbox remove circlip 5 and

withdraw the pump driveshaft 6 together with its 8
bearing 7 approximately 50 mm (2.0 in). The shaft can
then be engaged after the gearbox has been fitted,
making replacing the gearbox easier. Remember to
engage the pump drive shaft, refit the bearing and
circlip after the gearbox has been fitted.
2 Set the torque converter as described in Torque

Converter, Removal and Replacement.
3 Align the Torque Converter

1
It is vitally important that the torque converter is
fitted at the gearbox and engine flywheel correctly.
Failure to locate the converter correctly will result in
damage to the gearbox oil pump on engine start up.
Proceed as follows:
Make sure that the torque converter drive dogs 1 are

correctly engaged with the pump 2 on the gearbox.
Temporarily tie the converter onto the gearbox. Use
wire tied at a drive plate bolt hole to a convenient point 2
on the outside of the gearbox.
4
Take note of the flywheel and drive plate fixing hole
phasing. The heads of the bolts 3 will foul the flywheel 4
if phasing is incorrect. 3
Before bolting the torque converter housing to the
engine make sure the mating faces are fully together
(DO NOT USE FORCE). The drive plate 8 should also
be mated close to the flywheel. Do not force the
components together with the fixing bolts.
Make sure that the torque converter is free to rotate A396460

slightly within the clearance of the location bolt holes. If
you cannot rotate the converter it is trapped either by
bolt heads 3 or by incorrectly located pump drive
dogs.Make sure that all is well before tightening the
bolts.
4 Fill the gearbox with the specified amount and type of

oil (see Section 3, Routine Maintenance). Leave hose
R off until the filling operation is complete. After filling
refit hose R.
6
Torque Settings 5
B 79 8 58 7
D 44 4.5 32
H 237 24 175
J,T 98 10 72
A439140
9803/9090 Issue 1
1-5 1-5
1a
1a
C012230
1d
1e
1c
1b
C012160
2b
2a
3b
2d
2c
717700
3a
9803/9090 Issue 1
1-6 1-6
Dismantling
Note: The Dismantling, Inspection and Assembly
procedures in this manual illustrate and describe the 6x4
gearbox. Procedures for the 4x4 version of the gearbox are
identical in most respects. Where there are differences
procedures are identified under the heading ‘4x4 Gearbox’.
With the gearbox removed from the machine, place suitable

wooden blocks to securely support the assembly.
Cleanliness is of the utmost importance when servicing the
gearbox. All precautions to prevent any ingress of dirt, grit
etc. must be taken. To this end wash the exterior of the
gearbox assembly as follows:
Make sure that all open ports and orifices are effectively
plugged. Remove any deposits of dirt, grit and oil from the
outer casings using a suitable degreaser and water. Dry the
casings.
Note: If the gearbox is fitted with an integral park brake the

brake assembly must be removed before dismantling the
gearbox. See Integral Park Brake - Dismantling,
Inspection and Assembly.
1 Remove the Main Hydraulic Pump and Driveshaft
a If the main hydraulic pump has not already been

removed proceed as follows. Support the pump, undo
the 2 bolts 1a. Draw the pump away from the gearbox,
disengaging the drive shaft. Lift the pump clear.
b Remove the circlip 1b, withdraw the driveshaft 1d,

together with bearing 1c and sealing ring 1e.
2 Remove the Solenoid Control Valve Block
Note: If any of the individual solenoid valve cartridges 2c are

to be removed, take care not to grip the unit by its electrical
connector block 2d. The connector block is not designed as
a leverage point.
a Undo the 8 socket head cap screws 2a and lift off the
valve block assembly 2b. Do not use a screwdriver to
lever the block, the sealing faces will be damaged. If
the block is difficult to remove, lightly tap the manifold
block with a soft faced hammer.
b Remove and discard the valve block sealing gasket.

The gasket may disintegrate on removal, make sure all
traces are removed and discarded.
3 Remove the Layshaft Cover (if fitted)
Note: Unless the casings are to be renewed, or the gearbox

oil has been contaminated it is not necessary to remove the
cover.
a Undo the 6 bolts 3a and lift off the cover 3b.
9803/9090 Issue 1
1-7 1-7
A
5a
5b
5c
5d
B
b
717710
A395230
4c
4b
6b
6g
4a
6a
6e
6c
6d
6h
6f
717720
747110
9803/9090 Issue 1
1-8 1-8
Dismantling (cont’d)
Using suitable lifting equipment locate the gearbox in a work
cradle (892/01082) as shown at A. Clamp the gearbox in
position at the 3 clamping points on the rear casing as
shown at B. DO NOT ATTEMPT TO DISMANTLE THE
GEARBOX FURTHER UNLESS IT IS SAFELY LOCATED IN A
SUITABLE WORK CRADLE.
4 Remove the Torque Converter Housing
a Undo the bolts 4a (13 off). Lift off the housing 4b.
Retrieve the sealing ‘O’ rings 4c.
5 Remove the Gearbox Hydraulic Pump
a Undo the 4 fixing bolts 5a and lift the pump assembly

5b off the input shaft. Retrieve the 4 sealing washers 5c
and pump sealing ring 5d.
Note: A pump which is worn or damaged may have caused

further damage to the gearbox. Dismantle and inspect the
gearbox fully. For details of dismantling and inspecting the
pump, see Inspection.
6 Remove the 4WD Clutch Assembly
a Using service tool 892/00812 hold the output yoke 6a

and at the same time undo the bolt 6b. The bolt is very
tight, the help of an assistant will be required.
b Remove the thick washer 6g and yoke 6a. Undo the 8

bolts 6c and lift off the cover 6d, be sure to retrieve the
bearing outer cup from inside the cover. Retrieve the
‘O’ ring 6h. Remove the output shaft oil seal 6e. Take
care not to damage the seal housing.
c Lift the clutch and shaft assembly 6f from the housing.

Retrieve the inner bearing outer cup from the casing.
For 4WD clutch dismantling and assembly procedure see

2/4WD Clutch - Dismantling and Assembly in this section.
9803/9090 Issue 1
1-9 1-9
7a
7b
8f
7c
8e
8b 8d
7d
717740
717730
8a
9f
9g
9c
9b
9a 9h
9d
9e
8c
717760
9803/9090 Issue 1
1 - 10 1 - 10
7 Remove the Torque Converter Relief Valve
a Undo the plug 7a and remove the sealing washer 7b,

spring 7c and poppet 7d.
8 Separate the Front and Rear Casings
a Undo the 17 casing bolts 8a.
b Using suitable lifting equipment carefully lift off the front

case 8b. Be sure to retrieve all the shaft bearing outer
cups. The cups may be left on the bearings, or inside
the front case. Keep the cups with their associated
bearings.
c Remove and discard the sealing ‘O’ rings 8c from the

front case.
Note: The 3 oil transfer pipes 8d, 8e and 8f located inside

the front case need not be removed unless they are
damaged, or the gearbox oil has been contaminated. If they
are to be removed see Gearbox - Inspection.
4x4 gearbox: pipe 8f not fitted.
9 Remove the Clutch/Shaft Assemblies
a Carefully lift out the clutch/shaft assemblies in the

following order:
9a - 6 Speed clutch (not fitted to 4x4 gearbox)
9b - Reverse clutch unit
9c - Forward/Input clutch shaft
9d - Layshaft clutch
9e - Mainshaft clutch
b Retrieve the bearing outer cups from the rear case 9f

and centre of the transfer gear 9g. Note that the
layshaft bearing cup 9h can not be removed until the
transfer gear/output shaft has been removed, see step
11. Keep the cups together with their associated
bearings.
9803/9090 Issue 1
1 - 11 1 - 11
11b
11c
11a
11r
11d
11j
11p
11m 11k
10c
10b
10d
11g 10a
11h
11f
11e
C012170
9803/9090 Issue 1
1 - 12 1 - 12
10 Remove the Pressure Maintenance Valve
a Undo the plug 10a, remove spring 10b and valve spool
10c, discard sealing washer 10d.
11 Remove the Transfer Gear
a Using service tool 892/00812 hold the output yoke 11a

and at the same time undo the bolt 11b. The bolt is
very tight, the help of an assistant will be required.
Remove the bolt, thick washer 11c followed by the
yoke.
b Remove and discard the oil seal 11d. Take care not to
damage the seal housing.
c Support the transfer gear/shaft assembly 11e.

Withdraw the gear from inside the casing. The
assembly will lift away complete with the inner taper
roller bearing 11f, outer bearing cup 11g and solid
spacer 11h.
d Remove outer taper roller bearing 11j.
Note: Only remove bearing cups 11g and 11k if being

replaced.
Note: If the bearings 11j and 11f are to be reused, keep the
bearings together with their respective outer cups in their
original relationships. tag the bearings to ensure assembly in
their original positions.
If either bearing is worn or damaged, both bearings must be

renewed and a new solid spacer 11h selected and fitted, see
Assembly.
e Retrieve the layshaft bearing outer cup 11r from the

rear casing.
f If the speed sensor 11m is to be removed, undo bolt

11p and withdraw the sensor together with its sealing
‘O’ ring.
9803/9090 Issue 1
2-1 2-1
Inspection
4a
4b A395290
5b
5a
5c
717730
5e
744310
5f
9803/9090 Issue 1
2-2 2-2
Inspection
Before assembling the gearbox, make sure that a thorough b If the existing pump is to be re-installed proceed as
inspection of all components is carried out. Remember that follows;
although a failed component may be easy to identify, the Undo the security screw 4a and separate the pump
cause of that failure may be less easy to trace. It is also body. Carefully inspect the gear teeth, white metal
possible that a failed component may have caused damage bearing and gear/body mating faces for signs of wear
to other areas of the gearbox. and damage (if either is evident, the pump must be
renewed).
1 Cleaning Carefully remove and discard the oil seal 4b. Take care
not to damage the seal housing. Fit a new seal and
a Carefully remove all traces of gasket or gasket then re-assemble the pump.
compound from the following components:
c Make sure that pump the mating face on the gearbox
Note: When removing gasket compound use a gasket front cover is clean and free from surface damage.
removal product such as Loctite Chisel. Take care not to
damage the mating faces. Clean the faces with a fine 5 Oil Transfer Pipes
carborundum paper. Use a solvent cleaner and a clean cloth
to finally remove all traces of oil or debris. The front case incorporates oil transfer pipes 5a, 5b and 5c.
If the pipes are damaged or if the gearbox has been
Front and rear casing mating faces. contaminated, the pipes must be removed for cleaning or
Front casing and torque converter housing mating renewal.
faces. 4x4 Gearbox: pipe 5c not fitted.
Main hydraulic pump and rear casing mating faces.
Solenoid control valve manifold and casing mating a Using a ‘crows foot’ type spanner and a ratchet wrench
faces. undo the pipes from the adaptors in the casing. Unless
4WD casing mating faces. pipes are being transferred to a new casing it will not
Layshaft cover and rear casing mating faces. be necessary to remove the pipe adaptors.
Pressure maintenance valve bore (rear case). 6x4 Gearbox Only: If the adaptors are to be removed,
adaptor 5e must be removed last.
b Clean the inside of the casings using a suitable
degreasing agent. b If the adaptors have been removed make sure that the
sealing rings are renewed and fitted correctly.
2 General Inspection 6x4 Gearbox Only: Position the lock nut 5f on adaptor
5e as shown and then fit the adaptor to the case.
a Carefully inspect all gears, bearings and shafts for signs
Screw in until the locking nut reaches the case. Do not
of excessive wear or damage. If wear or damage is
tighten the locking nut down at this stage.
evident, components must be renewed.
All Gearboxes: Fit the adaptors. Torque tighten to
70 Nm.
b Make sure that all oil way cross drillings are clear and
free from debris. Blocked oil ways are a common cause
c Make sure the pipes are clear and free from debris
of bearing failure. If necessary use an air line to blow
before refitting. Loosly fit the pipes 5a and 5b. Make
through the oil ways.
sure they are fitted at the correct adaptors as shown.
6x4 Gearbox Only: Loosly fit the pipe 5c, rotate
3 Clutch Units
adaptor 5e so that the pipe is not strained. Torque
a If clutch failure is suspected see the relevant clutch tighten down the lock nut 5f to 70 Nm.
dismantling and assembly procedure in this section. All Gearboxes: Torque tighten the pipes to 30 Nm.
4 Gearbox Hydraulic Pump 6 Casings
a If tests have shown the pump performance to be If the gearbox casings are to be renewed, be sure to fit
unacceptable, the pump must be renewed as a blanking plugs and adapters as required. Inspect the original
complete unit. casings and identify the blanking plug and adapter positions.
Transfer the plugs and adapters to the new casings. Apply
Loctite 242 to the threads.
Note that new plugs may be supplied with a sealant ‘patch’,

in which case sealant need not be applied.
9803/9090 Issue 1
3-1 3-1
1k
1j
C
1h
1g
1f
11f
1a
1b
1e
1c
1d
717650
9803/9090 Issue 1
3-2 3-2
Assembly
Using suitable lifting equipment locate the gearbox rear
casing in a work cradle. Clamp the casing in position at the 3
clamping points as shown at A.
DO NOT ATTEMPT TO ASSEMBLE THE GEARBOX UNLESS
IT IS SAFELY LOCATED IN A SUITABLE WORK CRADLE.
Where ‘oil’ is referred to, use new, clean transmission oil of

the correct specification for the gearbox. See Section 3,
Lubricants and Capacities.
E
1 Pre-assemble the Transfer Gear/Output Shaft
Note 1: Before fitting the transfer gear/output shaft assembly

1d, fit the layshaft outer bearing cup to the casing (shown at
E).
Position the casing as shown at D.
a Make sure that you have fitted the layshaft outer bearing 717770
cup, see Note 1 above. Fit the outer bearing outer cup
1a into the casing.
b Lightly oil the inner bearing 1c. Push the inner bearing A
1c onto the transfer gear/shaft 1d followed by a service
spacer 1e (13.70mm).
c Fit the inner bearing outer cup 1b into the casing.
d Locate the transfer gear assembly in the casing from

inside. Using service tool 892/01083 retain the gear in
position (shown at C). If the gear is not held in position
the bearings may be damaged during assembly.
e Lightly oil the outer bearing 1f. Using service tool

892/01084 push on the outer bearing 1f. Do not fit oil
seal 1g at this stage.
717710
9803/9090 Issue 1
3-3 3-3
3d
3c
3b 2g
2b
2c
3a
2a
2e
3e
2d 2h
2g
2c
2b
4a
2d
2a
4b 2e
4d
4c
2h
2f 2g
C012170
744300
9803/9090 Issue 1
3-4 3-4
Assembly (cont’d)
2 Checking Transfer Gear/Output Shaft Assembly End 3 Transfer Gear/Output Shaft Final Assembly
Float
a Using service tool 892/01085 fit a new oil seal 3a. Make
a Fit service tool sleeve 2a over the transfer output shaft sure the seal is pushed square to the housing.
and secure with service tool 2b, torque tigtened to 50Nm
(36.9 lbf ft). b Fit yoke 3b followed by thick washer 3c and bolt 3d.
Hold the yoke using service tool 892/00812 and
b Temporarily release the retaining tool 892/01083. progressivily torque tighten the bolt to 300 Nm (221 lbf
ft). Provided the correct size spacer has been selected
c Fit support bracket 2d to gearbox casing, as illustrated. the combined seal and bearing rolling torque should not
exceed a maximum of 2.0 Nm (1.5 lbf ft) when fully
d Fit service tool 892/00918 2c so that the fork end torque tightened
engages in the groove of service tool 2b, tighten bolt 2d
to support bracket 2e. c If applicable fit the speed sensor 3e. Make sure that the
sealing ‘O’ ring is correctly located and then torque
e Fit dial test indicator 2f (DTI), to measure the end float of tighten the bolt to 28Nm (20 lbf ft).
the output shaft.
4 Fit the Pressure Maintenance Valve
f Set the torque wrench 2g to 35Nm (25.8 lbf ft) and
measure the end float while rotating the output shaft. a Oil the spool 4a and fit to the casing. Fit spring 4b. Apply
Loctite 242 to the plug 4c. Using a new sealing washer
g To select the right size spacer 2h, subtract the end float fit the plug and torque tighten to 56 Nm.
obtained at step e from the solid spacer (13.70 mm). Also
subtract 0.120 mm to allow for theorectical bearing
tolerance and pre-load. If there is no spacer of this size,
fit the next smallest spacer.
Example
Service spacer 13.70

Subtract end float 0.41
Total 13.29
Subtract tolerance & preload 0.12

Result 13.17
Use next smallest spacer i.e. 13.15
If the ‘Result’ measurement is outside the spacer kit range

check the assembly of the bearings.
h Dismantle and fit correct size spacer 2h. Re-assemble

the transfer gear/output shaft.
i Fit service tool sleeve (892/01165) 2a over the transfer

output shaft and secure with service tool 892/01164 2b,
torque tigtened to 50Nm (36.9 lbf ft). Check there is no
end float and rolling torque is less than 1.5Nm (1.0 lbf ft).
If the rolling torque exceeds 1.5Nm (1.0 lbf ft) check that
output shaft has been assembled correctly.
j If the rolling torque is too high, fit the next largest spacer.
If the rolling torque is too low, fit the next smallest spacer
k Re-attach the retaining tool 892/01083. Remove service

tool 2b and service tool sleeve 2a.
9803/9090 Issue 1
3-5 3-5
A 5e
5e
5f
5g
5c
5d
A396050
5a
5b
6a
717760
743430
6b
6c
6b
717730 717820
9803/9090 Issue 1
3-6 3-6
Assembly (cont’d)
5 Fit the Clutch/Shaft Assemblies
a Fit the bearing outer cups at their correct locations in the

rear case 5a and centre of the transfer gear 5b.
b Carefully fit the clutch/shaft assemblies in the following

order:
Note: When fitting the layshaft clutch take care not to

damage the rear bearing on the transfer gear teeth.
Note: Before fitting the input clutch shaft make sure that the
4 sealing rings (shown at A) are in good condition and
lubricated with oil.
5c - Mainshaft clutch
5d - Layshaft clutch
5e - Forward/Input clutch shaft
5f - Reverse clutch unit
5g - 6 speed clutch shaft (not fitted to 4x4 Gearbox)
c Make sure that the sealing rings on the ends of the

clutch shafts 5c, 5d, 5f and 5g are in good condition and
lubricated with oil.
4x4 Gearbox: clutch 5g (6 speed) not fitted.
6 Assemble the Front and Rear Casings
a Make sure that the ‘O’ rings 6a are correctly fitted to the
rear case.
b Apply a thin bead of Loctite 509 to the rear casing

mating face as shown at B.
c Make sure that the shaft bearing outer cups are correctly
located in the front case 6b and then carefully lower the
case over the clutch shafts until it mates with the rear
case. Do not use excessive force when fitting the case.
d Fit the 17 casing bolts 6c and progressively torque

tighten to 56 Nm (41 lbf ft).
9803/9090 Issue 1
3-7 3-7
7b 7d
7e Y 7a
X
7c
717820
9803/9090 Issue 1
3-8 3-8
Assembly (cont’d)
7 Checking the Clutch Shaft End Floats
Provided components are assembled correctly the end float

will be within the limits given. Check that the shafts can be
rotated by hand (turn the input shaft and output yoke). The
shafts should rotate smoothly. The end floats can be checked
to confirm correct assembly.
End float for all shafts (except the mainshaft) will be within the
range 0.02 mm to 0.16 mm (0.0008 to 0.0063 in).
All shafts except the Input Shaft:
Shaft 7a - Mainshaft (endfloat 0.02 mm to 0.18 mm (0.0008

to 0.00709 in)
Shaft 7b - Reverse clutch unit
Shaft 7c - Layshaft
Shaft 7d - 6 speed shaft (not fitted to 4x4 gearboxes)
a Remove the plugs X and Y from the front casing.

4x4 Gearbox: plug Y not fitted.
b Fit a bolt to the threaded hole in the end of the shaft. Pull
up on the bolt to detect excessive end float. Remove the
bolt.
c Apply Loctite 242 to the plugs X and Y as applicable.

Torque tighten the plugs to 102 Nm (75 lbf ft).
Input Clutch Shaft:
a Pull on the input shaft 7e to detect excessive end float

(0.02 to 0.16 mm (0.0008 to 0.0063 in)).
9803/9090 Issue 1
3-9 3-9
9c
8h
8g
9b
8f
9a
8d 8e
8b
8c
8a
717720
A 10c
8c
Z 10a 10d
Y X
Y
10b
Y
A395230
A709210
9803/9090 Issue 1
3 - 10 3 - 10
Assembly (cont’d)
8 Fit the 4WD Clutch Assembly 10 Fit the Gearbox Hydraulic Pump
a Make sure the shaft bearing outer cup is correctly a Make sure that the pump is fitted with a new oil seal 10a,
located in the front casing (not shown) and then locate see Gearbox, Inspection, step 4.
the clutch and shaft assembly 8a in the the housing.
Fit a new sealing ring 10b. Locate the pump over the
b Make sure that the front and 4WD casing (8b) mating input shaft aligning the bolt holes. Apply Loctite 242 to
faces are clean and undamaged. bolts 10c. Fit the bolts together with new sealing
Fit the ‘O’ ring 8c to the front casing. Note that the ‘O’ washers 10d. Progressively torque tighten the bolts to
ring deforms to locate in the recess as shown at Z. 28 Nm (20 lbf ft).
Apply a 3 mm bead of Loctite 509 to the front casing as
shown at A. Note that the bead is applied near the inner b Pour some clean, new, oil into the pump at position X.
or outer edge of the flange as applicable at positions Y.
Make sure that the shaft bearing outer cup (not shown)
is correctly located inside the 4WD casing and then fit
the casing. Fit 8 off bolts 8d and progressively torque
tighten to 56 Nm (41 lbf ft).
Check the 4WD clutch shaft end float:
Provided components are assembled correctly the end float

will be within the limits given. Rotate the shaft by hand, it
should rotate smoothly.
The end float can be checked to confirm correct assembly.
End float must be within the range 0.01 mm to 0.16 mm
(0.0004 to 0.0063 in).
c Fit a bolt to the threaded hole in the end of the shaft. Pull
up on the bolt to detect excessive end float.
d Fit a new oil seal 8e. Make sure the seal is pushed
square to the housing.
e Fit the output yoke 8f, followed by thick washer 8g and

bolt 8h. Hold the yoke using service tool 892/00812 and
at the same time torque tighten the bolt to 400 Nm (295
lbf ft).
9 Fit the Torque Converter Relief Valve
a Fit Poppet 9a followed by the spring 9b. Using a new

sealing washer fit plug 9c.
Torque tighten the plug to 56 Nm (41 lbf ft).
9803/9090 Issue 1
3 - 11 3 - 11
717840
11b
11a
11c
717850
9803/9090 Issue 1
3 - 12 3 - 12
Assembly (cont’d)
11 Fit the Torque Converter Housing
a Make sure that the front case and torque converter

housing (11a) mating faces are clean, dry and
undamaged.
b Fit the 5 ‘O’ rings 11b to the front case. Apply a 3 mm

wide bead of Loctite 509 sealant X to the front case.
c Fit the 13 bolts 11c and progressively torque tighten to

56 Nm (41 lbf ft).
9803/9090 Issue 1
3 - 13 3 - 13
C
12b
A
177
/10
12d
813
12c
12a
A390510
14a
13b
13a 14b
13c
717690
13d
9803/9090 Issue 1
3 - 14 3 - 14
Assembly (cont’d)
12 Fit the Solenoid Control Valve Block
Note: If any of the individual solenoid valve cartridges 12c

are to be replaced, take care not to grip the unit by its
electrical connector block 12d. The connector block is not
designed as a leverage point.
a Fit two guide studs at the valve interface on the front

case. Locate a new valve block sealing gasket 12a as
shown at C. Care is needed as the gasket is thin.
b Fit the 8 socket head cap screws and washers 12b. The
screws must be progressively torque tightened.
Gradually tighten all the screws to 35 Nm (26 lbf ft).
13 Fit the Main Hydraulic Pump Driveshaft
a Fit a new sealing ring 13a and bearing 13c to the shaft
13b. Apply clean oil to the sealing ring, bearing and fit
the shaft inside the gearbox.
b Fit the circlip 13d.
14 Fit the Layshaft Cover
a If applicable fit the layshaft cover 14a. Make sure the

casing mating faces are clean and undamaged. Apply a
thin bead of Loctite 509 to the rear casing and fit the
cover. Fit bolts 14b and progressively torque tighten to
56Nm (41 lbf ft).
Note: The main machine hydraulic pump can be fitted at this

stage. However, it is easier to fit the gearbox to the machine
and then fit the pump (if applicable). This procedure is the
reverse of Gearbox - Dismantling, Step 1.
9803/9090 Issue 1
4-1 4-1
Forward/Input & Reverser Clutch - Dismantling

22
21 23
8 11 14
9
10
6
1
5 7 20
4
19
18
17
2 3
16
16
13
17
18
23
19
20
8
15
21 14
12
22
9
10
11
12
13
24
15
25
29
26
27
28
30
A396140
6 14 15 16 11 29
12
3 23 27
2 26
24
17
10 28
13 19 21 22 20 18 30
A396270
9803/9090 Issue 1
4-2 4-2
Forward/Input & Reverser Clutch - Dismantling

Note: The illustration shows a reverser shaft assembly for 11 Lift off spring retaining plate 18.
the 6 - speed transmission. The input shaft assembly has
some small differences. An explanation of the differences will 12 Remove spring 19 and oil baffle 20.
be given as they occure in the procedure. The input and
reverser shaft assemblies for the 6 - speed transmission and 13 Turn the assembly over and knock the clutch shaft on a
the 4 - speed transmission are the same basic construction, piece of aluminium (or wood) to loosen the piston 21.
except the 4 - speed transmission have fewer
friction/counter plates. Note: If the piston does not loosen when the clutch shaft is
knocked on aluminium, then hand pump air down the shaft
1 Carefully remove piston ring seals 1. The input shaft oil inlet hole.
does not have piston ring seals fitted at this end of the
shaft. 14 Remove the piston 21. Remove and discard the piston
‘O’ ring 22 and shaft ‘O’ ring 23.
Note: If the piston ring seals are excessively worn then
check for burrs or damage on the shaft grooves. If necessary 15 To dismantle the opposite clutch, carefully remove
remove burrs with a fine grade abrasion paper and oil. piston ring seal 24. The input shaft has four piston ring
seals fitted at this end of the shaft.
2 Remove the clutch end bearing 2 and gear 3, using a
puller or press. 16 Loosen the clutch end bearing 25 and remove using a
puller.
3 Remove the thrust bearing 4 and thin thrust washer 5.
17 Remove thrust bearing 27 and thick and thin thrust
4 Withdraw the gear and splined hub 6 with the needle washers 26 and 28.
roller bearing 7.
18 Withdraw the gear and splined hub 29 with the needle
5 Remove thrust bearing 9 and thick and thin thrust roller bearing 30.
washers 8 and 10.
19 Repeat steps 5 to 14 to dismantle the clutch assembly.
6 Remove the friction/counter plates retaining circlip 11.
7 Remove pressure end plate 13 and shim 12, if fitted.
8 Remove the friction plates 14 and counter plates 15.

Keep them together in sets, DO NOT mix the plates with
those from other clutches.
9 Remove disc spring assembly 16.
10 Position clutch assembly in a suitable press, with a cut

away tube compress the piston spring then remove
circlip 17.
17
A401360
9803/9090 Issue 1
4-3 4-3
Forward/Input & Reverser Clutch - Assembly
22
21 23
8 11 14
9
10
6
1
5 7 20
4
19
18
17
2 3
16
16
13
17
18
23
19
20
8
15
21 14
12
22
9
10
11
12
13
24
15
25
29
26
27
28
30
A396140
6 14 15 16 11 29
12
3 23 27
2 26
24 A
11
13
17 A402700
10 28
13 19 21 22 20 18 30
A396270
9803/9090 Issue 1
4-4 4-4
Forward/Input & Reverser Clutch - Assembly

Visually inspect the friction and counter plates:
Counter plates - light scoring/polishing is permissible, 9 Using a dial test indicator as shown, measure the end
plates that are not flat, worn or heavily marked or scored float of the pressure end plate 13, which should be 1.90
must be replaced with a new set. to 2.50 mm (0.075 to 0.098 in).
If it is necessary to adjust the end float to bring it within

Friction plates - the cross hatching should be clearly
tolerance, there is a choice of fitting a 6.0mm (0.23in) or
visible, plates that are not flat, have friction material 6.5mm (0.25in) thick pressure end plate 13, with either a
damage or scoring must be replaced with a new set. shim 12 or an extra counter plate 15 between the
retaining circlip 11 and pressure end plate 12.
DO NOT mix old and new plates, if a plate is damaged/worn Use an airline to check the operation of the clutch.
fit a complete new set.
10 Fit thick and thin thrust washers 8 and 10, and thrust
Needle roller bearings should slide into position freely, do not bearing 9.
bend or distort the cage to fit. If the cage has been distorted
fit new bearings. 11 Carefully align the teeth of the clutch plates using a thin
rod (or screwdriver) and fit the gear and splined hub 6.
Take care when handling disc spring assemblies 16 to avoid
12 Fit needle roller bearing 7.
marking or damage, which could result in stress cracking. If
in doubt fit a new disc spring. 13 Fit thrust bearing 4 and thin thrust washer 5.
Note: The piston incorporates a small check valve. Visually
14 Smear the clutch end bearing with gearbox oil and
inspect the piston to ensure the ball is in place and that the
press the gear 3 and bearing 2 onto the shaft.
seat is free from contamination. If necessary clean the valve
by blowing through with an air line. DO NOT use a wire rod
15 Fit piston ring seals 1, refer to Piston Ring Seals -
(or screwdriver) as damage to the valve seat could occur.
Fitting Procedure. The input shaft does not have
1 Fit new 'O' rings 23 and 22. Lubricate the piston 21 with piston ring seals fitted at this end of the shaft.
oil and press fully into bore of clutch housing.
16 To assemble the opposite clutch repeat steps 1 to 10.
2 Fit the oil baffle 20, piston spring 19, make sure the
spring seats in the piston. 17 Carefully align the teeth of the clutch plates using a thin
3 Fit the spring retaining plate 18.
18 Fit needle roller bearing 30.
4 Compress the spring and secure with circlip 17.
19 Fit thrust bearing 27 and thick and thin thrust washers
5 Fit the disc spring assembly 16. Make sure that the disc 26 and 28.
spring is fitted with the teeth towards the clutch pack.
Make sure the teeth are not aligned with the lubrication 20 Smear the clutch end bearing with gearbox oil and
slots in the housing. press bearing 25 onto the shaft.
6 Fit one counter plate 15, followed by one friction plate 21 Fit piston ring seal 24, refer to Piston Ring Seals -
14. Continue fitting alternate counter and friction plates, Fitting Procedure. The input shaft has four piston ring
finishing with a friction plate. seals fitted at this end of the shaft.
7 Fit the pressure end plate 13. Make sure that the
chamfered face is fitted facing the clutch pack as
shown at A. Make sure the teeth are not aligned with
the lubrication slots in the housing. Do not fit shim 12 at
this stage.
8 Fit the clutch friction/counter plates retaining circlip 11.
S217590
9803/9090 Issue 1
5-1 5-1
Layshaft Clutch - Dismantling 11

9A
10
9
8
8
5
6
7
4 6
3 17
2
1
16
14
15
13
12
23
24
22
21
20
19
18
A396160
5 13 14 16
17
2 6
24
1 12
3 22
4
7 15 20
11 23
8 19 21 A396230
18
9803/9090 Issue 1
5-2 5-2
Layshaft Clutch - Dismantling

Note: The illustration shows a layshaft assembly for a 6 - 12 Lift off spring retaining plate 19.
speed transmission. The layshaft assembly for a 4 - speed
transmission has some small differences. An explanation of 13 Remove the spring 20 and oil baffle 21.
the differences will be given as they occure in the procedure.
14 Turn the assembly over and knock the clutch shaft on a
1 Carefully remove piston ring seals 1. piece of aluminium (or wood) to loosen the piston 22.
Note: If the piston ring seals are excessively worn then Note: If the piston does not loosen when the clutch shaft is
check for burrs or damage on shaft grooves. If necessary knocked on aluminium, then hand pump air down the shaft
remove burrs with a fine grade abrasion paper and oil. oil inlet hole.
2 Remove taper roller bearing 2 using a suitable puller or 15 Remove the piston 22. Remove and discard the piston
press. 'O' ring 23 and shaft 'O' ring 24.
3 Remove circlip 3 and withdraw the 4 wheel drive

transfer gear 4. Make a note which way round the gear
is fitted for assembly. The 2 wheel drive machines have
a spacer fitted instead of a gear.
4 Withdraw the gear and splined hub 5 together with thin

thrust washers 6 and thrust bearing 7.
5 Remove the two needle roller bearing assemblies 8.

4-speed transmissions have only one needle roller
bearing fitted.
6 Remove the thin thrust washer 9, thrust bearing 10, thin

thrust washer 9A and thick thrust washer 11.
7 If end bearing 12 is to be removed it must be renewed.

Remove the bearing using puller. Discard the bearing.
Note: This bearing would not normally be removed unless it

was damaged. If a collet tool is not available, then it is
permissible to use standard bearing puller, although damage
to the bearing cage may be incurred which will require a new
bearing.
8 Remove the clutch friction/counter plates retaining

circlip 13.
10 Remove the clutch friction plates 16 and counter plates

17. Keep them together in sets, DO NOT mix the plates
with those from other clutches.

18
away tube compress the piston spring as shown, then
remove circlip 18.
A401360
9803/9090 Issue 1
5-3 5-3
Layshaft Clutch - Assembly
Note: See Note on next page regarding 11A

bearing 8.
11/11A
9A
10
9
8
5
6
7
4 6
5 9 9A B
C
6
3 A405340
4
7 10 11
8
9803/9090 Issue 1
5-4 5-4
End Float Setting - Plate Carrier and Gear
If any of the components listed below are to be renewed, the

end float of gear 5 must be measured and reset as required:
Note: Roller bearings 8, single fitted to 4 speed box, twin

fitted to 6 speed box.
Item
B Shaft assembly
5 Gear and plate carrier assembly
6,7 Thrust washer assembly
9,10 Thrust washer assembly
4 4WD transfer gear or spacer as applicable
C Not fitted if brake is not fitted.
Check and reset the endfloat of gear 5 as follows:
1 Temporarily fit thick thrust washer 11, thin thrust washer

9A, thrust bearing 10 and thin thrust washer 9. Fit
needle roller bearing 8.
2 Temporarily fit the gear and plate carrier assembly 5. Fit

the thin thrust washer 6 and thrust bearing 7 followed
by the remaining thrust washer 6.
3 Temporarily fit the 4 wheel drive transfer gear 4 onto the

layshaft spline. Make sure that the gear is fitted the
correct way round. 2 wheel drive machines have a
spacer fitted instead of a gear. Fit the circlip 3.
4 Make sure that the 4 wheel drive gear (or spacer) is fully
seated against circlip 3. Measure the end float of gear 5.
It must be between 0.01 to 0.15 mm (0.0004 to 0.006 in)
If the end float requires adjustment select a suitable
thrust washer from 11A and reassemble the
components as described above.
Note: 11A = kit 823/10420 - comprises 6 thrust washers of

the following thicknesses:
4.3 mm (0.169 in)
4.4 mm (0.173 in)
4.5 mm (0.177 in)
4.6 mm (0.181 in)
4.7 mm (0.185 in)
4.8 mm (0.189 in)
5 Recheck the end float and then dismantle the

components. Assemble the clutch as detailed on the
next page. Be sure to fit the correct thrust washer 11 on
final assembly.
9803/9090 Issue 1
5-5 5-5
Layshaft Clutch - Assembly 11

9A
10
9
8
8
5
6
7
4 6
3 17
2
1
16
14
15
13
12
23 A
24 13
22
21 14
20
19
18
007204A
A396160
5 13 14 16
17
2 6
24
1 12
3 22
4
7 15 20
11 23
8 19 21 A396230
18
9803/9090 Issue 1
5-6 5-6

Visually inspect the friction and counter plates:
Counter plates - light scoring/polishing is permissible, 9 Fit the thick thrust washer 11, thin thrust washer 9A,
plates that are not flat, worn or heavily marked or scored thrust bearing 10 and thin thrust washer 9.
must be replaced with a new set.
10 Fit the two needle roller bearings 8. The 4-speed
transmissions have only one needle roller bearing fitted.
visible, plates that are not flat, have friction material 11 Carefully align the teeth of the clutch plates using a thin
damage or scoring must be replaced with a new set. rod (or screwdriver) and fit the gear and splined hub 5.
DO NOT mix old and new plates, if a plate is damaged/worn 12 Fit the thin thrust washers 6 and thrust bearing 7.
fit a complete new set.
13 Fit the 4 wheel drive transfer gear 4 onto the layshaft
Needle roller bearings should slide into position freely, do not spline. Make sure that the gear is fitted the correct way
bend or distort the cage to fit. If the cage has been distorted round. The 2 wheel drive machines have a spacer fitted
fit new bearings. instead of a gear. Fit the circlip 3.
Note: The piston incorporates a small check valve. Visually 14 Smear the clutch end bearings 2 and 12 with gearbox
inspect the piston to ensure the ball is in place and that the oil. Oil and press the bearings onto the shaft.
by blowing through with an air line. DO NOT use a wire rod 15 Fit piston ring seals 1, refer to Piston Ring Seals -
(or screwdriver) as damage to the valve seat could occur. Fitting Procedure.
1 Fit new 'O' rings 24 and 23. Lubricate the piston 22 with
2 Fit oil baffle 21, piston spring 20, make sure the spring
seats in the piston.
5 Fit one counter plate 17 followed by one friction plate

16. Continue fitting alternate counter and friction plates,
finishing with a friction plate.
6 Fit the pressure end plate 14, do not fit shim 15 at this
stage. Make sure that the chamfered face is fitted
facing the clutch pack as shown at A. Make sure the
teeth are not aligned with the lubrication slots in the
housing.
Note: A spring disc is not fitted in this clutch pack.
8 Using a dial test indicator as shown, measure the end

float of the pressure end plate 14, which should be 1.9
to 2.5 mm (0.075 to 0.098 in).

tolerance, there is a choice of fitting a 6.0 mm (0.23 in)
or 6.5 mm (0.25 in) thick pressure end plate 14, with
either a shim 15 or an extra counter plate 17 between
the retaining circlip 13 and pressure end plate 14.
Use an airline to check the operation of the clutch.

217590
9803/9090 Issue 1
6-1 6-1
Mainshaft Clutch - Dismantling
4
3
14
15
16
2 11
17 12
13
1
1 20
18
9 12
(4-speed type)
19
10
5
6
7
8
A396150
19 15 10 9
2 3 4 7
18
5
1
6
17
20 14
16 13 12 11 8
A396250
9803/9090 Issue 1
6-2 6-2
Mainshaft Clutch - Dismantling

Note: The illustration shows a mainshaft assembly for a 6 - 9 Lift off spring retaining plate 12. The 4 - speed
speed transmission. The mainshaft assembly for a 4 - speed transmissions have a different shaped spring retaining
transmission has some small differences. An explanation of plate fitted.
the differences will be given as they occur in the procedure.
The mainshaft assemblies for the 6 - speed and the 4 - 10 Remove the spring 13 and oil baffle 14.
speed transmission are the same basic construction, except
the 4 - speed transmission have fewer friction/counter 11 Turn the assembly over and knock the clutch shaft on a
plates. piece of aluminium (or wood) to loosen the piston 15.
1 Carefully remove piston ring seals 1. Note: If the piston does not loosen when the clutch shaft is
Note: If the piston ring seals are excessively worn then oil inlet hole.
check for burrs or damage on shaft grooves. If necessary
remove burrs with a fine grade abrasion paper and oil. 12 Remove the piston 15. Remove and discard the piston
‘O’ ring 16 and shaft ‘O’ ring 17.
2 Remove taper roller bearing 2 using a puller or press.
13 Remove circlip 18 and withdraw the clutch housing 19
3 Withdraw the gears 3 and 4. Make a note which way from the shaft. Remove and discard the ‘O’ ring 20.
round the gears are fitted for assembly.
4 At the opposite end, use a suitable puller to remove the

taper roller bearing 5.

circlip 6.
6 Remove the pressure end plate 8 and shim 7, if fitted.


remove circlip 11.
11
A401360
9803/9090 Issue 1
6-3 6-3
Mainshaft Clutch - Assembly
4
3
14
15
16
2 11
17 12
13
1
1 20
18
9 12
(4-speed type)
19
10
5
6
7
8
A396150
19 15 10 9
2 3 4 7
18
5
1
A
6
6
17
A402700
20 14
16 13 12 11 8
A396250
9803/9090 Issue 1
6-4 6-4
Mainshaft Clutch - Assembly

Visually inspect the friction and counter plates: Use an airline to check the operation of the clutch.
Counter plates - light scoring/polishing is permissible, 11 Smear the taper roller bearing 5 with gearbox oil and
plates that are not flat, worn or heavily marked or scored press the bearing onto the shaft.
must be replaced with a new set.
12 At the opposite end press gears 3 and 4 onto shaft
spline. Make sure that the gears are fitted the correct
way round.
visible, plates that are not flat, have friction material
damage or scoring must be replaced with a new set. 13 Smear the taper roller bearing 2 with gearbox oil and
press the bearing onto the shaft.
DO NOT mix old and new plates, if a plate is damaged/worn
fit a complete new set. 14 Fit piston ring seals 1, refer to Piston Ring Seals -
Fitting Procedure.
Needle roller bearings should slide into position freely, do not
fit new bearings.

1 Fit a new ‘O’ ring 20.
2 Press the clutch housing 19 onto the shaft spline and fit
circlip 18.
3 Fit a new 'O' rings 17 and 16. Lubricate the piston 15

with oil and press fully into bore of clutch housing.
5 Fit the spring retaining plate 12. The 4-speed

transmissions have a different shaped spring retaining
plate fitted.
7 Fit one counter plate 10 followed by one friction plate 9.

Continue fitting alternate counter and friction plates,
8 Fit pressure end plate 8. Make sure that the chamfered

face is fitted facing the clutch pack as shown at A.
Make sure the teeth are not aligned with the lubrication
slots in the housing. Do not fit shim 7 at this stage.
Note: A spring disc is not fitted in this clutch pack.
9 Fit the clutch friction/counter plate retaining circlip 6.

float of the pressure end plate 8, which should be 1.9 to
2.5 mm (0.075 to 0.098 in).

either a shim 7 or an extra counter plate 10 between the
retaining circlip 6 and pressure end plate 8. 217590
9803/9090 Issue 1
7-1 7-1
6 Speed Clutch - Dismantling

24
23
25
13
3 15
14
2
1
16
17
19
20
21
22
18
1
4
6
7
8
9
5
10
11
12
A396170
3 16 17 15 13 12
18
19 9
2
25 7
1
6
22
8
24
23 21 14 20 5
A396240
9803/9090 Issue 1
7-2 7-2
6 Speed Clutch - Dismantling

1 Carefully remove piston ring seals 1 at each end of the
shaft. 13 Lift off spring retaining plate 20.
Note: If the piston ring seals are excessively worn then 14 Remove the spring 21 and oil baffle 22.
check for burrs or damage on shaft grooves. If necessary
remove burrs with a fine grade abrasion paper and oil. 15 Turn the assembly over and knock the clutch shaft on a
piece of aluminium (or wood) to loosen the piston 23.
2 Remove taper roller bearing 2 using a collet tool and
press. Note: If the piston does not loosen when the clutch shaft is
3 Withdraw the gear 3. Make a note which way round the oil inlet hole.
gear is fitted for assembly.
14 Remove the piston 23. Remove and discard the piston
4 At the opposite end, remove the clutch end bearing 4 'O' ring 24 and shaft 'O' ring 25.
using a puller.
5 Withdraw the gear and splined hub 5 together with thick

thrust washer 6, thrust bearing 7 and thin thrust washer
8.
6 Remove the needle roller bearing 9.
7 Remove the thin thrust washer 10, thrust bearing 11

and thick thrust washer 12.

circlip 13.

11 Remove the disc spring assembly 18.

remove circlip 19.
19
A401360
9803/9090 Issue 1
7-3 7-3
6 Speed Clutch - Assembly

24
23
25
13
3 15
14
2
1
16
17
19
20
21
22
18
1
4
6
7
8
9
5
10
11
12
A396170
3 16 17 15 13 12
18
19 9
2
25 7
A
1 13
14
6
22 A402700
8
24
23 21 14 20 5
A396240
9803/9090 Issue 1
7-4 7-4
6 Speed Clutch - Assembly

Visually inspect the friction and counter plates: 9 Using a dial test indicator as shown, measure the end
Counter plates - light scoring/polishing is permissible, to 2.5 mm (0.075 to 0.098 in).
plates that are not flat, worn or heavily marked or scored
must be replaced with a new set. If it is necessary to adjust the end float to bring it within
visible, plates that are not flat, have friction material the retaining circlip 13 and pressure end plate 14.Use
damage or scoring must be replaced with a new set. an airline to check the operation of the clutch.
DO NOT mix old and new plates, if a plate is damaged/worn 10 Fit the thick thrust washer 12, thrust bearing 11 and thin
fit a complete new set. thrust washer 10.
Needle roller bearings should slide into position freely, do not 11 Fit the needle roller bearing 9.
fit new bearings. 12 Carefully align the teeth of the clutch plates using a thin
Take care when handling disc spring assemblies 18 to avoid
13 Fit the thin thrust washer 8, thrust bearing 7 and thick
marking or damage, which could result in stress cracking. If thrust washer 6.
in doubt fit a new disc spring.
14 Smear the clutch end bearing 4 with gearbox oil and
15 At the opposite end, press the gear 3 onto the shaft
spline. Make sure that the gear is fitted the correct way
round.
oil and press fully into bore of clutch housing. 16 Smear the clutch end bearing 2 with gearbox oil and
seats in the piston. 17 Fit piston ring seals 1 at each end of the shaft, refer to
Piston Ring Seals - Fitting Procedure.
5 Fit the disc spring assembly 18. Make sure that the disc
spring is fitted with the teeth towards the clutch pack.
Make sure the teeth are not aligned with the lubrication
slots in the housing.

housing.
217590
9803/9090 Issue 1
8-1 8-1
2/4WD Clutch (Pressure ON) - Dismantling
10 9 12 11
7
18 1
3
15a
4
6 17
5 15 16
8 14 13 A396260
9803/9090 Issue 1
8-2 8-2
2/4WD Clutch (Pressure ON)

- Dismantling
1 Remove bearing 1, only if to be renewed.
2 Carefully remove piston ring seal 2. Note, If the piston

ring seal is damaged or excessively worn then check for
burrs or damage on the shaft groove. If necessary
remove burrs with a fine grade abrasion paper and oil.
3 Using a puller or press, withdraw the 4WD gear and

splined hub 5, together with its bearing 3, needle roller
bearings 6 and thrust washer 4. Remove thrust washer
7. (Note that thrust washers 4 and 7 are not 13
interchangeable).

circlip 8.

A401360

remove circlip 13.
8 Lift off spring retaining plate 14.
9 Remove the spring 15 and oil baffle 15A.

piece of aluminium (or wood) to loosen the piston 16.
Note: If the piston does not loosen when the clutch shaft is
knocked on aluminium, then hand pump air down the shaft oil
inlet hole.

'O' ring 17 and shaft 'O' ring18.
9803/9090 Issue 1
8-3 8-3
2/4WD Clutch (Pressure ON) - Assembly
10 9 12 11
7
18 1
3
A
8 2
10
15a
4
007204A 6 17
5 15 16
8 14 13 A396260
9803/9090 Issue 1
8-4 8-4
2/4WD Clutch (Pressure ON)

- Assembly
Visually inspect the friction and counter plates: 11 Smear the clutch end bearing 3 with gearbox oil and
press the bearing onto the shaft to seat on thrust
Counter plates - light scoring/polishing is permissible, washer 4.
plates that are not flat, worn or heavily marked or
scored must be replaced with a new set. 12 Fit piston ring seal 2, refer to Piston Ring Seals -
Fitting Procedure.
visible, plates that are not flat, have friction material
damage or scoring must be replaced with a new set.
DO NOT mix old, new and worn plates, if a plate is

damaged/worn fit a complete new set.
Needle roller bearings should slide into position freely, do not

fit new bearings.
2 Fit oil baffle 15A, piston spring 15, make sure the spring

housing.

to 2.5 mm (0.075 to 0.098 in).

either a shim 9 or an extra counter plate 12 between the
retaining circlip 8 and pressure end plate 10.
Use an airline to check the operation of the clutch.
9 Fit thrust washer 7.
10 Carefully align the teeth of the clutch plates using a thin

rod (or screwdriver) and fit the 4WD gear and splined 217590
hub 5, needle roller bearings 6 and thrust washer 4.
9803/9090 Issue 1
9-1 9-1
2/4WD Clutch (Spring ON) - Dismantling
10 15 16 9
3
4 19
2
7
5 20
6 21
11 12 14 13 17 18
A409750
9803/9090 Issue 1
9-2 9-2
2/4WD Clutch (Spring ON)

- Dismantling
1 Carefully remove piston ring seal 1. Note, If the piston

ring seal is damaged or excessively worn then check for
burrs or damage on the shaft groove. If necessary
remove burrs with a fine grade abrasion paper and oil.
2 Using a suitable puller or press, withdraw the 4WD gear

and splined hub 4, together with its taper roller bearing
2, needle roller bearings 5 and thrust washer 3. Remove
the thick thrust washer 6. (Note that thrust washers 3
and 6 are not interchangeable).
3 Using a suitable puller or press, remove taper roller

bearing 7.
4 Undo the locknut 8 using adaptor spanner (service tool

998/10738) and a 1/2” square drive socket wrench, refer to
Service Tools - Section 1.
Note: Use the 4WD output yoke secured in a vice as a holding

fixture, to support the clutch assembly and prevent it rotating
when torque is applied.
5 Lift off the disc springs 9.
6 Turn the assembly over and remove the clutch

friction/counter plates retaining circlip 10.
7 Remove pressure end plate 12 and shim(s) 11, if fitted.

9 Remove the pressure end plate 15.

piece of aluminium (or wood) to loosen the piston 16. Match
mark the piston and the clutch housing, to ensure that
the piston is assembled in the same orientation when
re-fitted on assembly.
Note: If the piston does not loosen when the clutch shaft is
knocked on aluminium, then hand-pump air down the shaft oil
inlet hole.

'O' rings 17 and 18, and the shaft 'O' ring 19.
12 Remove the capscrews 20 and reaction pins 21, only if

they are to be renewed.
9803/9090 Issue 1
9-3 9-3
2/4WD Clutch (Spring ON) - Assembly
10 15 16 9
8
3
4
A 4 19
B
10 2 5
7
9
12 3
1
007204A
8
A402700 A410280
5 20
6 21
1
11 12 14 13 17 18
A409750
14
9803/9090 Issue 1
6 20
7
9-4 9-4
2/4WD Clutch (Spring ON)

- Assembly
Visually inspect the friction and counter plates: 6 Fit the thick thrust washer 6.
Counter plates - light scoring/polishing is permissible, 7 Carefully align the teeth of the clutch plates using a thin
plates that are not flat, worn or heavily marked or rod (or screwdriver) and fit the 4WD gear and splined
scored must be replaced with a new set. hub 4 and needle roller bearings 5.
Friction plates - the cross hatching should be clearly 8 Fit the thrust washer 3. Smear the clutch end bearing 2
visible, plates that are not flat, have friction material with gearbox oil and press the bearing onto the shaft to
damage or scoring must be replaced with a new set. seat on thrust washer 3.
DO NOT mix old, new and worn plates, if a plate is 9 Turn the assembly over and fit a new shaft ‘O’ ring 19.
damaged/worn fit a complete new set. Fit new piston 'O' rings 17 and 18. Lubricate the piston
16 with gearbox oil and press fully into bore of clutch
Needle roller bearings should slide into position freely, do not housing (note the match marks made during the
bend or distort the cage to fit. If the cage has been distorted dismantling).
fit new bearings.
10 Fit the first two disc springs 9 with their concave sides
Assembly of reaction pins (if applicable) uppermost (there are four disc springs, which are
If removed during the dismantling, re-fit the reaction pins 21 identical). Place the other two disc springs 9 with their
to the piston 16. Adopt the following method to ensure concave sides down, on top of the first two as shown at
correct alignment of the pins: inset B.
a Place the piston into the bore of the clutch housing,
do not fit any ‘O’ rings at this stage. Align piston 11 Fit the locknut 8 and torque tighten to 300 Nm (221 lbf
holes with reaction pin holes in case 22. ft) using adaptor spanner (service tool 998/10738) and a 1/2”
b Insert each reaction pin in turn from the opposite square drive torque wrench, refer to Service Tools - Section
end of the housing and secure to the piston with 1. Note that the locknut is assembled dry with NO
capscrew 20. Apply Loctite 242 to the threads of threadlock or sealant on the threads.
the capscrews before fitting.
c When all four reaction pins are fitted, torque tighten Note: Use the 4WD output yoke secured in a vice as a holding
the capscrews to 10 - 12 Nm (7.3 - 8.8 lbf ft). fixture, to support the clutch assembly and prevent it rotating
d Match mark the piston and the clutch housing, to when torque is applied.
ensure that the piston is assembled in the same
orientation when re-fitted later in the procedure. 12 Check the operation of the clutch using the pressure
e Temporarily remove the piston from the clutch test adaptor and clamp assembly (service tool
housing and assemble the clutch pack as follows: 993/59300), refer to Pressure Testing the 2/4WD
Clutch, Service Procedures, for the correct procedure.
1 Fit the pressure end plate 15. Ensure that the clutch fully disengages at a working
pressure of 13 bar (190 lbf/in2).
2 Fit one friction plate 13 followed by one counter plate
14. Continue fitting alternate friction and counter plates, 13 Smear the clutch end bearing 7 with gearbox oil and
finishing with a friction plate. press the bearing onto the shaft.
3 Fit the pressure end plate 12, do not fit shim 11 at this 14 Fit piston ring seal 1, refer to Piston Ring Seals -
stage. Make sure that the chamfered face is fitted Fitting Procedure.
facing the clutch pack as shown at inset A. Make sure
the teeth are not aligned with the lubrication slots in the
housing.

to 5.0 mm (0.157 to 0.197 in).

the retaining circlip 10 and pressure end plate 12.
217590
9803/9090 Issue 1
10 - 1 10 - 1
Polytetrafluoroethylene (PTFE) Piston Ring Seals - Fitting Procedure

1 Wind the PTFE piston ring seal around your finger as
shown, so that the seal forms a 'coil'.
157250
2 Smear the seal with grease and then fit the seal to the
shaft.
Make sure that the seal sits below or flush with the
outer diameter of the shaft. If necessary, use finger
pressure as shown to make the seal flush with the shaft.
CAUTION: If the seal is not set below or flush with the outer
diameter of the shaft, then the seal will 'cut' when the shaft is
fitted to its mating component.
157260
9803/9090 Issue 1
11 - 1 11- 1
Torque Converter
10 Remove the access plate from the bottom of the engine
Removal
flywheel housing and through the access hole fit and
See the relevant gearbox removal procedure for torque
hand tighten one M8 flanged bolt (item 3) in the six 'O'
converter removal.
clock position.
Replacing
11 Rotate the flywheel until the next bolt hole is
Ensure that flywheel face, drive plate, and hardware are
accessible, fit and hand tighten the next bolt 3. Repeat
clean and free from burrs or other surface imperfections.
the operation until all bolts are fitted. Finally torque
tighten bolts 3 to 44 Nm (32 lbf ft), rotating the flywheel
When Replacing
each time to align bolts 3 with access hole. Refit
access plate.
1 Offer drive plate 1 to the torque converter.
2 Place the torque converter alignment tool A (service tool

892/01110, refer to Service Tools - Section 1) over the
torque converter spigot. Note that the alignment tool is
used one way round for the 12” and the other way
round for W300 torque converters. Make sure that the
tool locates in two of the converter bolt holes as shown.
Note: It is important that the converter drive tube is

protected against damage or contamination at all times. A
2
3 Fit four of the M10 flanged bolts 2 and torque tighten to
84 Nm (62 lbf ft). Remove the alignment tool and fit the
remaining two retaining bolts 2.
1
4 Offer the torque converter and drive plate assembly to
the flywheel, bolt the drive plate to the flywheel (use
only 3 bolts). Check the converter run-out as shown at
B, which should not exceed 0.38mm (0.015 in.).
Note: In the unlikely event that the run-out exceeds 0.38 mm

(0.015 in.), remove the converter and check the spigot for
burrs, remove the drive plate and rotate it 180° on the torque S436720
converter, repeat steps 2 to 4.
5 Remove the torque converter and drive plate assembly

from the flywheel.
6 Install the torque converter with its drive plate assembly

onto the transmission input shaft, make sure that the
dogs on the converter pump drive shaft engage with the
recesses in the pump, also take care not to damage the
oil seal.
7 Rotate the engine flywheel so that one bolt hole is in a

six O' clock position.
B
8 Rotate the torque converter and drive plate assembly so
that one bolt hole is in a six O' clock position.
9 Install the transmission/torque converter assembly to

the engine. See the relevant gearbox replacement
procedure. It is vitally important that the torque S161470
converter is fitted at the gearbox and engine
flywheel correctly. Failure to locate the converter
correctly will result in damage to the gearbox oil pump
on engine start up.
9803/9090 Issue 1
11 - 2 11- 2
Torque Converter
A265990
9803/9090 Issue 1
12 - 1 12- 1
Integral Park Brake
Check Park Brake Plate Wear
J
D
H
X B
X C
C002180-C3
9803/9090 Issue 1
12 - 2 12- 2
Integral Park Brake (cont’d)
Check Park Brake Plate Wear (cont’d)

If the parking brake performance deteriorates the first
adjustment should be at the park brake operating D
mechanism. If all adjustment at the mechanism is taken up
then it is likely that either the brake plates or the cable is
worn out. (Cables should not need adjusting and in many
cases no adjustment is provided.)
Firstly the travel at the brake actuator should be checked as

follows:
1 Clean all mud and debris from the brake housing. X

B
2 With the brake applied, remove the two M10 x 70 mm
long bolts X (17 mm A/F) from the right hand side of the Z
brake and five M6 x 14 mm long B (10 mm A/F) screws X
that hold the inspection cover in position. C
3 Using a flat bladed screwdriver, prise the cover to

break the sealant using slot Z provided on the right A
hand vertical face between the two 10 mm holes (no oil
C013930-C2
should be lost).
4 To use the inspection cover as a wear limit sighting aid,

refit it at right angles to the correct position using only
the upper M10 bolt X. Ensure the cover is pulled down
as the bolt is tightened to remove any clearance.
With the brake correctly adjusted and applied, the

Y
hexagonal key hole on clevis bolt Y must not be visible. If
even the slightest sign of the hexagonal can be seen the
entire brake plate stack should be replaced. Wear beyond
this point will give substantially reduced performance, risk
the actuator return springs becoming damaged or the cable
bottoming out.
Note: It is permissible to apply and release the brake with

the inspection cover removed without refitting the two M10
mounting bolts.
C014180-C1
X C
9803/9090 Issue 1
12 - 3 12- 3
Integral Park Brake (cont’d)
Dismantling
J
D
H
X B
X C
C002180-C3
9803/9090 Issue 1
12 - 4 12- 4
Integral Park Brake

This may not be fitted to all gearboxes.
This may not be fitted to all gearboxes. K
The integral park brake consists of a wet multi plate friction
pack and a mechanical actuator assembly.
L
If the plates are worn out (see Checking Park Brake Plate
Wear) or have carried out an emergency stop then they
need to be removed for detailed examination or
replacement. N
Note: It is assumed that the rear propshaft has been
removed. The output yoke should be vertical.
1 Clean all mud and debris from the brake and cable,
paying particular attention where the cable enters.
2 Release the parking brake operating mechanism.

M
Dismantle the Multi Plate Brake Pack
1 Undo bolts A (2 off) at positions X, and bolts B.

Remove cover plate C. Note that no gearbox oil should C006950-C2
be lost.
11
2 Undo the remaining bolts A and carefully pull off cover
D, keeping it square to the mating face on the gearbox.
Be aware that the reaction pins F may come away with 2
the cover.
3
3 Remove thrust plate G, friction plates H (5 off) and
counter plates J (5 off).
4
4 If the brake assembly is being removed prior to gearbox
dismantling, remove reaction pins F.
5 If necessary remove the park brake cable K. Undo 5

screw M, remove circlip L and then withdraw the cable
from the cover D.
Dismantle the Brake Actuator 6
1 Gently prise needle roller bearing E from actuator plate

6.
2 Carefully undo screw 1, note that the tension from

springs 4 and 5 is relieved before screw 1 is fully 7
removed.
3 Remove washers 2 and 3, followed by springs 4 and 5.

9
4 Lift out the brake actuator plate 6 followed by balls 7 (5
off).
88
C002190-C2
9803/9090 Issue 1
12 - 5 12- 5
Integral Park Brake
Inspection
F
Before inspecting the brake components, carefully remove
all traces of sealing compound from component mating
faces. Using a suitable degreaser, clean the brake
components including the brake housing in the gearbox rear
casing.
1 Carefully inspect the friction plates A and counter

plates B. If any of the plates show signs of damage or
distortion, renew the complete friction pack.
2 Assemble the friction and counter plates (including the

thrust plate C) on a suitable datum table. Measure the D
overall thickness of the assembled friction pack. If the
thickness X is less than the minimum service limit of
37.1 mm, renew the friction pack.
C002380
3 Inspect the following components for signs of E

excessive wear or damage: Balls D and their tapered
locating slots (cover E and actuator plate F), needle
roller thrust bearing G and the corresponding bearing G
surfaces (actuator plate F and thrust plate C).
NOTE: The position of item C (the thrust

plate and items B (counter plates) is C
extremely important.
Item C must be fitted against Item G (roller
thrust bearing).
A
This must be checked as correct on
assembly, as it is extremely important.
Item C has a larger internal diameter than
item B. B
Plate Stack Wear Limits
Maximum allowable plate stack height 39.6 mm

(1.56 in)
Minimum allowable plate stack height 37.1 mm

C002350-C1
(1.46 in
Minimum friction plate thickness 3.4 mm

(0.13 in)
9803/9090 Issue 1
12 - 6 12- 6
Integral Park Brake
Cable Inspection
K
1 The cable should be smooth and free in operation. It is
most important that the cover is not cut or split since
this will allow water into the transmission.
2 No corrosion or debris should have passed the ‘O’ ring L

seal N.
Torque Settings
N
Item Nm lbf ft kgf m

* M (4 mm hexagonal key) 9 6.64 0.92
C006950-C2
Assembly
11
Assemble the Brake Actuator
2
1 Apply a little grease to the ball locating slots in cover 8
and actuator plate 6. Locate balls 7 in their slots in 3
cover 8.
2 Fit actuator plate 6 followed by springs 4 and 5.

4
3 Locate washers 2 and 3, together with springs 4 and 5.

Fit screw 1, see Torque Settings.
5
4 Ensure washer 3 is located over central pin 9.
Torque Settings
6
* 1 (4 mm hexagonal key) 16 11.8 1.63
88
C002190-C2
9803/9090 Issue 2*
12 - 7 12- 7
Integral Park Brake NOTE: The position of item G (thrust plate)

and items J is extremely important. Item G
Assembly (cont’d) must be fitted against item E (roller thrust
bearing).
J
D
H
X B
X C
Z
C002180-C4
9803/9090 Issue 1
12 - 8 12- 8
Integral Park Brake
Assembly (cont’d)
Assemble the Multi Plate Brake Pack

K
1 Assembly the reaction pins F followed by the friction
pack in the gearbox casing. Note that a counter plate J
is fitted first followed by a friction plate H and so on. Fit R
the thrust plate G last.
L
2 Make sure that the needle roller thrust bearing E is
correctly clipped on the actuator assembly, and is free
to turn.
N
3 Before fitting cover D, apply a bead of Multigasket
sealant (4102/1200) to the mating face on the gearbox
casing as shown at Y. Torque tighten bolts A (4 off),
see Torque Settings. Note that 2 bolts at position X
are not fitted at this stage.
Note: If the park brake cable K is not to be fitted at this

stage omit steps 4 and 5. Loosely fit cover C and the M
remaining 2 bolts at positions X.
4 If applicable, fit the park brake cable K. Feed the cable

into the housing and fit the fork end to the brake C006950-C3
P
actuator P with screw M. Make sure that ‘O’ ring N is
undamaged and correctly fitted on collar R. Locate the
collar inside the brake housing and retain with circlip L.
5 Before fitting cover plate C, apply a bead of Multigasket

(4102/1200) sealant to the mating face on the gearbox
casing as shown at Z. Fit screws B (5 off) and bolts A (2
off), see Torque Settings.
Torque Settings

A 56 41 5.7
B 16 11.8 1.63
*M 9 6.64 0.92
NOTE: The free play of park brake cable

must be a minimum of 20mm (0.79 in).
Note: Confirm the brake is producing sufficient torque to

hold the machine on an incline by carrying out a stall test on
the level in the specified gear. If the brake will hold the
machine it will easily comply with the parking brake
requirement on a 20% grade.
Machine Type Select Gear Machine should hold at:
4 Speed Powershift PS7644 XLR 3 Full Throttle Stall
6 Speed Powershift PS7646 XLR 4 Full Throttle Stall
Note: The park brake mechanism may need to be released

slightly to re-engage the transmission prior to carrying out
this test.
9803/9090 Issue 2*
FRONT AND REAR
AXLES OPERATING
MANUAL
General Information 1
Care & Safety 2
Routine Maintenance 3
Hydraulics 4
Service Axles
5
Manual
Brakes
6
WREXHAM
United Kingdom
LL13 9UF NOTE
All references in this manual to ‘Forward’ and
Tel: (01978) 661140
Fax: (01978) 661863
‘Reverse’ assume a front-mounted engine.
SD 55-3 PIECE
AXLES
Issue 2
Introduction
This publication is designed for the benefit of Service Engineers.
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated
with the maintenance and repair of hydraulic equipment.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of
course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe
connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all
else
SAFETY MUST COME FIRST!
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 = General Information - includes torque settings and service tools.

2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants etc.
The remaining sections deal with Dismantling, Overhaul etc. of specific components:
4 = Hydraulics
5 = Axles
6 = Brakes
The page numbering in each section is not continuous. This allows for the insertion of new items in later issues of the manual.
Section contents, technical data, operation descriptions etc. are inserted at the beginning of each section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid
reference.
Page cross references are generally made by presenting the subject title printed in bold, followed by the title of the section
containing the subject. For example:
“24 If the axle is still on the machine, fit the brake calipers (see Brake Caliper Removal and Replacement, Section 6).”
Note: If only the subject title in bold is given, i.e. no section title, the cross reference is to another part of the same section.
Use the contents list at the beginning of each section to find the exact page number.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.
‘Left Hand’ and ‘Right Hand’ are as viewed from the rear of the machine facing forwards.
9803/9282 Issue 1
i i
Contents Page No.
Unit Identification 1-1
Replacement Parts 1-1
Axle Build Identification 1-1
Torque Settings 2-1
Service Tools Numerical List 3-1
Service Tools 4-1
Sealing and Retaining Compounds 5-1
9803/9282 Issue 1
1-1 1-1
Unit Identification
Axle Serial Plate
The axle serial number is stamped on a plate mounted on

the face of the axle, as shown.
SD 55 - 3 Piece Axle
A403640
Replacement Parts Axle Build Identification

1 When replacement parts are required, always ensure To identify an axle build the number on the axle data plate
that the correct parts are obtained, e.g. in the case of should be cross-referenced with the part number in the parts
gear replacements, always check the part number information.
Example:
the serial plate shown. 450 / 2760 / 1 / 0091

A B C
dismantling, should be renewed on reassembly.
A 450/2760: Axle assembly part number (450/27600)
4 On reassembly care should be taken that all parts are without the final zeros.
/1: Internal issue number of the main manufacturing
incorrectly assembled can lead to a complete failure. B
drawing.
as provided in this manual. It is important to adhere to C /0091: Axle serial number. The complete 12 digit number
must be quoted for warranty purposes. The parts
information will detail the number of friction plates
6 It is advisable to lightly lubricate with a recommended required for the axle.
9803/9282 Issue 2
2-1 2-1
Torque Settings
Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the
figures stated. For lubricated threads the values should be REDUCED by one third.
UNF Grade 'S' Bolts

in (mm) in Nm kgf m lbf ft
1/4 (6.3) 7/16 14 1.4 10

5/16 (7.9) 1/2 28 2.8 20
3/8 (9.5) 9/16 49 5.0 36
7/16 (11.1) 5/8 78 8.0 58
1/2 (12.7) 3/4 117 12.0 87
9/16 (14.3) 13/16 170 17.3 125
5/8 (15.9) 15/16 238 24.3 175
3/4 (19.0) 11/8 407 41.5 300
7/8 (22.2) 15/16 650 66.3 480
1 (25.4) 11/2 970 99.0 715
11/4 (31.7) 17/8 1940 198.0 1430
11/2 (38.1) 21/4 3390 345.0 2500

(mm) mm Nm kgf m lbf ft
M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105
Bolt Size Torque Settings

(mm) Nm kgf m lbf ft
M8 (8) 48 4.9 35
M10 (10) 94 9.6 69
M12 (12) 166 16.9 122
M14 (14) 320 32.6 236
M16 (16) 400 40.8 295
Note: All bolts are high tensile and must not be replaced by bolts of a lesser tensile specification.
9803/9282 Issue 1
3-1 3-1
Service Tools Numerical List Page No.
4003/0211 Anti-Seize Paste 5-1

4101/0251 Loctite 242 5-1
4101/0451 Loctite 932 5-1
4101/0250 Loctite 243 5-1
4102/0552 Loctite 275 5-1
4102/1212 Loctite 574 or Permabond A136 5-1
4102/1951 Loctite 577 5-1
4104/0251 Activator (Aerosol) 5-1
4104/0253 Activator (Bottle) 5-1
4104/1557 Cleaner/Degreaser 5-1
892/00174 Measuring Cup - Pinion Head Bearing 4-2
892/00182 Bearing Pad Driver 4-1
892/00224 Impulse Extractor Set for Hub Bearing
Seals 4-2
892/00225 Adaptor - Impulse Extractor 4-2
892/00333 Heavy Duty Socket 4-1
892/00812 Drive Coupling Spanner 4-1
892/00822 Splined Bolt Socket 4-1
892/00833 Annulus Removal Tool 4-2
892/00891 Oil Seal Insertion Tool 4-2
892/00918 Setting Tool Kit 4-3
892/01075 Support Bracket 4-3
921/52627 Spacer 14.20 Service use 4-3
921/53300 Spacer Kit 4-3
928/10060 Shim Kit - Dropbox
992/04000 Torque Multiplier 4-1
992/07601 Spanner for Half Shaft Nuts 4-1
992/07603 Replacer - Pinion Head Bearing Cup 4-1
992/07604 Replacer - Crownwheel Bearing and
Differential Cones 4-1
992/07606 Measuring Cup - Pinion Bearing 4-1
992/07607 Spacer - Pinion Bearing Preload 4-1
992/07609 Adapter - Steer/Drive Axle Pinion
Bearing Cone 4-1
993/70111 Breakback Torque Wrench 4-3
9803/9282 Issue 1
4-1 4-1
Service Tools
992/07604 Replacer - Crownwheel Bearing 992/07606 Measuring Cup - Pinion Bearing

and Differential Bearing Cones
992/07609 Adapter - Steer/Drive Axle Pinion Bearing

Cone
892/00817 17 mm A/F x 3/4 in square drive

992/07607 Spacer - Pinion Bearing Preload 892/00333 19 mm A/F x 3/4 in square drive
892/00812 Drive Coupling Spanner for axle

yoke couplings
892/00182 Bearing Pad Driver

S196720
992/07601 Spanner for Half Shaft Nuts 992/07603 Replacer - Pinion Head Bearing Cup
9803/9282 Issue 1
4-2 4-2
S197030
A272520
992/04000 Torque Multiplier (use in conjunction with a
torque wrench to give a 5:1 multiplication 892/00891 Oil Seal Insertion Tool
when tightening pinion nuts)
892/00822
Splined Bolt Socket for

driveshafts
892/00174
Measuring Cup - Pinion Head

Bearing S197060
S190770
S197070
892/00224
Impulse Extractor Set for Hub Bearing Seals 892/00833 Annulus Removal Tool
892/00225 Adapter - Impulse Extractor

Small 17 mm to 25 mm
Medium 25 mm to 45 mm
Large 45 mm to 80 mm
9803/9282 Issue 1
4-3 4-3
Solid Spacer Setting Kit
1 892/00918 Setting Tool Kit 4-3

1 2 921/52627 Spacer 14.20 Service use 4-3
3 993/70111 Breakback Torque Wrench 4-3
4 892/01075 Support Bracket 4-3
5 921/53300 Spacer Kit - SD55 Axles 4-3
Comprises of:
Spacer thickness mm
921/53322 13.550
921/53323 13.575
921/53324 13.600
921/53325 13.625
921/53301 13.650
921/53302 13.675
921/53303 13.700
921/53304 13.725
921/53305 13.750
921/53306 13.775
921/53307 13.800
921/53308 13.825
921/53309 13.850
921/53310 13.875
2 921/53311 13.900
921/53312 13.925
921/53313 13.950
921/53314 13.975
921/53315 14.000
921/53316 14.025
921/53317 14.050
921/53318 14.075
3 921/53319 14.100
921/53320 14.125
921/53321 14.150
Note: After using a spacer, obtain a replacement to keep the

A396950 set complete.
A396960
9803/9282 Issue 1
5-1 5-1
Sealing and Retaining Compounds
Loctite 574 or A medium strength sealant suitable for all

Permabond A136 sizes of gasket flanges, and for hydraulic
fittings of 25-65 mm diameter. 4102/1212
Loctite 275 or For all size of flanges where the strength

Permabond A140 of the joint is important. † 4102/0552
Loctite 932 or For all retaining parts which are likely to

Permabond A137 be dismantled and for use on threads larger
than 50 mm dia. 4101/0451
Loctite 242 or A medium strength locking fluid for sealing

Permabond A113 and retaining nuts, bolts, and screws up to
50mm diameter, and for hydraulic fittings
up to 25 mm diameter. † 4101/0251
Loctite 243 A medium strength locking fluid similar

to Loctite 242 but with greater resistance
to thread contamination. 4101/0250
Loctite 648 or For retaining parts which are unlikely

Permabond A118 to be dismantled. 4101/0651
Loctite 577 A medium strength thread sealing compound. 4102/1951
Loctite Activator A cleaning primer which speeds the curing † 4104/0251 Aerosol
rate of anaerobic products. † 4104/0253 Bottle
Cleaner/Degreaser For degreasing components prior to use of

anaerobic adhesives and sealants. † 4104/1557 Aerosol
Anti-Seize Paste A compound used for assembly and prevention

of thread seizure. † 4003/0211
Note: The above list is the range of sealants and retaining compounds available. Items marked † are those referred to within
the sections.
9803/9282 Issue 1
i i
Contents Page No.

Safety Notices 1-1
General safety 2-1
Operating safety 3-1
Maintenance safety 4-1
9803/9282 Issue 1
1-1 1-1
Safety Notices
In this publication and on the machine, there are safety notices. Each notice starts with a
signal word. The signal word meanings are given below.
! DANGER
Denotes an extreme hazard exists. If proper precautions are not taken, it is highly
probable that the operator (or others) could be killed or seriously injured.
INT-1-2-1
! WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator (or others)
could be killed or seriously injured.
INT-1-2-2
! CAUTION
Denotes a reminder of safety practices. Failure to follow these safety practices could
result in injury to the operator (or others) and possible damage to the machine.
INT-1-2-3
9803/9282 Issue 1
2-1 2-1
All machinery, whether mobile or static, can be hazardous.

When equipment is correctly operated and properly
maintained it can be safe to work with. But when it is
carelessly operated or poorly maintained it can become a
danger.
Do not work with any equipment until you are sure that it is
serviceable, that you know how to control it and be aware of
all relevant safety requirements.
If the equipment covered by this manual forms part of a

larger product (eg. a vehicle) be sure to observe the safety
requirements which relate to the product as a whole, as well
as those given in this manual.
On this and the following pages and throughout this manual,

you will find safety messages. Please read and understand
these safety messages before using and working on the
equipment covered in this manual.
Make sure you also read and understand all other safety
messages contained in operator handbooks and service
manuals concerned with the product of which this
equipment forms part.
Remember
BE CAREFUL
BE ALERT
BE SAFE
General Safety
! WARNING
Decals ! WARNING
This equipment may include safety decals Lifting Equipment
You can be injured if you do not obey decal safety You can be injured if you use faulty lifting equipment. Make
instructions. Keep decals clean. Replace unreadable or sure that lifting equipment is in good condition. Make sure
missing decals with new ones before operating the that lifting tackle complies with all local regulations and is
equipment. Make sure replacement parts include warning suitable for the job. Make sure that lifting equipment is
decals where necessary. strong enough for the job.
INT-1-3-7
! WARNING ! WARNING
Clothing Raised Attachments
You can be injured if you do not wear the proper clothing. Raised attachments on certain kinds of equipment can fall
Loose clothing can get caught in the equipment. Wear and injure you. Do not walk or work under raised
protective clothing to suit the job. Examples of protective attachments unless they are safely blocked.
clothing are: a hard hat, safety shoes, safety glasses, a well INT-1-3-8
fitting overall, ear-protectors and industrial gloves. Keep

cuffs fastened. Do not wear a necktie or scarf. Keep long ! WARNING
hair restrained.
Alcohol and Drugs
It is extremely dangerous to operate machinery when under
! WARNING the influence of alcohol or drugs. Do not consume alcoholic
Care and Alertness drinks or take drugs before or whilst operating the machine
All the time you are working with or on the equipment, take or attachments. Be aware of medicines which can cause
care and stay alert. Always be careful. Always be alert for drowsiness.
hazards. INT-1-3-9
9803/9282 Issue 1
3-1 3-1
Operating Safety
! WARNING ! WARNING
Equipment Condition Communications
Defective equipment can injure you or others. Do not Bad communications can cause accidents. Keep people
operate equipment which is defective or has missing parts. around you informed of what you will be doing. If you will be
Make sure all maintenance procedures are completed working with other people, make sure any hand signals that
before using the equipment. may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands.
INT-2-2-3
! WARNING
Controls ! WARNING
You or others can be killed or seriously injured if you operate The transmission can be in 4 wheel drive until de-selected
machine control levers from outside the cab. Operate the by hydraulic pressure to 2 wheel drive. If the machine is to
control levers only when you are correctly seated inside the be raised and the engine/transmission run, make sure all
cab. four wheels are off the ground and supported by axle
stands. If only the rear wheels are raised, the machine could
still drive through the front axle.
! WARNING
Equipment Limits
Operating equipment beyond its design limits can damage
the equipment, it can also be dangerous. Do not operate the
equipment outside its limits. Do not try to upgrade the
equipment performance with unapproved modifications.
! WARNING
Engine/Steering Failure
If the engine or steering on the ‘parent’ machine fails, stop
the machine as quickly as possible. Do not operate the
machine until the fault has been corrected.
! WARNING
Engine
The engine on the ‘parent’ machine has rotating parts. Do
not open the engine cover while the engine is running. Do
not use the machine with the cover open.
! DANGER
Sparks
Explosions and fire can be caused by sparks from the
exhaust or the electrical system. Do not use the machine in
closed areas where there is flammable material, vapour or
dust.
INT-2-2-10
! WARNING
Exhaust Gases
Breathing the ’parent’ machine exhaust gases can harm and
possibly kill you. Do not operate the machine in closed
spaces without making sure there is good ventilation. If
possible, fit an exhaust extension. If you begin to feel
drowsy, stop the machine at once. Get out of the cab into
fresh air.
9803/9282 Issue 1
4-1 4-1
Maintenance Safety
! WARNING ! DANGER
Repairs Hydraulic Pressure
Do not try to do repairs or any other type of maintenance Hydraulic fluid at system pressure can injure you. Before
work you do not understand. To avoid injury and/or damage disconnecting or connecting hydraulic hoses, stop the
get the work done by a specialist engineer. engine and operate the controls to release pressure trapped
GEN-1-5
in the hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11/1
! WARNING
Modifications and Welding
Non-approved modifications can cause injury and damage. ! WARNING
Welds on cast iron can weaken the structure and break. Do Oil
not weld cast iron. Contact your distributor for advice before Oil is toxic. If you swallow any oil, do not induce vomiting,
modifying the equipment. seek medical advice. Used engine oil contains harmful
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier
! WARNING cream or wear gloves to prevent skin contact. Wash skin
Metal Splinters contaminated with oil thoroughly in warm soapy water. Do
You can be injured by flying metal splinters when driving not use petrol, diesel fuel or paraffin to clean your skin.
INT-3-2-3
metal pins in or out. Use a soft faced hammer or drift to
remove and fit metal pins. Always wear safety glasses.
INT-3-1-3
! WARNING
Soft Ground
! WARNING A machine can sink into soft ground. Never work under a
Electrical Circuits machine on soft ground.
INT-3-2-4
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong connection
can cause injury and/or damage.
INT-3-1-4 ! WARNING
Always wear safety glasses when dismantling assemblies
containing components under pressure from springs. This
! WARNING will protect against eye injury from components accidently
Battery Gases flying out.
GEN 6-2
Batteries give off explosive gases. Keep flames and sparks
away from the vehicle battery. Do not smoke close to the
battery. Make sure there is good ventilation in closed areas
where batteries are being used or charged. Do not check the ! CAUTION
battery charge by shorting the terminals with metal; use a Cleaning
hydrometer or voltmeter. Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents and
solvents.
INT-3-2-11
! WARNING
Hydraulic Fluid ! CAUTION
Fine jets of hydraulic fluid at high pressure can penetrate the
'O' rings, Seals and Gaskets
skin. Do not use your fingers to check for hydraulic fluid
Badly fitted, damaged or rotted 'O' rings, seals and gaskets
leaks. Do not put your face close to suspected leaks. Hold a
can cause leakages and possible accidents. Renew
piece of cardboard close to suspected leaks and then
whenever disturbed unless otherwise instructed. Do not use
inspect the cardboard for signs of hydraulic fluid. If hydraulic
Triochloroethane or paint thinners near 'O' rings and seals.
fluid penetrates your skin, get medical help immediately. INT-3-2-12
INT-3-1-10/1
9803/9282 Issue 1
4-2 4-2
Maintenance Safety (cont'd)
! WARNING ! WARNING
Fires Fluoroelastomeric Materials
Do not use water to put out an equipment fire, you could Certain seals and gaskets (e.g. transmission oil seals) may
spread an oil fire or get a shock from an elecrical fire. Use contain fluoroelastomeric materials such as Viton, Fluorel
carbon dioxide, dry chemical or foam extinguishers. Contact and Technoflon. Fluoroelastomeric materials subjected to
your nearest fire department as quickly as possible. high temperatures can produce highly corrosive hydrofluoric
Firefighters should use self-contained breathing apparatus. acid. THIS ACID CAN SEVERELY BURN.
! WARNING New fluoroelastomeric components at ambient temperature

require no special safety precautions.
Jacking
A machine can roll off jacks and crush you unless the wheels Used fluoroelastomeric components whose temperatures
have been chocked. Always chock the wheels at the have not exceeded 300°C require no special safety
opposite end of the machine that is to be jacked. Do not precautions. If evidence of decomposition (e.g. charring) is
work underneath a machine supported only by jacks. Always found, refer to the next paragraph for safety instructions DO
support a jacked-up machine on axle stands before working NOT TOUCH COMPONENT OR SURROUNDING AREA.
underneath it.
INT-3-2-8
Used fluoroelastomeric components subjected to
temperatures greater than 300°C (e.g. engine fire) must be
! WARNING treated using the following safety procedure. Make sure that
Hydraulic Hoses heavy duty gloves and special safety glasses are worn:
Damaged hoses can cause fatal accidents. Inspect the
hoses regularly for: 1 Ensure that components have cooled then remove and
- Damaged end fittings place material into plastic bags.
- Chafed outer covers
- Ballooned outer covers 2 Thoroughly wash contaminated area with 10% calcium
- Kinked or crushed hoses hydroxide or other suitable alkali solution, if necessary
- Embedded armouring in outer covers use wire wool to remove burnt remains.
- Displaced end fittings.
INT-3-3-2 3 Thoroughly wash contaminated area with detergent and
water.
! WARNING
4 Contain all removed material, gloves etc. used in this
Make the machine safe before working underneath it. Park operation in sealed plastic bags and dispose of in
the machine on level ground. Apply the parking brake, put accordance with Local Authority Regulations.
the transmission in neutral and stop the engine. Chock both
sides of all four wheels. DO NOT BURN FLUOROELASTOMERIC MATERIALS.
Disconnect the battery, to prevent the engine being started If contamination of skin or eyes occurs, wash the affected
while you are beneath the machine. area with a continuous supply of clean water or with calcium
GEN-1-2/IT
hydroxide solution for 15-60 minutes. Get medical attention
immediately.
! WARNING INT-3-3-5/1/IT
To avoid burning, wear protective gloves when handling hot

components. To protect your eyes, wear goggles when ! WARNING
using a wire brush to clean components. Protect your eyes when grinding metal. Wear safety glasses
HYD 1-3
or goggles. Remove or protect any combustible materials
from the area which could be ignited by sparks.
! WARNING GEN-1-12
Some lubricants contain lead. The repeated swallowing of

very small quantities can cause chronic lead poisoning. Do ! WARNING
not smoke or touch food while handling this lubricant. Before carrying out any servicing, park the machine on firm
Dispose of waste (rags etc.) in accordance with local level ground and apply the parking brake. Make sure the
regulations. transmission selector and gear lever are in the neutral
2-1-1-8/IT
position. Switch OFF the engine and remove the starter key.
Operate the control levers and remove the hydraulic filler
cap to vent any residual pressure. Disconnect the battery.
GEN-1-13
9803/9282 Issue 1
i i
Contents Page No.
Lubricants & Capacities 1-1
Lubricants - Health and Safety 1-2
Service Schedules 2-1
Greasing
- SD 55 - 3 Piece Axle 3-1
Axle Hub Oil Level

- Check Differential Oil Level 4-1
- Change Differential Oil 4-1
- Check Hub Oil Level 4-1
- Change Hub Oil 4-1
9803/9282 Issue 1
1-1 1-1
Lubricants & Capacities

ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL
Litres UK Gals SPECIFICATION
Axle - SD 55 - 3 piece
Housing TBA TBA
Hubs (x2) TBA TBA Mobil Fluid 424 API-GL-4, M2C-41B/134D
JD20C
MF M1135/M1141/M1143
Axle - SD 55 - 3 piece with Dropbox

Housing TBA TBA
Hubs (x2) TBA TBA Mobil Fluid 424 API-GL-4, M2C-41B/134D
JD20C
MF M1135/M1141/M1143
Grease Points - - Mobil HP222 Mobil HP222
Brake System Mobil DTE 11M ISO VG 15

CAUTION: Do not use ordinary brake fluid (J 1703)
Note 1: Mobil 424 should always be used for axles fitted with brakes. For Axles without brakes, Mobilube HD90 or Mobil Fluid
424 can be used.
Note 2: For axles with limited slip differentials, Mobil Fluid 424 must be used.
9803/9282 Issue 1
1-2 Lubricants - Health and Safety 1-2
Hygiene
Lubricants are not a health risk when used properly for their 2 Apply a barrier cream to the skin before handling used
intended purposes. oil.
However, excessive or prolonged skin contact can remove 3 Note the following when removing oil from skin:
the natural fats from your skin, causing dryness and
irritation. a Wash your skin thoroughly with soap and water.
Low viscosity oils are more likely to do this, so take special b Using a nail brush will help.
care when handling used oils, which might be diluted with
fuel contamination. c Use special hand cleansers to help clean dirty
hands.
Whenever you are handling oil products you should maintain
good standards of care and personal and plant hygiene. For d Never use petrol, diesel fuel, or paraffin for washing.
details of these precautions we advise you to read the
relevant publications issued by your local health authority, 4 Avoid skin contact with oil soaked clothing.
plus the following.
5 Don't keep oily rags in pockets.
Storage
6 Wash dirty clothing before re-use.
Always keep lubricants out of the reach of children.
7 Throw away oil-soaked shoes.
Never store lubricants in open or unlabelled containers.
First Aid - Oil
Waste Disposal
Eyes
All waste products should be disposed of in accordance In the case of eye contact, flush with water for 15 minutes. If
with all the relevant regulations. irritation persists, get medical attention.
The collection and disposal of used oil should be in Swallowing

accordance with any local regulations. Never pour used oil If oil is swallowed do not induce vomiting. Get medical
into sewers, drains or on the ground. advice.
Skin
Handling In the case of excessive skin contact, wash with soap and
water.
New Oil
There are no special precautions needed for the handling or

Spillage
use of new oil, beside the normal care and hygiene
practices. Absorb on sand or a locally approved brand of absorbent
granules. Scrape up and remove to a chemical disposal
Used Oil area.
Used lubricants contain harmful contaminants. Fires

Here are precautions to protect your health when handling Extinguish with carbon dioxide, dry chemical or foam. Fire-
used oil: fighters should use self-contained breathing apparatus.
1 Avoid prolonged, excessive or repeated skin contact

with used oils.
9803/9282 Issue 1
2-1 2-1
Service Schedules
A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular
maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working
condition.
! WARNING
A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one
end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the
machine when working under it.
Disconnect the battery, to prevent the engine being started while you are beneath the machine.
GEN-1-1
Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings
to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure any defects found during the
regular maintenance checks are rectified immediately.
Calendar equivalents:
10 Hours = Daily
50 Hours = Weekly
500 Hours = Six Months
1000 Hours = Yearly
2000 Hours = 2 Years
Service checks should be carried out as in the table at whichever time occurs first.
Pre-start Cold Checks Operation 10 50 †100 500 1000 2000

Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr
AXLES AND STEERING

Axle Hub Oil Level ➀ - Check ● ● ● ●
Axle Hub Oil - Change ● ● ● ●
Steer Axle Movement/Shimming ➁ - Check ● ● ● ●
Axle Pivot and Steering Joints †† - Grease ● ● ● ●
HYDRAULICS
Cylinders - Chrome Condition - Check ● ● ●
Functional Test Operation 10 50 †100 500 1000 2000

and Final Inspection Hr Hr Hr Hr Hr Hr
AXLES AND STEERING

Steering Modes - Operation - Check ● ● ● ● ● ●
Steering Proximity Switch - Operation ➁ - Check ● ● ● ●
Wheel Nut Torque - Check ● ● ● ● ● ●
Steer Phasing ➁ - Check ● ● ●
Steer Cylinder - Balance ➁ - Check ● ● ● ●
Steer Circuit Pressure ➁ - Check ● ● ● ●
† Note: First 100 Hours Service only, to be completed by your Distributor.
†† Note: Mobil HP222 Grease must be used at 500 Hour intervals. If an alternative grease is used, the Service Intervals
must be reduced to 50 hours/weekly.
➀ Note: Check for leaks every 50 hours, check level if leaking.
➁ Note: Jobs which should only be done by a specialist are indicated by a ➁.
Note: Check generally for leaks on ALL systems, for example, hydraulics, axles etc. If a leak is evident find the source
and repair as required. Make sure that the system is topped up with the recommended fluid after repair.
Note: Faults in the braking system must be rectified immediately. Ensure the correct brake fluid is used (see
Lubricants and Capacities), and all equipment is clean and free from water contamination. Under no circumstances
should water be allowed to enter the braking system.
9803/9282 Issue 1
3-1 3-1
Greasing - SD 55 - 3 Piece Axle

for Interval see Service Schedule
Pad Mounted - Total 6 Grease Points
Trunnion Mounted - Total 8 Grease Points
Note: (All Axles) When greasing, raise the wheels and swing
them from lock to lock. This will ensure full penetration.
Note: (Trunnion Mounted Axles) On some axles an

additional grease nipple X may be fitted. Rock the axle to
ensure free movement of the trunnion.
7
6
X 8
3
2
A403650
9803/9282 Issue 1
4-1 4-1
Axle Oil Level

Check Differential Oil Level - for Interval see Service Change Hub Oil - for Interval see Service Schedule
Schedule
1 Set the machine level, with the tyres just clear of the
1 Remove fill/level plug A and its sealing washer. Oil ground. Manually rotate the wheels to bring the OIL
should be level with the bottom of the fill/level hole. LEVEL mark on the hubs to the vertical position, with
the fill/level plugs C at the bottom.
2 If necessary, top up with oil (see Lubricants and
Capacities). Clean and refit fill/level plug A with new
sealing washer.
Change Differential Oil - for Intervals see Service Schedule
1 Remove fill/level plug A and drain plug B, together with

their sealing washers. Allow time for the oil to drain out.
2 Clean and refit drain plug B with a new sealing washer.

Tighten to 90 Nm (66 lbf ft).
LEVEL
OIL
3 Fill the axle with oil (see Lubricants and Capacities)
through the fill/level hole A. Oil should be level with the C
4 Clean and refit fill/level plug A with a new sealing

washer. Tighten to 90 Nm (66 lbf ft).
ITL00710
2 Remove fill/level plugs C. Allow time for the oil to drain

out.
A 3 Set OIL LEVEL marks to the horizontal.
B OIL
A403700 LEVEL
C
Check Hub Oil Level - for Interval see Service Schedule
1 Make sure the OIL LEVEL mark on the hub is

horizontal.
ITL00710
2 Remove fill/level plug C. Oil should be level with the
4 Fill the hubs with oil (see Lubricants and Capacities),
3 If necessary, top up with oil (see Lubricants and through the fill/level holes C. Oil should be level with
Capacities). Clean and refit fill/level plug C. the bottom of the fill/level hole.
5 Clean and refit fill/level plugs C.
9803/9282 Issue 1
Section 4 Hydraulics Section 4
i i
Contents Page No.
Technical Data 1-1
Cylinders
Steer Cylinder
- Dismantling and Assembly 2-2
Steering System - Bleeding Procedure 3-1
9803/9282 Issue 1
Steering
Relief Valve Pressure @ 1500 rpm Refer to machine Operator Handbook

Shock Valve Pressure Refer to machine Operator Handbook
Sizes
Bore Diameter 75 mm (2.95 in)

Rod Diameter 42 mm (1.65 in)
Note: The above data refers to JCB Drivetrain Steer Cylinders, please check the type of cylinder fitted before using this
section. For different cylinders refer to original manufacturer’s data.
9803/9282 Issue 2
2-1 Cylinders 2-1
Steer Cylinder
Removal and Replacement 5 Using a soft faced hammer, tap the closed end of the
cylinder and carefully withdraw the cylinder and track-
! WARNING rod from the housing.
Note: Before removal, mark the cylinder flange and housing
Position the machine on a firm, level surface before
for relocation.
raising one end. Ensure the other end is securely
Replacement
Replace the power track rod by reversing the removal
procedure.
GEN-1-1
Apply Anti-Seize Paste, Part No. 4003/0211 to pivot pins B
to facilitate subsequent removal.
Removal
After connecting hoses, check the hydraulic fluid level, and if
Note: Depending on accessibility, the steer cylinder can be
necessary top-up.
removed and replaced with the axle on the machine. Where
accessibility is limited, the axle should be removed before
Bleed the Hydraulic System (see Steering System -
removal of the cylinder (see Removal and Replacement,
Bleeding Procedure).
Section 5).
Torque Settings
1 Thoroughly clean external parts.
2 Disconnect and cap hydraulic hoses to prevent loss of
A 56 5.6 41
fluid and ingress of dirt. Label hoses for identification
C 166 16.8 122
and correct refitting.
3 Remove locking screws A and pivot pins B. Swing the

track-rod clear of the steering joints.
4 Remove screws C and washers D (4 off each) from the

cylinder mounting flange.
A
B
C
D
A B
A403660
9803/9282 Issue 1
2-2 Cylinders 2-2
Steer Cylinder
Dismantling and Assembly
10
7
11
1
4
5
9
8
D
2
F 10
A
E
B
Z o
3552°
X T X
C
V
ITL01150
9803/9282 Issue 1
2-3 Cylinders 2-3
Steer Cylinder (cont’d)

Dismantling and Assembly (cont’d)
The following procedures can only be carried out with the iii Using the spanner at 5 to lock the rod, rotate the
axle removed from the machine. spanner at G to undo the other ball joint.
It will be necessary to provide a suitable stand on which to Note: Mark cover 2 and cylinder flange 3 relative to housing
support the axle once it has been removed from the flange 4 before removal.
machine.
3 Take out screws 1 (4 off) and remove the cylinder
Dismantling cover/piston guide 2. Remove and discard seals 9 and
10 with cover seal 11.
1 Remove setscrew A, extract pivot pin B and disengage
the track rod ends from the steering knuckles. 4 Pull piston/rod assembly 5 out of the cylinder. Remove
and discard guide rings 8 and seal 7 from the piston.
2 Remove the ball joints D.
Note: The piston is shrunk onto the piston rod. DO NOT
Note: The piston rod operates at full length and damage to
attempt to remove it.
the surface will cause fluid leaks. DO NOT attempt to grip
the rod with pipe grips etc.
5 Using a soft faced hammer, carefully tap the closed
end of cylinder 3 and withdraw the cylinder from its
i Using two suitable open ended spanners located on
housing 4. Remove and discard seals 9 and 10.
the flats at F and G, rotate against each other until
one ball joint unscrews.
Assembly
1 Fit new seal 7 and guide rings 8 to the piston. Ensure

they are seated correctly.
2 Grease piston rod seal 9, wiper ring 10 and fit them into
G the grooves in the closed end of cylinder 3. Ensure they
are seated correctly.
F 3 Grease the machined external shoulders on cylinder 3

and insert the closed end into housing 4. Using a soft
faced hammer, carefully tap the flange until the cylinder
is fully seated in the housing. Align the flange marking
with the housing mark.
A403670
4 Apply grease to piston seal 7 and the surfaces of the
piston rod. Insert piston/rod assembly 5 into the
cylinder, ensuring it is the correct way round, with the
ii Unscrew the ball joint until an open ended spanner
piston sleeve towards the closed end of the cylinder,
can be fitted on rod 5. Screw the ball joint against
carefully guiding the rod through the seals in the closed
the spanner to secure the spanner and to prevent
end of cylinder 3.
damage to the rod.
5 Grease and fit seal 9, wiper ring 10 and cover seal 11 to
the cylinder cover/piston guide. Ensure they are seated
correctly.
6 Apply Loctite 574 to cylinder flange face 3.

G
Locate cover/piton guide 2 onto the piston rod and
slide into position against cylinder flange 3, aligning the
5 location mark made during dismantling.
7 Insert screws 1 (4 off) and torque tighten to 166 Nm

(122 lbf ft).
A403680
8 Coat the first three external threads of track rod end
ball joint D with Loctite 242 and screw into the end of
the steering piston rod. Torque tighten to 400 Nm (295
lbf ft).
9803/9282 Issue 1
2-4 Cylinders 2-4
Steer Cylinder (cont’d)

Assembly (cont’d)
9 Grease and fit new web seals C to the hub steering

knuckle. Ensure the seals are fitted correctly and are
fully seated in position.
10 Connect the track rod ends to the hub carrier steering

knuckles.
Coat the surface of pivot pin B with anti-seize paste (see

Sealing and Retaining Compounds, Section 1) and
insert the pin into the hub carrier and fit the setscrew A.
Apply Loctite 242 to the threads and torque tighten to
56 Nm (41 lbf ft).
11 Centralise the steering so that the distance T measured

from the end of the piston guide to the steering ball joint
face is 134 mm (5.27 in).
12 Attach a straight edge X to both hubs using a wheel

mounting nut.
Make a mark at position Y which corresponds to the

distance Z, wheel centre to rim flange on each straight
edge.
13 Measure the distance V between the two straight edges.

Rotate both hubs through 180° and measure the
distance W. The two measurements should be the
same. It not, carry out step 14.
14 Loosen the locknut E on each track rod end. To adjust

the tracking, use a spanner to rotate the inner ends of
the track rods.
Repeat steps 13 and 14 until the two measurements are

the same.
Finally check that a steering angle of 40° can be

achieved in both directions. If the steering angle is not
the same in both directions it is necessary to adjust both
track rod ends to compensate while still meeting the
requirements of step 13.
Finally torque tighten the locknut E on each track rod

end to 240/260 Nm (177/192 lbf ft).
9803/9282 Issue 1
3-1 3-1
Steering System - Bleeding Procedure

Whenever any hydraulic steering component is
disconnected or removed the system must be bled as
follows:
With the engine running, this procedure must be carried out

in the correct order that is laid down. You must not alter the
order of selections and operations.
1 Select 2 Wheel Steer
a Turn steering wheel to left, until front wheels are

fully locked to the left.
b Turn steering wheel to right, until front wheels are
fully locked to the right.

a Turn steering wheel to full right lock.

b Turn steering wheel to full left lock.
c Turn steering wheel to full right lock.
a Turn steering wheel to left, until the front wheels are




a Turn steering wheel to left, until the front and rear

wheels are fully locked.
9803/9282 Issue 1
Section 5 Axles Section 5
i i
Contents Page No.
Technical Data 1-1
Descriptions
- Trunnion Mounted 2-1
- Pad Mounted with Drop Box 2-2

- Trunnion Mounted 3-1
- Pad Mounted 3-3
- Pad Mounted with Optional Dropbox 3-5
Dropbox
- Dismantling and Assembly 3-9
Propshafts
Hub and Driveshaft

- Dismantling 5-1
- Assembly 5-3
Axle Arm and Brakes

- Dismantling 6-1
- Assembly 6-3
Drive Head - Maxtrac

- Dismantling 7-1
- Assembly 7-3
- Crownwheel and Pinion Meshing 7-8
Drive Head with Limited Slip Differential

- Dismantling 8-1
- Assembly 8-2
- Friction Plate Wear Limits 8-2
No SPIN Differential
- Description 9-1
- Dismantling 9-3
- Assembly 9-3
- Testing 9-6
Renewing the Pinion Oil Seal 10 - 1
9803/9282 Issue 1
Type JCB Drivetrain spiral bevel input with epicyclic hub reduction.
Designation SD55- 3 Piece
Installation Trunnion or rigid pad mount
Number of steer cylinders 1 (double rod)
Weight
(with oil and steer cylinders ) 398kg (no drop box)
(TBA with drop box)
Ratios 11.625:1
17.54:1
18:1
20.67:1
21.33:1
23.25:1
26.25:1
9803/9282 Issue 2
2-1 Descriptions 2-1
Trunnion Mounted
A403650
9803/9282 Issue 1
2-2 Descriptions 2-2
Pad Mounted (with Dropbox)
A403710
9803/9282 Issue 1
3-1 Removal and Replacement 3-1
Trunnion Mounted
H
J
H
J F F
E
E
D
D
-238.14 A
B C
A403720
9803/9282 Issue 1
Trunnion Mounted (cont’d)
! WARNING
Replacement
Replacement is the reverse of the removal sequence.
1 Apply Loctite 242 to the threads of bolts A and F.
2 Whenever a wheel has been removed, check the wheel
nut torques every two hours until they stay correct.
GEN-1-1
! WARNING
Removal If, for whatever reason, a wheel stud is renewed, all the
studs for that wheel must be changed as a set, since the
1 Using Tool No. 892/00822 remove screws A to remaining studs may have been damaged.
disconnect the propshaft from the axle (refer to 2-3-2-8
Propshaft, Removal and Replacement).

! CAUTION
2 Disconnect the brake pipes H from the axle, blank off Bleed the brake system before driving the machine.
the exposed connections. BRAK 1-6
3 Disconnect the hydraulic pipes J from the steer Bleed the brake system (see Bleeding, Section 6) and
cylinder, blank off all exposed connections. steering system (see Steer System, Bleeding Procedure,
Section 4).
4 Loosen the road wheel retaining nuts B.
5 Make sure that the wheels are blocked. Raise the Torque Settings
machine and engage the parking brake if appropriate.
6 Prop the machine on each side as shown at C. A 20.9-23.7 2.13-2.42 15.4-17.5
B 680 69 500
7 Remove the road wheels. D 476 49 351
8 Position a jack underneath the balance point of the axle

and support the axle weight.
9 Remove nuts D, trunnion mounting bolts F and washers

E.
10 Ensure the trunnion pads are free from their mountings.
11 Lower the jack and remove the axle.
9803/9282 Issue 1
Pad Mounted
H
J
H
A
-238.14
B
C
C
A403730
F K
9803/9282 Issue 1
Pad Mounted (cont’d)
! WARNING Replacement
Position the machine on a firm, level surface before Replacement is the reverse of the removal sequence.
chocked. Do not rely solely on the machine hydraulics or 1 Make sure that the strap plates K are fitted in their
jacks to support the machine when working under it. original positions.
Disconnect the battery, to prevent the engine being 2 Apply Loctite 242 to the threads of bolts A and E.
GEN-1-1
Removal
! WARNING
1 Using Tool No. 892/00822 remove screws A to
disconnect the propshaft from the axle (refer to If, for whatever reason, a wheel stud is renewed, all the
Propshaft, Removal and Replacement). studs for that wheel must be changed as a set, since the
remaining studs may have been damaged.
2-3-2-8
2 Disconnect the brake pipes H from the axle, blank off
the exposed connections.
! CAUTION
3 Disconnect the hydraulic pipes J from the steer Bleed the brake system before driving the machine.
cylinder, blank off all exposed connections. BRAK 1-6
4 Loosen the road wheel retaining nuts B. Bleed the brake system (see Bleeding, Section 6) and
steering system (see Steer System, Bleeding Procedure,
5 Make sure that the wheels are blocked. Raise the Section 4).
machine and engage the parking brake if appropriate.
Torque Settings
6 Prop the machine on each side as shown at C.
7 Remove the road wheels.
A 20.9-23.7 2.13-2.42 15.4-17.5
B 680 69 500
8 Position a jack underneath the balance point of the axle
D 476 49 351
and support the axle weight.
9 Remove nuts D, bolts E and washers F and ensure the

axle pads are free from their mountings. Note the
position of the strap plates K.
9803/9282 Issue 1
N
L
K N A
M
J
G P H
C
B
F R A403740
D
9803/9282 Issue 1
Pad Mounted with Optional Dropbox

(cont’d)
! WARNING 13 Locate the axle arms on suitable blocks.

14 Remove drain plug H and drain the Dropbox oil into a
suitable container.
15 Undo bolts N, and remove the support strap. Support
the Dropbox to prevent damage to oil transfer pipe P.
16 Using a jack to support the Dropbox, release bolts G
GEN-1-1 and pull to the rear to release oil transfer pipe P and
remove the Dropbox.
Removal
Replacement
1 Using Tool No. 892/00822 remove screws A and
disconnect the propshafts from the Dropbox couplings
Replacement is the reverse of the removal sequence.
(refer to Propshafts, Removal and Replacement).
1 Assemble strap plates R in their original positions.
2 Disconnect the hydraulic pipes from the axle and steer
cylinder (see Removal and Replacement - Pad
2 Apply Loctite 242 to the threads of bolts A and new
Mounted Axle). Blank off all exposed connections and
Verbus Ripp mounting bolts G.
identify for reassembly.
3 Renew ‘O’ ring seals to the balance pipe.
3 Loosen the wheel retaining nuts B.
4 Ensure the road wheels are blocked. Raise the
machine.
5 Take care not to damage the ‘O’ ring seal between axle
5 Prop the machine on each side as shown at C.
and Dropbox during fitting.
7 Remove the road wheels.
6 Adjust the parking brake cable.
8 Position a jack underneath the axle and Dropbox at the
7 Fill to the correct level with the appropriate grade of oil.
balance point and support the axle weight.
9 Disconnect parking brake return spring J. ! WARNING

If, for whatever reason, a wheel stud is renewed, all the
10 Remove spring clip K, clevis pin L and circlip M, studs for that wheel must be changed as a set, since the
release parking brake cable from the dropbox. remaining studs may have been damaged.
2-3-2-8
Note: Because the Dropbox is offset, the balance point is

not the centre of the axle. Attach a cradle to the jack which
! CAUTION
will safely support the axle and Dropbox. Bleed the brake system before driving the machine.
BRAK 1-6
! WARNING Bleed the brake system (see Bleeding, Section 6) and

Lifting Equipment steering system (see Steer System, Bleeding Procedure,
You can be injured if you use faulty lifting equipment. Section 4).
Make sure that lifting equipment is in good condition.
Make sure that lifting tackle complies with all local Torque Settings
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job. Item Nm kgf m lbf ft
INT-1-3-7 A 20.9-23.7 2.13-2.42 15.4-17.5
11 Remove nuts D, bolts E and washers F and ensure the B 680 69 500
axle pads are free from their mountings. Note the D 476 49 351
positions of axle strap plates R. G 166 16.9 122.5
H 50 5.1 37
9803/9282 Issue 1
3-7 Dropbox 3-7
N
L
K N A
M
J
G P H
9803/9282 Issue 1
3-8 Dropbox 3-8

Removal Replacement
! WARNING Replacement is the reversal of the removal procedure.

Position the machine on a firm, level surface before Discard old seals and fit new seals and ‘O’ rings.
chocked. Do not rely solely on the machine hydraulics or Take care not to damage ‘O’ ring seal between axle and
jacks to support the machine when working under it. Dropbox during fitting.
Disconnect the battery, to prevent the engine being Adjust the park brake cable.
GEN-1-1 Fill the axle to the correct level with the appropriate grade of
oil (see Lubricants and Capacities, Section 3).
Note: The following procedure assumes that the dropbox is
to be removed with the axle fitted to the machine. Torque settings
Make sure the wheels are chocked as the parking brake will Item Nm kgf m lbf ft
no longer function when the Dropbox is removed.
A 125 12.75 92.0
Undo bolts A and disconnect bottom and top driveshafts. N 110 11.2 81.0
H 50 5.1 37.0
Remove return spring J.
Remove clevis pin L and spring clip K to disconnect parking

brake.
Undo plug H and drain the oil into a suitable container.
Support the Dropbox, release bolts N and remove the

retaining straps.
Unto bolts G and pull the dropbox clear of the axle.
9803/9282 Issue 1
3-9 Dropbox 3-9
9803/9282 Issue 1
Section 5 Transmission Section 5
3 - 10 Dropbox 3 - 10
Dismantling and Assembly (cont’d)

Dismantling Assembly
Remove the parking brake assembly (see Removal and Replacement is the reversal of the removal procedure.
Replacement).
Inspect bearings and bearing housings for wear and
Undo nut 1 and remove output drive yoke 2. damage.
Undo nut 4 and remove input drive yoke 5. Discard old seals and fit new seals and ‘O’ rings.
Undo bolts 9 and separate casings 10 and 23. Be sure to Bearings to be lightly oiled before assembly.
remove any shims 8. Make sure that location dowels 24 are
not lost. Clean mating faces of the Dropbox and apply Loctite 574
sealant.
To remove mounting support 20 undo bolts 19. Make sure
that location dowels 20A are not lost. Fit shims 8 (see Service Tools, Section 1) to ensure end
float of 0 to 0.125 mm (0 to 0.005 in) on shafts 14 and 22.
Pack cavity between seals 3 and 6 with grease (see

Lubricants and Capacities, Section 3).
Torque tighten nuts 1 and 4 and then stake using a square

ended staking tool as shown at A.
Torque Settings

1/4 300 30.5 221.25
7 50 5.0 37
9 56 5.7 41.25
19 166 17.0 122
13 23 12 10 9
11
8
6
14
19
26 8
3
21
22 1
20
18
20A
A403760
17 16
9803/9282 Issue 1
4-1 Propshafts 4-1

Removal
Before removing propshafts always mark both companion

flanges and also mark the sliding joints prior to removal.
Replacement
Upon reassembly, after lubricating sliding joints with Mobil

HP222 grease, align the shafts against identification marks
previously made or, in the case of a shaft being renewed,
use the manufacturer's alignment markings.
Apply Loctite 242 to threads of all flange bolts.
Retaining straps C stretch with use, therefore these straps A B

must always be replaced with new ones.
Note: Propshafts should be installed with their main shaft

sections fitted to the axle end, and their sliding sections
fitted to the transmission wheel drive unit. S157510
Note: The propshaft must have both ends exactly on the

same plane as shown at X. The yokes must not be at right
angles as at Y or at an intermediate angle as at Z.
Torque Settings

A 75 - 85 7.7 - 8.7 55 - 63
B 118 12 87
C
A
X
S232350
Z A
S189610 S157500
9803/9282 Issue 1
5-1 Hub and Driveshaft 5-1
Dismantling
9803/9282 Issue 1
1 Drain oil from the axle hub. 15 Remove the top and bottom trunnion seals 24 and
bearings 25.
2 Remove screws 1.
16 Withdraw driveshaft 26 from the axle casing.
3 Using a soft-faced mallet, tap the planet gear carrier 2
to 'crack' the joint between the carrier and bearing 17 Prise out driveshaft outer oil seal 27 from the hub
carrier 12, then lever the planet gear carrier off the swivel.
bearing carrier. Remove and discard 'O' ring 3.
18 Remove bearing 28 using tool 892/00225.
4 Remove a planet gear 4 only if it is defective. Note that
a planet gear can only be renewed as an assembly, 19 Prise out inner oil seal 31 from the axle arm casing.
which comprises the pinion, the bearing 5 and two 'L'
shaped circlips 6. To remove a planet gear, first remove 20 Remove circlip 32.
the external circlip 7, then pull off the planet gear.
21 Remove driveshaft inner bearing 33 using tool
5 The driveshaft thrust pad 8 is drilled and tapped M6 for 892/00225.
removal purposes.
22 If there has been a component failure, remove all traces
6 Remove external circlip 9 and spacer 10. of debris and clean the magnetic drain plug.
7 Remove Verbus Ripp bolts. These bolts are very tight

and care must be taken not to distort the bolt heads.
Use as short an extension bar as possible with a six
sided socket. Discard Verbus Ripp bolts after removal.
8 Using special tool (part Number 892/00833) as jacking

screws, jack the annulus assembly 14, 15 and 16 off the
bearing carrier 12. Ensure that the ring dowels 13
remain either in the hub swivel 23 or the annulus carrier
14.
Note 1: Fretting between the hub swivel and annulus carrier

mating faces might be evident; this condition is normal, do
not attempt to repair.
If the hub swivel and annulus carrier are to be renewed they
must be renewed as pairs and not individually.
9 Remove internal circlip 15 to separate the annulus ring

16 from the annulus carrier 14.
10 Pull off the bearing carrier 12 together with the outer

wheel bearing cone and cup 17. Remove the seal 19.
Withdraw the inner bearing cup from the inboard side of
the carrier.
11 Pull off the inner wheel bearing 18.
12 Remove and discard combination seal 19.
13 Disconnect the track rod and steering cylinder from the

axle steer knuckles (see Section 4).
Note 2: The top and bottom trunnions are very similar

(bottom trunnion not illustrated).
14 Mark position of top and bottom trunnions 20, remove

bolts 21 and remove trunnions. Withdraw the hub
carrier 23.
9803/9282 Issue 1
Assembly
9803/9282 Issue 1
Assembly (cont’d)
Note: The top and bottom trunnions are very similar (bottom 13 Fit a new combination seal 19 into the bearing carrier.
trunnion not illustrated), the only difference being that shims
22 are fitted to the top trunnion only.
1 Tap the drive shaft inner bearing 33 into position in the

axle casing.
2 Fit circlip 32. X

3 Fit new oil seal 31. Pack grease between the lips of the
seal.
4 Tap the driveshaft outer bearing 28 into position in the

hub swivel driveshaft bore.
5 Fit new oil seal 27. Pack grease between lips of seal.
6 Fit driveshaft 26, taking care to locate inner end into

splines of differential gears.
7 Press new top and bottom trunnion oil seals 24 into A272180
position followed by bearings 25. Grease bearing and
Do not lubricate before fitting. Using service tool and
oil seal before fitting to axle.
spacer drive the seal squarely into carrier 12 until flush,
8 Locate hub swivel 23 and fit bottom trunnion 20. Apply as shown at X.
Loctite 242 to threads of bottom trunnion bolts 21 and
then torque tighten bolts to 98 Nm (72 lbf ft, 10 kgf m). Note: After assembling the bearing carrier to the swivel hub,
Fit top trunnion 20 and leave top trunnion bolts 21 make sure that there is sufficient clearance between the hub
finger tight. and seal.
9 Attach a spring balance to track rod swivel and note 14 Install the cup of outer wheel bearing 17 into the
pull required to turn the swivel. Tighten the top trunnion bearing carrier 12. Grease the bore of the seal and the
bolts 21 to eliminate endfloat but without bearing pre- surface of the stub.
load, i.e. no increase in spring balance reading.
15 Fit the bearing carrier 12 onto the hub swivel 23.
16 Lightly oil the bearing race of outer wheel bearing 17.

Fit the bearing onto the axle arm. Rotate the carrier 12
(and therefore the bearings) during fitting.
17 Assemble the annulus ring 16 to the annulus carrier 14.

Secure with circlip 15.
18 Fit annulus assembly in the same angular position as

removal (see Note 2 in Dismantling) using new 'Verbus
JS07460 Ripp' bolts 11. Do not fully tighten bolts but allow the
bearing carrier to rock slightly.
10 Refit top trunnion. Apply Loctite 242 to the top trunnion Continued.......
bolt threads, fit and torque tighten to 98 Nm (72 lbf ft,
10 kgf m).
Check spring balance reading which should be 4.5 kgf

(10 lbf) more than the reading recorded at Step 9.
11 Connect the track rod and steering cylinder to the axle

steer knuckles (see Section 4).
12 Lightly oil the inner wheel bearing 18 and its cup, then
fit them into the bearing carrier 12.
9803/9282 Issue 1
Assembly (cont’d)
19 Check the seal drag rolling force: 24 Fit screws 1 and torque-tighten to 56 Nm (41.3 lbf ft,
5.71 kgf m).
i Use a spring balance and cord wrapped around the
planet carrier flange as shown. Pull the spring 25 Fill the axle hub with oil (see Lubricants and
balance so that the hub rotates, do several times to Capacities, Section 3).
let the seal bed in and record the reading.
ii Remove the planet gear carrier and tighten M14

Verbus Ripp bolts 11 to 320 Nm (236 lbf ft, 33 kgf
m).
iii Repeat steps 19, 19i and record the reading.
iv To get the rolling force, subtract seal drag rolling

force (see step 19 i) from reading obtained at this
step, the result should be 2 to 22 Nm (1.5 to 16 lbf
ft; 0.2 to 2.24 kgf m).
If the resulting figure is outside these limits check;

the seal 19 is fitted correctly; and/or renew
bearings 17 and 18.
Note: A high rolling force reading may indicate that the seal
was damaged during fitting.
20 Fit spacer 10 and external circlip 9.
21 Press the driveshaft thrust pad 8 (chamfered side

lowermost) into the recess in the planet gear carrier 2.
22 Fit new planet gears 4 in place of any that were

removed. (See Step 4 in Dismantling.) Secure with
circlip 7.
Note: Large radius at end of bearing bore fits onto pin first.
23 Fit new 'O' ring 3.
Fit the planet gear carrier 2 onto the bearing carrier 19

turning it slightly to engage the gear teeth and aligning
the two tapped holes W in the planet gear carrier with
their mating holes in the bearing carrier. (The tapped
holes are diametrically opposite one another.) Ensure
the planet gear carrier butts fully against the bearing
carrier.
Note: Do not strike the centre of the planet gear carrier 2

when fitting as this may dislodge the driveshaft thrust pad 8.
9803/9282 Issue 1
6-1 Axle Arm and Brakes 6-1
Dismantling 8
15
16
11 10
17
13
14
12
2 3
6 4
1
A403790
9803/9282 Issue 1
Axles are fitted with brake controlled back off to maintain a 7 Before removing the brake housing and piston
constant clearance of 0.6mm (0.02in) within the brake pack. assembly support the differential with a drive shaft or
other suitable support, as shown at 6.
It is important that only one side at a time is dismantled to
prevent damage to the bearings and preserve the 8 Match mark the brake piston housing 7 and the drive
crownwheel and pinion backlash setting. head. Undo four capscrews 9 and remove the brake
housing and piston assembly.
! WARNING
A raised and badly supported machine can fall on you. Note: Do not disturb nut 10 otherwise the bearing pre load
Position the machine on a firm, level surface before will have to be reset.
chocked. Do not rely solely on the machine hydraulics or 9 Remove circlips 11, remove back off pins 12, tension
jacks to support the machine when working under it. bushes 13 and springs 14.
Disconnect the battery, to prevent the engine being 10 Remove brake piston 15 from brake housing 7.
GEN 1-1 11 Remove and discard seals 16 and 17. Inspect the
housing bore for damage and scoring. Nicks or cuts in
the seals may be responsible for loss of brake fluid.
1 It is recommended that the axle be removed from the
machine when dismantling the rear axle brakes, refer to
Removal and Replacement.
Note: Before dismantling it is good practice to mark

components for alignment and identify them as right and
lefthand to ensure correct assembly.
2 Remove bolts 1. Use a heavy duty (6 point) socket to

unscrew them.
3 Carefully separate the stub axle arm from the drive

head. If necessary tap the casing with a soft faced
hammer. Remove all traces of the old sealant from the
mating faces.
Note: The brake pack comprises 4 friction plates and 5

counter plates. There are two counterplates 2, one at each
end of the brake pack, which are not secured to the plate
carrier 3. If the plates are to be re-used, note their positions
and which way round they are then withdraw the brake pack.
4 Remove the circlip 4. If the brake pack is to be re-used,

note the positions of the plates before removing them.
5 The wear limit of friction plates is to the depth of the

cross hatching A. Check all plates for flatness and
damage. (Some scoring of the counterplates is normal.)
Renew the brake pack complete if worn or damaged.
Do not renew individual plates.
6 Remove the three reaction pins 5. Inspect for damage.
Note: If new brake and friction plates are being fitted new
brake back off pins and tension bushes must also be fitted.
Failure to do so could result in the brake being permanently
on.
9803/9282 Issue 1
Assembly 8
15
16
11 10
17
13
14
12
2 3
6 4
1
A403790
9803/9282 Issue 1
Assembly (cont’d)
1 Remove all traces of old sealant from the mating faces 12 Apply Loctite 574 to the mating face of the drive head,
of the drive head and the brake piston housing. and Loctite 242 to the threads of bolts 1. Locate the
stub axle arm onto the drivehead, ensure that the match
2 Fit new seals 17 and 16. Make sure they seat squarely marks made during dismantling are aligned.
in their grooves.
13 Fit bolts 1 and torque tighten to 98 Nm (72 lbf ft, 10 kgf
3 Apply Loctite 242 to threads of back off pins 12. Screw m).
the back off pins 12 into the brake piston. Carefully
press the piston 15 all the way into its housing 7.
4 Fit the springs 14 over the back off pins.
5 Place the tension bush 13 over the back off pin 12.
Using a suitable tool (steel tube) drive the tension bush
onto the back off pin using a soft face hammer until the
circlip 11 can just be fitted.
6 Apply Loctite 574 to the drive head mating face, then fit
the brake piston housing assembly. Ensure that the
match marks made during dismantling are aligned.
7 Fit capscrews 9 and torque tighten to 56 Nm (42 lbf ft,

5.7 kgf m).
8 Remove the differential support.
9 Assemble the five friction plates and six counterplates 2

onto the brake carrier 3. If the original brake pack is
being re-used, return the plates to their original
positions, refer to Dismantling. Soak new friction plates
in Mobil Fluid 424 before assembly. Fit circlip 4.
Note: On assembly of the brake packs, the oil flow holes B

must be aligned with each other when being fitted to the
brake plate carrier.
10 Locate the three reaction pins 5 into their grooves,

securing them with grease. Push the pins fully into their
location holes in the housing.
11 Install one counterplate 2 into the housing securing it in

place with grease, then the brake pack, then the other
counterplate. Return re-used counterplates to their
original positions. Push the brake pack fully home.
9803/9282 Issue 1
7-1 Drive Head - Maxtrac 7-1
Dismantling
As the drivehead cannot be dismantled whilst fitted on the
machine, we recommend that the complete axle is removed,
1
refer to Removal and Replacement.
Note: The crownwheel and pinion are matched and should

be renewed as a pair if either one is damaged or excessively
2
worn. The two differential case halves are also matched as
are the differential side gears and planet gears, do not use
unmatched halves or gears.
1 Position the drive head as shown, with the crownwheel

at the top. Remove capscrews.
S256050
2 Match - mark the brake piston housing and drive head.

Pull off the brake piston housing.
3 Drive out the differential side nut locking pin, to allow

readjustment on assembly. Remove the other brake
piston housing only if damaged, but remove its locking
pin regardless (to allow sideload adjustment on
assembly).
S256060
4 Lift out the crownwheel/differential assembly.
Note: If both brake piston housings are to be removed,

mark the crownwheel end of the drive head casing to ensure
4
that the assembly is returned to its original position.
S256070
5 Using a soft faced hammer, hit the pinion end shaft until
the pinion is free from its front bearing, then withdraw
the pinion.
5 7
6 Withdraw the pinion seal and outer bearing cone.
7
7 If necessary, drive out the pinion inner bearing cup and
shims. Discard the shims. Repeat for the outer bearing 7
cup if required. Note that there are no shims for the
outer bearing cup.
6
S256080 6
9803/9282 Issue 1
Dismantling (cont'd)
8 Remove and discard the pinion spacer.
9 Pull off the bearing cone. 9
S256080
10 To dismantle the differential assembly, first remove

bolts.
11 Lift off the top half housing.

0
12 Remove the differential gears and spherical washers.
Pull off both differential bearing cones.
@ @
S256100
9803/9282 Issue 1
Assembly
Pinion Depth Setting
1 Place new pinion head bearing assembly on a flat

surface and position service tool 892/00174 over the
bearing. Measure gap A (e.g. 0.20 mm) and add this to
the cup depth stamped on the tool (e.g. 30.01 mm) to
obtain the bearing depth. A
2 From the face of the pinion, obtain the etched deviation

figure B (e.g. + 2) which is in units of 0.01 mm. If A184400
positive, add this to the bearing depth; if negative,
subtract from the bearing depth.
3 Obtain the deviation figure C (e.g. - 1) stamped on the

differential housing bolt flange. If negative, add to
bearing depth; if positive, subtract from bearing depth.
4 Subtract the total of the above figures from the B

standard value of 31.19 mm. The result will be the
thickness of shims required behind the pinion head
bearing cup.
5 Example (all dimensions in millimetres)
S256110
Cup depth 30.01
Gap A +0.20
Bearing depth 30.21
Pinion deviation B (+ 2) +0.02
Housing deviation C (- 1) +0.01
Total 30.24
Standard value 31.19

Less Total above 30.24
Shim Thickness 0.95
6 Note: In the event that the setting data stamp has been
ommited from the drivehead casing, adopt the
following setting procedure:
C
S256120
Revise the shim pack size by the difference in setting
height marked on the old and new crownwheel pinion
sets.
9803/9282 Issue 1
Assembly (cont’d)
Note: The crown wheel and pinion are matched and should
be renewed as a pair if either one is damaged or excessively 8
worn. The two differential housing halves are also matched.
Do not use unmatched halves. If required, fit a new
crownwheel to the differential case half, torque tighten
crownwheel retaining bolts to 166 Nm 122 lbf ft; 17 kgf m).
7 Assemble the differential gears and their spherical

washers into the bottom half housing. Fit the differential 8
bearing cones.
8 Position the top half housing onto the differential,
7
aligning the match mark letters (see Note above). Apply S256100
Loctite 242 to the threads of bolts, then fit and torque -
tighten to 56 Nm (42 lbf ft, 6 kgf m). Check the gears for
free rotation. 7
9 Fit the new inner bearing cone on to the pinion and the
largest available solid spacer Eg (14.20 mm) from the
9
9
solid spacer setting kit, refer to Service Tools, Section
1.
S256090
10 Determine the correct thickness required for the shims

10, refer to Pinion Depth Setting.
11 Fit shims 10 behind the pinion inner bearing cup. To

ensure the cup is fitted square, use a suitable puller
0
assembly. Do not use a hammer. Fit the outer bearing
cup.
0
12 Insert the pinion into its bore. (Before inserting, ensure
that the pinion matches the crownwheel. The code
numbers etched on the pinion end face and the
crownwheel perimeter should be the same. @
13 Fit the pinion outer bearing cone. Do not fit the oil seal
at this stage.
S256080
@
9803/9282 Issue 1
Assembly (cont'd)
14 Fit special tool sleeve B and special pinion shaft 18 To select the right size solid spacer, subtract the end
adapter C. Tighten adapter C to approximately 50 Nm, float obtained at step 17 from the solid spacer size
making sure the pinion is free to rotate and there is end (14.20 mm). Also subtract 0.04 mm to allow for
float, this will prevent any damage to the bearing. If the theoretical bearing tolerance and pre load. The result is
pinion is not free to rotate or there is no end float at this the size of spacer to be fitted from the solid spacer
stage check the bearing is fitted correctly. Also check setting kit. If there is no spacer of this size, fit the next
the correct size spacer has been fitted. nearest size spacer, refer to Service Tools, Section 1.
Example
15 Fit special bracket D to the drive-head housing using Temporary spacer size 14.20
two M10 x 30 nuts and bolts. Fit special tool support Subtract end-float 0.25
pillar E to bracket D so that the fork end engages in Total 13.95
adapter C. Ensure that fork E is centrally located on Subtract tolerance & preload 0.04
adapter C. If necessary, re-align bracket D to suit.
Result 13.91
C (No spacer available this size, use next nearest size

spacer i.e 13.900)
19 Remove sleeve B and temporary spacer. fit correct size

B spacer from solid spacer setting kit, refer to Service
Tools, Section 1. During removal take care to avoid
damaging the outer bearing.
20 Fit sleeve B. Tighten adapter C to no more than 50 Nm
D
to protect against bearing damage while spacer
selection is verified making sure the pinion is free to
rotate. Check there is no end float and pinion is free to
turn smoothly by hand. Remove adapter C and fit stake
nut K. Then check that rolling torque is less than 2.0
Nm. If the rolling torque exceeds 2.0 Nm, check that the
shaft has been assembled correctly.
Note: If the pinion is not free to rotate check the correct size
spacer has been fitted.
A396970 21 If rolling torque measured at step 20 is too high, fit the

next larger size spacer. If rolling torque is too low, fit the
16 Fit dial test indicator (DTI) F. Ensure that the DTI is
next smallest size spacer. If a correct spacer is not
mounted on the drive head and not on bracket D.
available from the range, check that drive head is
assembled correctly.
17 Set torque wrench G to 35 Nm (25.8 lbf ft) and measure
the end float while rotating the shaft. 22 Remove adapter C and sleeve B.
A396850
9803/9282 Issue 1
Assembly (cont'd)
23 Fit new oil seal H, grease between seal lips before
fitting. Fit coupling yoke J and NEW stake nut K.
K H
J
24 Progressively torque tighten stake nut K, occasionally

rotating coupling yoke, up to a minimum of 250 Nm.
Providing the correct size spacer has been selected the
rolling torque should be between 2.3 and 3.4 Nm
including seal drag. When the torque is correct, stake
the nut to the pinion shaft using a square-ended staking
tool.
Note: The nut tightening torque can be increased to a

maximum of 300 Nm provided that the pinion rolling torque
does not exceed the maximum of 3.4 Nm.
S256130
25 If both brake piston housings were removed, fit the one

at the opposite end to the crownwheel, using the
procedure in Step 26. Then install the crownwheel
/differential assembly into the drive head.
S256070
9803/9282 Issue 1
Assembly (cont'd)
26 Apply Loctite 574 to the drive head mating face, then fit
the brake piston housing. Ensure that the match -
marks made during dismantling are aligned. Fit 28
capscrews. Torque - tighten to 56 Nm (42 lbf ft, 5.7 kgf 27
m). (Applies to both piston housings.)
27 Adjust differential side nuts to give a bearing preload of 26

1.13-2.26 Nm (0.8-1.6 lbf ft; 0.1-0.2 kgf m). (Measure
the preload by taking another rolling torque reading and
subtracting the torque figure measured at step 24. The
difference is the bearing preload.)
S256140
28 Measure the crownwheel backlash, which should be

0.17 - 0.28 mm (0.006 - 0.010 in). Adjust the differential
side nuts by equal amounts when altering backlash.
When backlash and preload are both correct, fit the
sidenut locking pins, see step 27.
29 Check tooth marking to verify crownwheel and pinion

are set correctly, refer to Crownwheel and Pinion
Meshing.
S256150
9803/9282 Issue 1
Assembly (cont'd)
Crownwheel and Pinion Meshing
Meshing of the gears should be checked by marking three of
the pinion teeth with engineers marking compound and
rotating the pinion.
The marking will then be transferred to the crown wheel

teeth.
Correct tooth marking.
A386940
ITL00600
Pinion too deeply in mesh.
Decrease the shim thickness between the pinion inner

bearing cup and the axle casing. Move the crown wheel
towards the pinion to correct the backlash.
A386950
Pinion too far out of mesh.
Increase the shim thickness between the pinion inner

bearing cup and the axle casing. Move the crown wheel
away from the pinion to correct the backlash.
A386960
9803/9282 Issue 1
8-1 Limited Slip Differential 8-1
6 7 8
9
1
10
14
13
12
10
9
8
7 6
3
11
S212800
S171530
S212790
9803/9282 Issue 1
8-2 Limited Slip Differential 8-2
Dismantling
Note: For removal of the differential and pinion assembly Friction Plate Wear Limits
from the drive head casing refer to Drive Head - Maxtrac -
Dismantling, steps 1 - 9. Measure and note the thickness of the friction plate, the
result must not be less than 1.25 mm (0.049 in).
The numerical sequence shown on the illustration is
intended as a guide to dismantling Check the condition of the friction material, which should be
even over both surfaces.
The two differential halves are matched, before dismantling
mark the two halves for subsequent assembly. If in doubt, discard the set (friction and counter plates).
Note the relative positions of the friction and counter plates Note: For assembly of the pinion and differential assembly
before dismantling, they must be fitted in the same to the drive head casing, refer to Drive Head - Maxtrac -
positions. Assembly.
If worn, the friction and counter plates must be renewed as a

complete set.
Assembly
1 Assemble trunnion pins 12, side gears 11 with pressure
plates 10, counter plates 8, friction plates 9, planet
gears 13 and thrust washers 14 into the 'crownwheel
half of the differential assembly 5.
Note: Do not fit the shims 6 at this point.
2 Align the two halves of the differential assembly with

the marks made during dismantling. Assemble using
bolts 3.
3 Using a dial test indicator (or feeler gauges), with two

screwdrivers or suitable levers, gently apply pressure to
side gear 11 away from the trunnion pins 12 as shown.
Measure and note the end-float of the side gear.
4 Turn the differential assembly over and repeat step 3

for the second side gear.
5 Dismantle the differential assembly. Add shims 6 to

give end-float between 0.1 and 0.2mm (0.004 and
0.008in.).
Note: Shimming must be carried out whenever the

differential is dismantled, however the end float 0.1 and 0.2
mm (0.004 and 0.008 in.) can be exceeded on previously
assembled differential as this is only an initial setting figure
which allows for bedding in.
6 Repeat steps 2, 3, and 4. If the end float is correct,

tighten bolts 3 to 56 Nm (41 lbf ft).
7 Fit crownwheel 2 using new Verbus Ripp bolts 1,

tighten bolts to 166 Nm (122 lbf ft).
9803/9282 Issue 1
9-1 NoSPIN Differential 9-1
159990
9803/9282 Issue 1
Description
The main functions of the NoSPIN differential are:- The progressive stages of disengagement are shown
diagrammatically at Z.
1 To allow variation in driving wheel rotational speed
which must occur when the vehicle is either turning or At position 1, the spider teeth B are driving the clutch D,
travelling over an uneven surface. while the inner clutch teeth G are fully engaged with cam
ring H. The cam is offset by distance K.
2 To prevent loss of traction which would otherwise
occur when one driving wheel spins out. At position 2, the clutch D is accelerating and the inner teeth
G are caused to ride up the cam, thus forcing the clutch out
These functions are achieved by allowing, when necessary, of engagement.
either driving wheel to rotate faster than the crownwheel and
by also ensuring that when power is applied, neither wheel At position 3, the inner teeth have reached the peak of the
can rotate more slowly than the crownwheel. cams and the clutch is now fully disengaged.
The NoSPIN assembly is mounted in a two-piece differential In the reverse condition the spider teeth take up the
case which is bolted to the crownwheel. Drive is transmitted backlash in the unit so that the cams are now displaced to
from the crownwheel, via the differential case, to the spider the opposite side of the spider teeth as shown at 1a.
A. This is provided, on each side, with clutch teeth B which
engage with corresponding teeth on clutch assemblies C Acceleration of one road wheel in reverse causes clutch
and D. The clutches are splined to side gears, which in turn disengagement, as at 2a and 3a, in the same manner as in
are splined to conventional axle shafts, thus conveying the forward travel.
drive to the road wheels.
When a clutch is rotating faster than the spider, continual
When the machine is travelling straight ahead over an even tooth re-engagement would cause excessive noise. This is
surface as at X, both wheels are driven by positive prevented by the provision of a hold-out ring between each
engagement of the teeth on the spider A and on both clutch and the spider to ensure that the clutch remains
clutches C and D. If one wheel loses traction, the clutches disengaged until the speeds again coincide.
remain engaged, ensuring that drive is still transmitted by
the other wheel until traction is regained.
When the machine negotiates a turn as at Y, the outer wheel

E, due to the larger turning radius of its path, is forced to
travel further and rotate faster than the inner wheel. This is
permitted by the disengagement of clutch D from the spider
as shown. A similar action occurs when one wheel is forced
to rotate faster in order to negotiate irregularities in the
ground surface.
The internal operation of the NoSPIN differential is shown on

the lower illustration.
Spider A, rotating in the direction of arrow Aa, is driving

clutch C by means of teeth B. (Positive tooth engagement
being assured by the mating undercuts on the driving faces
of the teeth.) Clutch D, rotating at a greater speed, is shown
disengaged.
In addition to the driven teeth, each clutch is provided with a

row of inner teeth G. Those on clutch C are in engagement
with centre cam H which is therefore rotating and locked in
relation to this clutch.
Due to the tooth backlash J, the engaged clutch C and

centre cam H are trailing behind the spider A, with the effect
that the cams are offset in relation to the spider teeth by
distance K. When a clutch starts to rotate faster than the
spider, the inner teeth of the clutch ride up the cams, thus
forcing the clutch out against spring pressure until the
driving teeth are disengaged as shown on clutch D.
9803/9282 Issue 1
160000
9803/9282 Issue 1

Use the numerical sequence as a guide to dismantling.
For assembly, reverse the sequence.
Dismantling Assembly
Note 1: For removal of the differential and pinion assembly All parts should be lightly lubricated.
from the drive head casing refer to Drive Head - Maxtrac -
Dismantling, steps 1 - 9. Ensure that spring retainers 5 and 12 face in the directions
shown.
Fit a suitable bolt and nut A fitted with flat washers larger
than 38 mm (1.49 in) but smaller than the case shaft bore to Ensure that extended tooth E locates in the gap of each
give clearance. This will retain the NoSPIN components hold-out ring as at F.
against spring pressure.
Ensure that clutch teeth mesh correctly and that there is no
Note 2: The differential case halves 2 and 3 should be binding or overlapping of spring coils.
marked to assist reassembly in their original relative
positions. Fit a suitable bolt and nut A, together with necessary flat
washers (see Dismantling) to the No SPIN components.
Remove bolts 1 and lift off case half 2.
Fit NoSPIN differential to case halves 2 and 3. Align
The NoSPIN differential may now be lifted clear. differential case halves 2 and 3, using the index marks (see
Note 2 in left hand column).
Remove the retaining bolt, nut and washers.
Treat bolts 1 with Loctite 242, fit to case and torque tighten
! CAUTION to 46 Nm (34 lbf ft, 47 kgf m).
Springs 6 and 10 exert a force in excess of 353 N (36 kgf,
Refit crownwheel and differential assembly to casing.
80 lbf). When removing retaining nut, ensure that the
NoSPIN assembly is securely held.
AXL 8-1 Note: For assembly of the pinion and differential assembly
to the drive head casing, refer to Drive Head - Maxtrac -
Spider assembly 8 and clutch assemblies 7 and 9 should not Assembly.
be individually dismantled, as component parts are not
serviceable.
Inspecting
Examine all components for fractures, chipping, burrs,

scoring and excessive wear, paying special attention to
clutch teeth and cams, trunnion holes B, hold-out rings C, all
splines and thrust or bearing surfaces.
Minor chips and burrs may be dressed using an abrasive

stone but if components show wear or scoring, the complete
assembly should be renewed.
Hold-out rings C should be free to rotate on their clutches

with only a little resistance.
Centre cam ring D should be free to rotate within limits

imposed by the extended tooth E.
Springs 6 and 10 should require a load of 230 N (52 lbf, 23.5

kgf) to compress them to a height of 15.5 mm (0.61 in).
9803/9282 Issue 1
A B
C D
A234551
9803/9282 Issue 1
Testing
The following test will show whether or not the NoSPIN
differential is operating correctly.
1 Engage the parking brake, place the transmission in

gear.
2 Raise the axle until both tyres are completely clear of

the ground. Position adequate supports.
3 With the help of an assistant, rotate both wheels as far

as possible in a forward direction as at A. Both wheels
will normally be stopped after absorbing the backlash in
the NoSPIN assembly and between the crownwheel
and pinion.
4 With the left hand wheel firmly held forward against the
stop, rotate the right hand wheel rearward for one of
two revolutions as at B. (A regular clicking sound may
be heard).
5 Rotate both wheels rearward as far as possible as

shown at C, until stopped when backlash is absorbed
as described in Step 3.
6 With the left hand wheel held firmly rearward against

the stop, rotate the right hand wheel forward for one or
two revolutions as at D. (A regular clicking sound may
be heard).
7 Repeat Steps 3, 4, 5 and 6 but this time hold the right

hand wheel and rotate the left hand wheel.
Note: It is important that the wheel is held firmly against the

stop, otherwise the other wheel will not be free to rotate.
If the NoSPIN is operating correctly, the wheel being rotated

should be free until the direction of its rotation is reversed or
until the pressure on the opposite wheel is relaxed. If the
rotated wheel is not free under the conditions described
check for possible brake drag.
If either wheel is not stopped as described in Step 3, check

that the axle shaft and hub gears are intact before
condemning the NoSPIN assembly.
Note: When one wheel is being rotated a light clicking noise

may be heard as the clutch teeth pass over the cams,
followed by a louder click as the clutch engages when the
rotation is stopped and slightly reversed. If an abnormally
loud clicking is repeatedly heard, it may be that a hold-out
ring is faulty or has been incorrectly assembled into the
spider.
Service Precautions
1 When checking the axle operation or checking brakes

etc., ensure that both wheels are raised clear of the
ground.
2 It is important that the axle is fitted with matching tyres

at equal pressures. If in doubt, check that the distances
from axle centre to ground level are equal on each side.
9803/9282 Issue 1
10 - 1 Renewing the Pinion Oil Seal 10 - 1
The pinion oil seal 4 may be renewed without removing the 4 Align the locating marks on the yoke and splined shaft.
axle from the machine. Fit the coupling yoke and new combined stake nut and
washer.
! WARNING
Note: Do not excessively hammer the yoke during assembly
or damage to the shaft bearings could occur. If necessary,
press fit the parts. Fully support the shaft during assembly.
4.1 Using Service Tool 892/00812, tighten the nut to
300 Nm (221 lbf ft; 30.6 kgf m).
4.2 Measure the rolling torque. The reading should be
0.5 to 1 Nm (0.37 to 0.74 lbf ft; 0.05 to 0.1 kgf m)
GEN-1-1
more than that recorded in Step 1 (see Note).
1 Remove the roadwheels and uncouple the axle
4.3 If necessary, progressively torque tighten nut to
propshaft. Measure the axle rolling torque and record
achieve correct rolling torque.
the reading.
4.4 Stake the nut using a square ended staking tool.
2 Mark the position of the coupling yoke on the splined
shaft. Using Service Tool 892/00812, remove the drive
5 Refit the roadwheels and couple the propshaft.
yoke 1 together with its stake nut 2.
3 Remove the seal 4 and fit a new one. Pack between the
lips of the new seal with grease before fitting. Take care
not to damage the housing when removing old oil seal.
4
A403800
9803/9282 Issue 1
Section 6 Brakes Section 6
i i
Contents Page No.
Technical Data 1-1
Dismantling and Assembly 2-1
Bleeding Procedure 2-2
Residual Brake System Pressure 3-1
Brake Piston Seal Leakage Test 4-1
9803/9282 Issue 1
Service Brakes
Type Oil-immersed multi-plate disc
Actuation Hydraulic
Location Inboard - Axle Arms
Piston operation Positive retraction
9803/9282 Issue 1
2-1 Dismantling and Assembly 2-1

The service brakes are located in the rear axle, as shown at
A. Instructions for dismantling and assembly of the brake are
described in Section 5.
9803/9282 Issue 1
2-2 Bleeding 2-2
! WARNING
Before proceeding with the bleeding procedure it is
important to ensure that the parking brake is engaged
and that one pair of wheels is blocked on both sides.
BRAK 1-2
! WARNING
Use of incorrect fluid will cause serious damage to the
seals which could in turn cause brake failure.
BRAK 1-1
1 Fill the master cylinder reservoir with the correct fluid,

refer to Lubricants & Capacities, Section 3 and ensure
that throughout the bleeding process the level is not
allowed to fall below the MINIMUM mark.
2 Unlatch the pedals, and bleed each brake separately as

follows:
3 Right Hand Master Cylinder
a Attach a tube to the right hand brake bleed screw

A, ensuring that the free end of the tube is
immersed in fluid contained in a suitable container.
b Open the brake bleed screw and apply full pedal

strokes of the right hand brake pedal until all air is
expelled.
c Close the brake bleed screw with the pedal fully

depressed.
4 Left Hand Master Cylinder
a Repeat procedure as for 'Right Hand Master

Cylinder' but use left hand bleed screw and pedal.
5 Bridge Pipe
a Attach a tube to either the left or right hand brake

bleed screw, ensuring that the free end of the tube
is immersed in fluid contained in a suitable
container.
5
b Make sure that the brake pedals are locked
together.
c Open the bleed screw and apply full pedal strokes

of the brake pedals until all air is expelled.
d Close the bleed screw with the pedals fully

A
depressed.
6 Repeat the procedures as necessary.
7 Top up the reservoir to the full mark.
S107710-1
9803/9282 Issue 1
3-1 Residual Brake System Pressure 3-1
(Brakes Operated by Machines Main Hydraulic

System)
If residual pressure is greater than the pressure required to

overcome the brake retraction springs in the axle, brake
piston retraction will not occur resulting in excessive heat
and wear of brake components.
If the residual pressure in the braking system is above 0.35

bar (5 lbf/in2) in the hot condition, the system should be
checked to identify the cause of the problem.
Note: Pressure cannot build up in the hydraulic tank until the

oil is hot, or if the pressure is vented by removing the tank
cap/breather.
Checking for Residual Pressure
The following checks should be done with the engine

running and the oil at working temperature.
1 Apply and release the brakes. Check the brakes release

immediately.
2 If the brakes do not release immediately, place a

container under the axle to catch any spilt oil. Unscrew
the bleed nipple on the axle to release any residual
pressure.
Note: The same effort should be needed to rotate the

hub with the bleed nipple either open or closed.
3 If the brakes release immediately, residual pressure
should be suspected.
4 If the brakes do not release immediately, tighten the

bleed nipple and check the following:
(a) Foot brake valve adjustment and linkage

(b) Operation of the hydraulic tank breather
(c) Clear plastic return lines from foot valve are not
restricted
(d) Hydraulic tank not over-filled
9803/9282 Issue 1
4-1 Brake Piston Seal Leakage Test 4-1
The following procedure explains how to check if a brake

piston seal is severely damaged/perished or if the seal has a
small cut or nick. The test must only be done when the axle 5 Repeat steps 1 to 4 for the opposite brake piston seal.
is COLD.
6 Reconnect all brake pipes and bleed the brake system,
! WARNING see Bleeding.
Before working on the brake system make sure the
machine is on level ground and chock all four wheels.
BRAK 1-4
! WARNING
Do not drive the machine with any part of its brake
system disconnected. When the following test has been
completed reconnect all brake pipes and bleed the brake
system using the recommended procedure.
BRAK 2-1
1 Remove and cap brake piston feed pipe A.
2 Fill the brake piston housing with Mobil DTE 11M

Hydraulic Fluid.
3 Check for severe piston seal damage:
3.1 Install a hand pump (see Note 1) fitted with a 0 - 40

bar (0 - 600 lbf/in2) pressure gauge to port B, as
shown at X.
Note 1: The hand pump MUST be filled with Mobil DTE 11M
Hydraulic Fluid. DO NOT exceed 69 bar (1000 lbf/in2).
3.2 Use the hand pump to generate a pressure in the

brake piston housing.
3.3 If the pressure falls off rapidly, or if no pressure

reading can be obtained, the seal is severely 159830-X
damaged and needs replacing with a new one.
4 Check for small cuts or nicks in the piston seal:
4.1 Install an adapter fitted with a piece of clear tube

(approximately 122 mm [4.8 in] long) to the brake
piston port B, as shown at Y (see Note 2).
Note 2: The tube must be kept vertical during the test, use
tape to attach the tube to the side of the machine.
4.2 Fill the tube until approximately three quarters full

with Mobil DTE 11M Hydraulic Fluid.
4.3 Using a suitable pen, mark the level line of the

brake fluid on the tube, as shown at C.
4.4 After approximately 1/2 hour, check if the level has

dropped below the original marked line, if it has
then check the brake piston seal for slight nicks,
cuts or generally for wear.
159830-Y
9803/9282 Issue 1
DROPBOX OPERATING
MANUAL
General Information 1
Care & Safety 2
Routine Maintenance 3
Transmission 4
Service
Manual
WREXHAM
United Kingdom
LL13 9UF
Tel: (01978) 661140

Fax: (01978) 661863
TG300
TG310
TRANSFER BOX
Issue 3
1-1 1-1
Unit Identification
Gearbox Serial Plate
The gearbox serial number is stamped on a plate mounted

to the face of the gearbox, as shown.
ITL00480
Replacement Parts
1 When replacement parts are required, always ensure
that the correct parts are obtained, e.g. in the case of
gear replacements, always check the part number

the serial plate shown.

dismantling should be renewed on reassembly.
4 On reassembly care should be taken that all parts are

incorrectly assembled can lead to a complete failure.

as provided in this manual. It is important to adhere to
6 It is advisable to lightly lubricate with a recommended

9803/9050 Issue 3
Section 4 Transmission Section 4
TG300/310 Transfer Box
Type JCB Drivetrain helical gears

Installation 3 bolt mounting
Weight (dry) 67 kg (147 lb)
Ratio 1:1 (Permanently engaged)
Drop Dimension 300 mm
Oil Type Mobil HD90
Oil Capacity 1 litre
Nominal Rating: TG300 56.7 kW (76 bhp)
TG310 79.0 kW (106 bhp)
Maximum Input Speed 3000 rpm
Input and Output Drive
TG300 1480 Half yoke
TG310 1550 Half yoke (Note: Standard 1480 yokes can be fitted.)
9803/9050 Issue 2
IS21 CONCRETE
SPRAYING MACHINE
SPARE PART
MANIPULATOR SPARE
PART
•
Titan
T1500-008-01
Manipülatör
Manipulator
Montaj No (Pos) Parça No (Code) Adet (Qty) Tanım Description Açıklama

1 T150-02-009 1 Hidrolik Silindir Hydraulic Cylinder -
2 T1510-004-01 1 Gövde - Kule Montajı Body - Column Assembly -
3 T1530-002-01 1 Bom Kızak Komplesi Extension Booms Assembly
4 T1840-001-01 1 Robot Robot -
5 T207-05-007 2 Pim Komplesi Pin Assembly
6 T207-05-008 1 Pim Komplesi Pin Assembly
7 T101-01-002 4 Civata Bolt M16x45
8 T101-01-014 2 Civata Bolt M8x80
9 T101-01-031 4 Civata Bolt M8x20
10 T101-01-034 4 Civata Bolt M8x40
11 T101-01-035 4 Civata Bolt M8x45
12 T101-01-043 3 Civata Bolt M8x60
13 T101-02-034 3 Civata Bolt M10x20
14 T102-01-006 4 Altıköşe Somun Hexagon Nut M8
15 T102-08-009 3 Fiberli Somun Fibered Nut M8x1.0
16 T103-04-009 3 Segman Circlip DiN 471 - 40x1.75
17 T153-02-008 1 Hidrolik Valfler Hydrolic Valves
18 T153-02-010 4 Valf Valve -
19 T153-06-001 2 Çek Valf Non-Return Valve -
20 T153-09-004 1 Hidrolik Valf Hydrolic Valve
21 T153-09-005 1 Altılı Kumanda Valfi Six Port Operating Valve -
22 T2321-123-01 2 Bağlantı Plakası Connecting Plate -
23 T2324-102-01 1 Bağlantı Plakası Connecting Plate -
Titan
T150-02-009
Hidrolik Silindir
Hydraulic Cylinder
12
12
7
10
7
1
5
11
2
3
8
6
4
12
Note: ◯ = Seal Kit : T128-04-012

Titan
T150-02-009
Hidrolik Silindir
Hydraulic Cylinder

1 T102-06-007 1 Somun Nut 1 1/4'' - 12 UNF
2 T128-02-045 1 O-Ring O-Ring
3 T128-02-049 1 O-Ring O-Ring
4 T128-06-048 1 Keçe Seal -
5 T128-07-041 1 Keçe Seal -
6 T128-08-047 1 Keçe Seal -
7 T150-82-002 4 Burç Bushing -
8 T150-94-008 1 Kep Rod Cap -
9 T150-96-018 1 Rod Rod -
10 T150-97-009 1 Kovan Cylinder Tube -
11 T150-98-006 1 Piston Piston -
12 T154-14-002 2 Grasörlük Grease Nipple M8
Titan
T1510-004-01
Body- Column Assembly
Gövde- Kule Montajı
1 7 9
2
8
3
5
6
15
14
17
13
14
18
21 22 23
16
19
20
12 24
23
11 22
10 21
25
26
Titan
T1510-004-01
Gövde- Kule Montajı
Body- Column Assembly

1 T1512-001-01 1 Kule Column
2 T208-01-006 1 Burc Bushing -
3 T208-02-037 1 Burc Bushing -
4 T208-02-016 1 Burç Bushing -
5 T1511-101-01 1 Gövde Body -
6 T1542-002-01 1 Dengeleyici Ayak Komplesi Compensator
7 T103-04-014 1 Segman Circlip DIN 471 - 100 x 3
10 T1552-103-01 1 Civata Bolt M12 x 70
11 T1551-101-01 1 Kılavuz Pabucu Guide Shoe -
12 T1551-137-01 1 Stoper Stoper -
14 T101-04-025 16 Civata Bolt M12 x 45
15 T101-01-032 2 Civata Bolt M20 x 200
16 T203-05-001 1 Dişli Komplesi Rack Assembly -
17 T128-02-025 1 O-Ring O-Ring
18 T1552-101-01 1 Yataklama Ringi Bearing -
19 T101-04-018 6 Cıvata Bolt M6 x 16
20 T103-04-026 1 Segman Circlip DIN 471 - 120 x 4
21 T101-01-029 8 Civata Bolt M12 x 80
22 T1151-107-01 4 Kelepçe Clamp -
23 T150-01-014 2 Hidrolik Silindir Hydraulic Cylinder -
24 T1541-003-01 1 Destek Ayak Gövdesi Cross-Bar
25 T101-01-003 2 Civata Bolt M20 x 120
26 T102-01-004 4 Altıköşe Somun Hexagon Nut M20
Titan
T203-05-001
Dişli Komplesi
Rack Assembly
4
2
3
4
2
Note: ◯ = Seal Kit : T128-04-014

Titan
T203-05-001
Dişli Komplesi
Rack Assembly

1 T203-05-053 1 Dişli Rack m:8
3 T103-04-016 2 Segman Circlip DIN 471 - 28 x 1,5
4 T128-02-090 2 O-Ring O-Ring Ø23,6-3,55
Titan
T1541-003-01
Destek Ayak Gövdesi
Cross-Bar
4
Titan
T1541-003-01
Destek Ayak Gövdesi
Cross-Bar

1 T1541-004-01 1 Destek Ayak Gövdesi Cross-Bar
2 T1561-008-01 1 Bağlantı Komplesi Connecting Assembly -
3 T1561-009-01 1 Bağlantı Komplesi Connecting Assembly -
4 T101-01-019 8 Civata Bolt M10 x 25
Titan
T150-01-014
Hidrolik Silindir
Hydraulic Cylinder
15
6
10
11
14
9
7
4
13
12
16
8
5
Note : ◯ = Seal Kit : T128-04-010

Titan
T150-01-014
Hidrolik Silindir
Hydraulic Cylinder

2 T150-90-004 1 Pabuç Foot -
3 T102-06-004 1 Somun Nut -
4 T103-05-016 1 Segman Circlip -
5 T128-02-029 1 O-Ring O-Ring Ø40-5
6 T128-02-080 1 O-Ring O-Ring Ø85-5.3
7 T128-06-022 1 Keçe Seal -
8 T128-07-011 1 Keçe Seal
9 T128-08-024 1 Keçe Seal -
10 T128-09-001 1 Keçe Seal -
11 T128-15-023 1 Keçe Seal -
12 T150-81-001 1 Küre Sphere -
13 T150-81-002 1 Küre Sabitleme Sphere Guide -
14 T150-94-006 1 Kep Rod Cap -
15 T150-96-003 1 Rod Rod -
38
Titan
T1840-001-01
Robot
26
25 36
24
23
31
22
21 20
19
35
18 30
31
17
39
30
7
28
14
6
5 33
8 27
1 32
2 34
39 15
16
31
12
3
13 29
4
11
37
10
9
AIR COMPRESSOR
SPARE PART
ENDÜSTRİYEL VİDALI
HAVA KOMPRESÖRÜ
INDUSTRIAL AIR
COMPRESSOR
EKO SERİSİ / EKO SERIES

55 GD
LİSTESİ/PARTS
PARÇA LİSTESİ/ PARTS LIST
GELECEK BAŞVURULAR İÇİN
SAKLAYINIZ.
KEEP FOR
FUTURE
KOMPRESÖR TAHLİYE ve SKAVENÇ HATTI / DISCHARGE and SCAVENGE LINE / ENTLADUNG UND ÖLRÜCKLEITUNG
NO PARÇA ADI DESCRIPTION BEZEICHNUNG PARÇA NO/PART NO

1 depo kapağı cover, sump tank Sumpfbehälterdeckel 255905-1A
2 conta gasket, sump tank Dichtung 275754-1
3 seperatör seperator element Ölabscheider 275910-2
4 emniyet ventili, 1" (12BAR) valve, pressure relief 1" (12BAR) Sicherheitsventil 1" (12BAR) 290956-1
emniyet ventili 1" (14BAR) valve, pressure relief 1" (14BAR) Sicherheitsventil 1" (14BAR) 290956-2
5 yüksüklü düz rekor, 1/2"-Φ10 connector tube, 1/2"-Φ10 Schlauchstecker, 1/2"-Φ10 200312-1
6 boru, Φ10 tube, Φ10 Rohr Φ10 2CB302
7 yüksüklü perde rekor, 1/2"-Φ10 connector tubing, 1/2"-Φ10 Schlauchstecker, 1/2"-Φ10 200316-6
8 tutucu bracket Halter 200908-4
9 döner dirsek fişeği swivel elbow cartridge 200302-9
10 pislik tutucu , 1/2" strainer, 1/2" Schmutzfänger 1/2" 200905
11 redüksiyon, ¼”-1/2” (Ø1) 55Kw reducer, ¼”-1/2” (Ø1) 55Kw Reduzierstück , 1/4"-1/2" (Ø1) 55Kw 200338-3
redüksiyon, ¼”-1/2” (Φ1.5- 75kw) reducer, ¼”-1/2” (Φ.5- 75kw) Reduzierstück , 1/4"-1/2" (Φ1.5- 75kw) 200338-5
12 t, 1" tee, 1" t, 1" 200403
13 sıkmalı düz rekor, 1/4"-Φ6 connector hose, 1/4"-Φ6 Schlauchstecker, 1/4"-Φ6 200314Y
14 sıkmalı dirsek rekor, 1/4"-Φ6 connector hose, 1/4"-Φ6 Winkelstück-Schlauchstecker ,1/4"-Ø 6 200329Y
15 polyamid hortum Φ 6 hose, polyamide Φ 6 Polyamid -Schlauch , Ø 6 2PH381
16 nipel, 1/4"-1/4" nipple, 1/4"-1/4" nippel, 1/4"-1/4" 200204
17 dirsek, 1" elbow, 1" Krümmer , 1" 200256-1
18 yağ doldurma tapası M42 plug, fluid fill M42 Ölfüllschraube M42 200908
19 o-ring o-ring o-ring 237783
20 döner dirsek , 1/4"-Φ 10 swivel elbow hose, 1/4"-Ø 10 Schlauchstecker ,1/4"-Ø 10 200291-4
21 civata, M16x45 capscrew, M16x45 Schraube , M16x45 20C168
22 pul, M16 washer, M16 Unterlegscheibe,M16 20P112
23 küresel vana, ¾” valve, globe ¾” Kugelhahn , 3/4" 200902-1
24 körtapa, 3/4" plug, 3/4" Verschlußschraube, 3/4" 200382
25 hortum, Φ10 hose, Φ10 Rohr , Ø10 2PH382-1
26 depo sump, tank Sumpfbehälter 255905-1
27 1/4" check valf 1/4" check valve Rückschlagventil , 1/4" 230955-1
A redüksiyon, ¼”-1/2” (Φ1) 55Kw reducer, ¼”-1/2” (Φ1) 55Kw Reduzierstück , 1/4"-1/2" (Φ1) 55Kw 200338-3
skavenç orifisi, 1/2 - 1/4"-Φ1.5 (75kw) scavenge orifice, 1/2 - 1/4"-Φ1.5 (75kw) Öffnung Ölrückführung , 1/2"-1/4"-Ø1.5 (75kw) 200338-5
MİNİMUM BASINÇ VALFİ / MINIMUM PRESSURE VALVE (275951)
NO PARÇA ADI DESCRIPTION PARÇA NO/PARTS NO ADET/PICE

1 tamir kiti service kit 275951-A 1
1a o-ring o-ring - 2
1b o-ring o-ring - 1
1c klape yayı spring - 1
1d conta gasket - 1
2 yay baskı kapağı cover 275951-A3 1
3 basınç ayar yayı spring 275951-A4 1
4 üst gövde body 275951-A2 1
5 piston piston 275951-A5 1
6 klape klape 275951-A7 1
7 klape pulu washer 275951-A8 1
8 pul washer 20P104 1
9 civata capscrew 20C185 1
10 alt gövde body 275951-A1 1
TERMOSTATİK VALF / THERMAL VALVE ( 275952)
NO PARÇA ADI DESCRIPTION PARÇA NO/PARTS NO ADET / QTY

1 tamir kiti service kit 275952-A 1
1a o-ring o-ring - 1
1b termostatik valf elemanı thermal valve - 1
1c yay spring - 1
2 segman segman 275952-A4 1
3 termostatik valf tutucu kapak thermal valve cover 275952-A3 1
4 kovan housing 275952-A2 1
5 blok blok 275952-A1 1
24
HAVA EMİŞ SİSTEMİ / AIR INLET SYSTEM / LUFTEINLAUFSYSTEM
NO PARÇA ADI DESCRIPTION

1 conta, 150x150xΦ100x2 gasket, air inlet -elbow adaptor 150x150xΦ100x2
2 emiş valfi valve, air inlet
3 kelepçe, Φ92x110 clamp, Φ92x110
4 hortum, Φ100x100 hose, Φ100x100
5 hava filtre kovanı housing, air filter
6 hava filtre elemanı element, air filter
7 civata, M8x25 capscrew, M8x25
8 pul, M8 washer, M8
9 civata, M16x45 capscrew, M16x45
10 pul, M16 washer, M16
11 kelebek somun M8 nut, wing M8
12 somun, M8 nut, M8
13 flanş flange
14 conta, Ø220xØ110x2 gasket, air inlet -elbow adaptor Ø220xØ110x2
15 cıvata, 1/2" capscrew, 1/2"
4
T SYSTEM / LUFTEINLAUFSYSTEM
BEZEICHNUNG PARÇA NO/PARTS NO

Dichtung, 150x150xΦ100x2 255753
Lufteinlaufventil 250958
schelll, Φ92x110 215404-5
Schlauch, Φ100x100 255401
Luftfiltergehäuse 250405
Luftfilterelement 250406
Schraube, M8x25 20C148
Unterlegscheibe, M8 20P106
Schraube, M16x45 20C168
Unterlegscheibe, M16 20P112
Flügelmutter , M8 20S107
Mutter, M8 20S103
Flansch 275795
Dichtung, Ø220xØ110x2 275753-3
Schraube, 1/2" 20C271
4
KUMANDA PANEL GRUBU / INSTRUMENT PANEL GROUP / SCHALTTAFEL
NO DESCRIPTION DESCRIPTION BEZEICHNUNG PARÇA NO / PART NO

1 panel kasası instrument panel Schalttafel Rahmengestell 2250805-1
2 panel etiketi Ticket, panel Schalttafelschild 222871-2
3 kontrol paneli (S1) panel, control (S1) Schalttafel (Steuerung ) 222867
4 es emergency stop butonu button, es mergency stop Not - Aus Taste 215851-1
5 cıvata capscrew Schraube 20C103
6 somun, M4 nut, M4 Mutter , M4 20S108
7 pul, M5 washer, M5 Unterlegscheibe , M5 20P102
8 müşir yuvası 1/4"-1/8" termocouple connection 1/4"-1/8" Thermoelement Anschluß 1/4"-1/8" 215862
müşir yuvası 3/8"-1/8" termocouple connection 3/8"-1/8" Thermoelement Anschluß 3/8"-1/8" 230862
9 cıvata capscrew Schraube 20C107
10 panel sacı panel sheet Schalttafel Blech 222805-4
11 ısı sensörü tempature sensor Reset-Taste 230832
MOTOR ve VİDA ÜNİTESİ / MOTOR and COMPRESSOR UNIT/ MOTOR und KOMPRESSORBLOCK
NO PARÇA ADI DESRIPTION BEZEICHNUNG PARÇA NO/PARTS NO

1 elektrik motoru electric motor Motor ,elektrisch ( 275201-13
2 vida unit compressor Schraubenkompressorblock 255901-2
3 kaplin burcu vida couple bush,unit compressor Kupplungsbüchse, Schraubenkompressorblock 200606-40
4 laterna (Sullair) adapter, coupling (Sullair) laterna (Sullair) 200609-47
5 kaplin couple Kupplung 200606-36
6 titreşim takozu mount, vibration insulation Schwingungsisolator 255502-1
7 vida bağlantı sacı (Sullair) unit compressor, underside (Sullair) Verdichterstufe Anschlussblech (Sullair) 275501-30V
8 motor bağlantı sacı (S 1500d/d) motor, underside Motor- Anschlussblech (S 1500d/d) 275501-30M
9 saplama M20x170 thurist into M20 x 170 Gewindebolzen M20x170 2SP110
10 motor sabitleme pimi pin Motor-Verbindungsstift 200609-17
11 pul M20 washer, M20 Unterlegscheibe M20 20P114
12 somun M16 nut, M16 Mutter M16 20S109
13 cıvata M16x70 capscrew, M16x70 Schraube M16x70 20C182
14 cıvata 1/2" capscrew,1/2" Schraube 1/2" 20C280
15 pul (özel) washer (special) Unterlegscheibe 20P163
16 pul 1/2" washer , 1/2" Unterlegscheibe , 1/2" 20P110
17 cıvata ,1/2"-90mm capscrew,1/2"-90mm Schraube ,1/2"-90mm 2SP149
18 pul M16 washer, M16 Unterlegscheibe M16 20P112
19 somun, M20 nut, M20 Mutter, M20 20S125
20 kaplin burcu ( motor ) couple bush, (electric motor ) Kupplungsbüchse, ( Motor ,elektrisch ) 200606-46
21 pul (özel) washer (special) Unterlegscheibe 20P158
SOĞUTMA ÜNİTESİ / COOLER UNIT PARTS / KÜHLUNG SYSTEM
NO PARÇA ADI DESCRIPTION BEZEICHNUNG PARÇA ADI/PART NO

1 fan motoru (S) (55R-55) motor, fan (S) (55R-55) Lüftermotor (S) (55R-55) 255202-1
fan motoru (E) (55R-55) motor, fan (E ) (55R-55) Lüftermotor (E ) (55R-55) 255202-2
fan motoru (W) (55R-55) motor, fan (W) (55R-55) Lüftermotor (W) (55R-55) 255202
2 fan muhafazası (55R-55) guard, fan (55R-55) Lüftergitter (55R-55) 255255-1
3 civata, M10x30 capscrew, M10x30 Schraube, M10x30 20C155
4 pul, M8 washer, M8 Unterlegscheibe, M8 20P105
6 somun, M8 nut, M8 Mutter, M8 20S103
7 fan (komple) (55R-55) fan (komple) (55R-55) Lüfter (55R-55) 255603-6
9 pul, 2.5xØ8.5xØ22 washer, private 2.5xØ8.5xØ22 Unterlegscheibe, 2.5xØ8.5xØ22 20P106
10 davlumbaz (55R-55) venturi (55R-55) Lüftergestell (55R-55) 255602-1
11 radyatör (45-45S-55 -E55) cooler, oil/air (45-45S-55 -E55) Öl -,Luftkühler (45-45S-55 -E55) 255601-1
12 davlumbaz fitili (45-45S-55R-55) weatherstrip, venturi (45-45S-55R-55) Profildichtung (45-45S-55R-55) 255150-2
14 pul, 3xØ13xØ33 washer, 3xØ13xØ33 Unterlegscheibe, 3xØ13xØ33 20P152
15 pul, M10 washer, private M10 Unterlegscheibe, M10 20P107
14
SOĞUTMA ve YAĞLAMA SİSTEMİ/COOLING and LUBRICATION SYSTEM KÜHL -UND SCMIERSYSTEM TEILE
NO PARÇA ADI DESCRIPTION BEZEICHNUNG PARÇA NO/PARTS NO

1 yağ-hava hortumu 2" 90x0-100cm hose, air-fluid 2" 90x0-100cm Luftschlauch, 2" 90x0-100cm 2110345-5
2 minimum basınç valfi o-ringi Φ82xΦ87x3,5 o-ring, minimum presure valve Φ82xΦ87x3,5 o-ring Φ82xΦ87x3,5 275784-1
3 minimum basınç valfi valve, minumum pressure Minimales Druckventil 275951
6 vida boğazı adaptor, elbow-compressor unıt Krümmeradapter , Verdichterstufen 200602-10
7 vida boğaz o-ringi o-ring o-ring 255783
8 cıvata, 1/2"-1 1/4" capscrew, 1/2"-1 1/4" Schraube, 1/2"-1 1/4" 20C128
9 pul, 1/2" washer, 1/2" Unterlegscheibe, 1/2" 20P110
10 nipel, 2 1/2"-2" nipple, 2 1/2"-2" nippel, 2 1/2"-2" 200225-2
11 dirsek, 2" elbow, 2" Krümmer, 2" 200290-3
12 termostatik valf valve, thermal Thermisches Ventil 275952
15 yağ filtre nipeli, 1 1/4"-1" nipple, filter oil 1 1/4"-1" nippel , 1 1/4"-1" 200222-14
16 yağ filtre elemanı element, fluid filter Ölfilterelement 275702
17 nipel, 1 1/4"-1" nipple, 1 1/4"-1" nippel, 1 1/4"-1" 200219-2
18 yağ hortumu, 1" 90x0-90 cm hose fluid ,1"90x0-90 cm Ölschlauch ,1" 90x0-90 cm 255371-56
19 yağ hortumu, 1" 45x0-125 cm hose fluid , 1" 45x0-125 cm Ölschlauch , 1" 45x0-125 cm 2160371-16
20 yağ hortumu, 1" 90x0-90 cm hose fluid 1" 90x0-90 cm Ölschlauch , 1" 90x0-90 cm 255371-56
21 yağ hortumu, 1" 90x0-105 cm hose fluid 1" 90x0-105 cm Ölschlauch , 1" 90x0-105 cm 2110371-34
22 hava hortumu, 1 1/2" 90x0-100cm hose air, 1 1/2" 90x0-100cm schlauch, 1 1/2" 90x0-100cm 255351-17
23 nipel NPT 1 1/4"-1" nipple NPT 1 1/4"-1" nippel NPT 1 1/4"-1" 200219-1
24 nipel, 2"-1 1/2" nipple, 2"-1 1/2" nippel, 2"-1 1/2" 200220
25 nipel, 1" nipple, 1" nippel, 1" 200215-2
26 sıkmalı dirsek rekor, 1/4"-Φ6(*) connector elbow hose, 1/4"-Φ6 (*) Winkelstück-Schlauchstecker, 1/4"-Φ6 (*) 200329
27 nipel, 1 1/2" (*) nipple, 1 1/2" (*) nippel, 1 1/2" (*) 200237-1
28 perde rekor, Φ6 (*) connector, Φ6 (*) Schlauchstecker, Φ6 (*) 200316
29 polyamid hortum, Φ6 (*) hose, polyamide, Φ6 (*) Polyamid -Schlauch- Φ6 (*) 2PH382-2
30 kondenstop (*) seperator moisture (*) Wasserabscheider, 2" (*) 245921
31 nipel, NPT 1/4"-1/4" (*) nipple, NPT 1/4"-1/4" (*) nippel, NPT 1/4"-1/4" (*) 200209
32 pislik tutucu, 1/4" (*) strainer, 1/4" (*) Schmutzfänger , 1/4" (*) 200904
33 solenoid valf (*) valve, solenoid (*) Magnetventil (*) 2160954-6
* OPSİYONEL
KONTROL SİSTEMİ / CONTROL SYSTEM /KONTROLLSYSTEM-TEILE
NO PARÇA ADI DESCRIPTION BEZEICHNUNG PARÇA NO/PARTS NO

1 manşon, 1/4" manchon, 1/4" Muffe , 1/4" 200392
2 manometre gauge,pressure Druckanzeiger 215804
3 sıkmalı manşon rekor, 1/4"-Ø6 connector manchon hose 1/4"-Ø6 Schlauchstecker 1/4"-Ø6 200315Y
4 sıkmalı rekor, 1/8"-Φ6 connector hose, 1/8"-Φ6 Schlauchstecker , 1/8"-Ø6 200313Y
5 polyamid hortum, Φ6 hose polyamid, Φ6 Polyamid -Schlauch , Ø6 2PH381
6 basınç sensoru pressure transmitter Druckfühler 255833
7 sıkmalı dirsek rekor, 1/4"-Φ6 connector elbow hose, 1/4"-Φ6 Schlauchstecker, 1/4"-Ø6 200329Y
8 sıkmalı düz rekor, 1/4"-Φ6 connector hose, 1/4"-Φ6 Schlauchstecker, 1/4"-Ø6 200314Y
9 emniyet prosestatı switch, pressure-maximum pressure Sicherheitsdruckschalter 215802
10 sıkmalı t, 1/8"-Ø6 tee tubing, 1/8"-Ø6 Schlauch- T Stück-Stecker , 1/8"-Ø6 200359
11 sıkmalı manşon rekor, 1/4"-Ø10 connector manchon hose 1/4"-Ø10 Schlauchstecker 1/4"-Ø10 200318y
12 Ø10, Demir Boru 15cm IRON PIPE IRON PIPE 215301-5
13 Rekor (1/4"-Ø10, Yüksüklü sıkmalı hid. connector hose, Schlauchstecker, 1/2"-Ø10 200309
14 solenoid valf valve solenoid Magnetventil 2160954-6
15 sıkmalı t, 1/4"-Ø6 tee tubing, 1/4"-Φ6 Schlauch- T Stück-Stecker , 1/4"-Ø6 200360Y
16 sıkmalı dirsek rekor, 1/4"-Φ6 connector elbow hose, 1/4"-Φ6 Schlauchstecker, 1/4"-Ø6 200329Y
17 sıkmalı dirsek rekor, 1/4"-Φ10 connector elbow hose, 1/4"-Φ10 Schlauchstecker, 1/4"-Ø10 200325
18 polyamid hortum, Φ10 hose polyamid, Φ10 Polyamid -Schlauch , Ø10 2PH382
10
AKUSTİK KABİN / ACUSTIC CANOPY / AKUSTİSCHES MASCHINENGEHAEUSE
NO PARÇA ADI DESCRIPTION DESCRIPTION PARÇA NO/PARTS NO
1 akustik kabin acustic canopy Akustische Maschinengehäuse 255101-26

2 hareketli direk removable, pier bewegliche Pfosten 245101-26_23
3 cıvata, M8x15 capscrew, M8x15 schraube, M8x15 20C174
4 pul M8 washer, M8 Unterlegscheibe, M8 20P105
5 elektrik kaportası sag kanadı door, electric box (right) Schaltschranktür ,recht 255103-28
6 elektrik kaporta panel filtresi panel filter (electric box door) Filtermatte , Schaltschranktür 255161-1
7 elektrik kaportası panel filtre tutucu bracket, panel filter (electric box door) Filtermattenhalter ,Schaltschranktür 245103-7A
8 elektirik kaportası sol kanadı door, electric box (left) Schaltschranktür ,links 255103-27
9 menteşe hingen Scharnier 245106
10 cıvata capscrew Blechschraube 20C127
11 yan kaporta side, door Seitenwand 255104-6
12 yan kaporta izalosyonu material acuistical insulation, side door Akustische Isolation , Seitenwand 255115
13 kaporta fitili weatherstrip, door Profildichtung , Seitenwand 255150-29
14 damper kaportası door, roof Dachgestell 255111-11
15 damper kaportası izolasyonu material, acoustical insulatıon, roof door Dachgestellisolation 255121-3
16 üst kaporta 1 top door 1 Obere Wand 1 255106-8
17 üst kaporta izolasyonu 1 material acuistical insulation, top door 1 İsolation ,obere Wand 1 255121-2
18 hava emiş kapısı door, air inlet Tür , Luftansaugseite 255105-5
19 panel filtre panel filter Filtermatte , Luftansaugseite 255115
20 panel filtre tutucu bracket, panel filter Filtermattenhalter 255162-3
21 kilit lock, side door Seitentürverschluß 215140
ELEKTRİK KUTUSU / ELECTRIC BOX / SCHALTSCHRANK

1 elektrik pano sacı sheet, electrical box Schaltschrankblech 237830
2 mekeanik kilitleme mechanical interlock Mechanische Verriegelung 215870
L1-L2- giriş klemensi terminals, energy input Klemmen Stromeingang 275827-2
E1 sigorta, 2x1A circuit breaker, 2x1A Sicherung 2x1A 215806-2
E2 sigorta, 1x3A circuit breaker, 1x3A Sicherung 1x3A 290806
M1 ana motor termiği Starter, main motor Überlastrelais,Hauptmotor 255819-1
M2 fan motor termiği Starter, fan motor Überlastrelais,Lüftermotor 255821-3
K1-K2 kontaktör contactor Kontaktgeber 245814-3
K3 kontaktör contactor Kontaktgeber 245814-3
K5 röle relay Relais 211857-4
soket socket Sockel 211858-1
VT trafo transfomer Transformator 255808
trafo transfomer Transformator 290808-8
MKR motor koruma rölesi voltage monitoring relay-three phase Motorschutzrelais 230844
2..N bağlantı klemensi klemens, group Anschlußklemme 275839
PE topraklama barası line,ground Erdungsklemme 2110829-1
ELEKTRİK ŞEMASI / ELECTRIC WIRING DIAGRAM / ELEKTRISCHER SCHALTPLAN

L1-L2- giriş klemensi terminals, energy input Klemmen Stromeingang 275827-2
E2 sigorta, 1x3A circuit breaker, 1x3A Sicherung 1x3A 290806
M1 ana motor termiği Starter, main motor Überlastrelais,Hauptmotor 255819-1
M2 fan motor termiği Starter, fan motor Überlastrelais,Lüftermotor 255821-3
K1-K2 kontaktör contactor Kontaktgeber 245814-3
K3 kontaktör contactor Kontaktgeber 245814-3
K5 röle relay Relais 211857-2
soket socket Sockel 211858-1
VT trafo transfomer Transformator 255808
trafo transfomer Transformator 290808-8
ES Acil durdurma butonu button, emergency stop Not - Aus Taste 215851-2
P1 emniyet presostatı switch, pressure-regulation Sicherheitsdruckschalter 215802
MKR motor koruma rölesi voltage monitoring relay-three phase Motorschutzrelais 230844
SV 1 solenoid valf Valve, solenoid Magnetventil 255953-2
SV 2 solenoid valf Valve, solenoid Magnetventil 2160954-6
SV 3 solenoid valf (opsiyonel) Valve, solenoid (optional) Magnetventil (opsiyonel) 2160954-7
PS basınç sensoru Pressure sensor Druckfühler 245833
TS Isı senserü Termal sensor Temperaturfühler 230832
PE topraklama barası line,ground Erdungsklemme 2110829-1
DOSING PUMP SPARE
PART
HYDRAULIC
PUMP SPARE PART
Steering – Brake Pumps

PL20 02 S IE
RICAMBI SERIE POLARIS 20

SPARE PARTS POLARIS 20 SERIES
QUESTO CATALOGO SOSTITUISCE AGGIORNAMENTI
This catalogue Replaces Revisions
Codice Edizione Codice Edizione Novità pagina Modifiche pagina
Code Edition Code Edition News page Review page
PL20 02 S IE 02/08.2002 PL20 01 S IE 07.1996 1.32 - 1.33 - 1.34

Polaris 20
POLARIS 20
Ricambi
Spare parts
Indice
Index
Da pag. a pag.
From page to page
Unità singole
Single unit
1.2 1.56
Pompe multiple
Multiple pumps
2.1 2.10
R003-002/07.96
001 1.1
Polaris 20
POLARIS 20
Unità singole unificazione EUROPEA

Single unit EUROPEAN standard
Descrizione Da pag. a pag.

Pos.
Description From page to page
Albero conduttore
1 Drive shaft
82 1.5 1.6
Coperchio anteriore
2 Front mounting cover
E2 1.18 1.19
Spina
3 Dowel pin
1.31 1.31
Rasamento
R003-002/07.96
4 Thrust plate
1.32 1.34
Albero condotto
5 Driven shaft
1.35 1.35
Corpo
6 Gear housing
Versione bocche laterali
Side ports version
1.36 1.37
Versione bocche posteriori
Rear ports version
1.41 1.41
Coperchio posteriore
7 Rear cover 1.42 1.49
Vite
8 Screw
1.50 1.55
1.2 001
Polaris 20
POLARIS 20
Unità singole unificazione TEDESCA

Single unit GERMAN standard

Pos.
Albero conduttore
1 Drive shaft
54 1.7 1.8
12 1.9 1.10
95 1.11 1.11
Coperchio anteriore
B2 1.20 1.21
B4 1.22 1.23
B5 1.24 1.25
B6 1.26 1.26
R003-002/07.96
Spina
3 Dowel pin
1.31 1.31
Rasamento
4 Thrust plate
1.32 1.34
Albero condotto
5 Driven shaft
1.35 1.35
Corpo
6 Gear housing
Side ports version
1.38 1.38
Rear ports version
1.41 1.41
7 Rear cover
1.42 1.49
Vite
8 Screw
1.50 1.55
001 1.3
Polaris 20
POLARIS 20
Unità singole unificazione SAE

Single unit SAE standard

Pos.
Albero conduttore
1 Drive shaft
03 1.12 1.13
31 1.14 1.15
49 1.16 1.17
Coperchio anteriore
S1 1.27 1.28
(49) S1 1.29 1.30
Spina
R003-002/07.96
3 Dowel pin
1.31 1.31
Rasamento
4 Thrust plate
1.32 1.34
Albero condotto
5 Driven shaft
1.35 1.35
Corpo
6 Gear housing
Side ports version
1.39 1.40
Rear ports version
1.41 1.41
7 Rear cover
1.42 1.49
Vite
8 Screw
1.50 1.55
1.4 001
Polaris 20
POLARIS 20 82 E2
ALBERO CONDUTTORE 82
82 DRIVE SHAFT
1:8
Codice Q.tà Descrizione Prezzo cadauno

Pos.
Code Q.ty Description Cost each
Dado M 12x1,5 UNI 5589
1 36850000 1 Nut M 12x1,5 UNI 5589
Rosetta ferma dado
2 47950000 1 Tab washer
Linguetta
3 42520000 1 Shaft key
Albero conduttore PL. 20•4-82
4 27720000 1 Drive shaft PL. 20•4-82
Albero conduttore PL. 20•6,3-82
4 27720010 1 Drive shaft PL. 20•6,3-82
R003-003/07.96

4 27720020 1 Drive shaft PL. 20•8-82
4 27720030 1 Drive shaft PL. 20•11,2-82
4 27720040 1 Drive shaft PL. 20•14-82
4 27720050 1 Drive shaft PL. 20•16-82
4 27720060 1 Drive shaft PL. 20•20-82
4 27720070 1 Drive shaft PL. 20•25-82
4 27720080 1 Drive shaft PL. 20•31,5-82
001 1.5
Polaris 20
POLARIS 20 82 E2
ALBERO CONDUTTORE 82 (FS)
82 DRIVE SHAFT (FS)
1:8

Pos.
1 36850000 1 Nut M 12x1,5 UNI 5589
Rosetta ferma dado
2 47950000 1 Tab washer
Linguetta
3 42520000 1 Shaft key
Albero conduttore PL. 20•4-82/FS
4 27720842 1 Drive shaft PL. 20•4-82/FS
Albero conduttore PL. 20•6,3-82/FS
4 27720846 1 Drive shaft PL. 20•6,3-82/FS
R003-003/07.96

4 27720850 1 Drive shaft PL. 20•8-82/FS
4 27720851 1 Drive shaft PL. 20•9-82/FS
4 27720852 1 Drive shaft PL. 20•11,2-82/FS
4 27720854 1 Drive shaft PL. 20•14-82/FS
4 27720856 1 Drive shaft PL. 20•16-82/FS
4 27720858 1 Drive shaft PL. 20•20-82/FS
4 27720860 1 Drive shaft PL. 20•25-82/FS
4 27720862 1 Drive shaft PL. 20•31,5-82/FS
1.6 001
Polaris 20
POLARIS 20 54 B2-54 B4-54 B5

54 DRIVE SHAFT
1:5

Pos.
1 36850000 1 Nut M 12x1,5 UNI 5589
Rosetta ferma dado
2 47950000 1 Tab washer
Linguetta 3x6,5
3 42500000 1 Shaft key 3x6,5
4 27720100 1 Drive shaft PL. 20•4-54
4 27720102 1 Drive shaft PL. 20•6,3-54
R003-003/07.96

4 27720104 1 Drive shaft PL. 20•8-54
4 27720106 1 Drive shaft PL. 20•11,2-54
4 27720108 1 Drive shaft PL. 20•14-54
4 27720110 1 Drive shaft PL. 20•16-54
4 27720112 1 Drive shaft PL. 20•20-54
4 27720114 1 Drive shaft PL. 20•25-54
001 1.7
Polaris 20
POLARIS 20 54 B2-54 B4-54 B5

ALBERO CONDUTTORE 54 (FS)
54 DRIVE SHAFT (FS)
1:5

Pos.
1 36850000 1 Nut M 12x1,5 UNI 5589
Rosetta ferma dado
2 47950000 1 Tab washer
Linguetta 3x6,5
3 42500000 1 Shaft key 3x6,5
4 27721420 1 Drive shaft PL. 20•4-54/FS
4 27721424 1 Drive shaft PL. 20•6,3-54/FS
R003-003/07.96

4 27721428 1 Drive shaft PL. 20•8-54/FS
4 27721432 1 Drive shaft PL. 20•11,2-54/FS
4 27721434 1 Drive shaft PL. 20•14-54/FS
4 27721436 1 Drive shaft PL. 20•16-54/FS
4 27721438 1 Drive shaft PL. 20•20-54/FS
4 27721440 1 Drive shaft PL. 20•25-54/FS
1.8 001
Polaris 20
POLARIS 20 12 B2
ALBERO CONDUTTORE SCANALATO 12
12 SPLINED DRIVE SHAFT
B 17X14 DIN 5482

Pos.
1 27720118 1 Drive shaft PL. 20•4-12
1 27720120 1 Drive shaft PL. 20•6,3-12
1 27720122 1 Drive shaft PL. 20•8-12
1 27720124 1 Drive shaft PL. 20•11,2-12
1 27720126 1 Drive shaft PL. 20•14-12
R003-003/07.96

1 27720128 1 Drive shaft PL. 20•16-12
1 27720130 1 Drive shaft PL. 20•20-12
1 27720132 1 Drive shaft PL. 20•25-12
001 1.9
Polaris 20
POLARIS 20 12 B2
ALBERO CONDUTTORE SCANALATO 12 (FS)
12 SPLINED DRIVE SHAFT (FS)
B 17X14 DIN 5482

Pos.
1 27721450 1 Drive shaft PL. 20•4-12/FS
1 27721454 1 Drive shaft PL. 20•6,3-12/FS
1 27721458 1 Drive shaft PL. 20•8-12/FS
1 27721462 1 Drive shaft PL. 20•11,2-12/FS
1 27721464 1 Drive shaft PL. 20•14-12/FS
R003-003/07.96

1 27721466 1 Drive shaft PL. 20•16-12/FS
1 27721468 1 Drive shaft PL. 20•20-12/FS
1 27721470 1 Drive shaft PL. 20•25-12/FS
1.10 001
Polaris 20
POLARIS 20 95 B6
95 DRIVE SHAFT

Pos.
1 27721550 1 Drive shaft PL. 20•4-95
1 27721552 1 Drive shaft PL. 20•6,3-95
1 27721554 1 Drive shaft PL. 20•8-95
1 27721556 1 Drive shaft PL. 20•9-95
1 27721558 1 Drive shaft PL. 20•11,2-95
R003-003/07.96

1 27721560 1 Drive shaft PL. 20•14-95
1 27721562 1 Drive shaft PL. 20•16-95
1 27721564 Drive shaft PL. 20•20-95
1 27721566 1 Drive shaft PL. 20•25-95
001 1.11
Polaris 20
POLARIS 20 03 S1
SAE A-9 DENTI - 16/32

Radice piana centraggio sui fianchi
SAE A-9T-16/32 DP
Flat root side fit

Pos.
1 27720300 1 Drive shaft PL. 20•4-03
1 27720302 1 Drive shaft PL. 20•6,3-03
1 27720304 1 Drive shaft PL. 20•8-03
1 27720305 1 Drive shaft PL. 20•9-03
1 27720306 1 Drive shaft PL. 20•11,2-03
R003-003/07.96

1 27720308 1 Drive shaft PL. 20•14-03
1 27720310 1 Drive shaft PL. 20•16-03
1 27720312 1 Drive shaft PL. 20•20-03
1 27720314 1 Drive shaft PL. 20•25-03
1 27720316 1 Drive shaft PL. 20•31,5-03
1.12 001
Polaris 20
POLARIS 20 03 S1
SAE A-9 DENTI - 16/32

Radice piana centraggio sui fianchi
SAE A-9T-16/32 DP
Flat root side fit

Pos.
1 27720864 1 Drive shaft PL. 20•4-03/FS
1 27720868 1 Drive shaft PL. 20•6,3-03/FS
1 27720872 1 Drive shaft PL. 20•8-03/FS
1 27720873 1 Drive shaft PL. 20•9-03/FS
1 27720874 1 Drive shaft PL. 20•11,2-03/FS
R003-003/07.96

1 27720876 1 Drive shaft PL. 20•14-03/FS
1 27720878 1 Drive shaft PL. 20•16-03/FS
1 27720880 1 Drive shaft PL. 20•20-03/FS
1 27720882 1 Drive shaft PL. 20•25-03/FS
1 27720884 1 Drive shaft PL. 20•31,5-03/FS
001 1.13
Polaris 20
POLARIS 20 31 S1
ALBERO CONDUTTORE CILINDRICO 31
31 KEYED DRIVE SHAFT
SAE A

Pos.
Linguetta 3,97x3,97x18
1 42705000 1 Shaft key 3,97x3,97x18
2 27720320 1 Drive shaft PL. 20•4-31
2 27720322 1 Drive shaft PL. 20•6,3-31
2 27720324 1 Drive shaft PL. 20•8-31
2 27720325 1 Drive shaft PL. 20•9-31
R003-003/07.96

2 27720326 1 Drive shaft PL. 20•11,2-31
2 27720328 1 Drive shaft PL. 20•14-31
2 27720330 1 Drive shaft PL. 20•16-31
2 27720332 1 Drive shaft PL. 20•20-31
2 27720334 1 Drive shaft PL. 20•25-31
2 27720336 1 Drive shaft PL. 20•31,5-31
1.14 001
Polaris 20
POLARIS 20 31 S1
ALBERO CONDUTTORE CILINDRICO 31 (FS)
31 KEYED DRIVE SHAFT (FS)
SAE A

Pos.
Linguetta 3,97x3,97x18
1 42705000 1 Shaft key 3,97x3,97x18
2 27721300 1 Drive shaft PL. 20•4-31/FS
2 27721304 1 Drive shaft PL. 20•6,3-31/FS
2 27721308 1 Drive shaft PL. 20•8-31/FS
2 27721310 1 Drive shaft PL. 20•9-31/FS
R003-003/07.96

2 27721312 1 Drive shaft PL. 20•11,2-31/FS
2 27721314 1 Drive shaft PL. 20•14-31/FS
2 27721316 1 Drive shaft PL. 20•16-31/FS
2 27721318 1 Drive shaft PL. 20•20-31/FS
2 27721320 1 Drive shaft PL. 20•25-31/FS
2 27721322 1 Drive shaft PL. 20•31,5-31/FS
001 1.15
Polaris 20
POLARIS 20 49 S1
SAE A

Pos.
1 27721000 1 Drive shaft PL. 20•4-49
1 27721010 1 Drive shaft PL. 20•6,3-49
1 27721020 1 Drive shaft PL. 20•8-49
1 27721030 1 Drive shaft PL. 20•11,2-49
1 27721040 1 Drive shaft PL. 20•14-49
R003-003/07.96

1 27721050 1 Drive shaft PL. 20•16-49
1 27721060 1 Drive shaft PL. 20•20-49
1 27721070 1 Drive shaft PL. 20•25-49
1 22721080 1 Drive shaft PL. 20•31,5-49
1.16 001
Polaris 20
POLARIS 20 49 S1
SAE A

Pos.
1 27721360 1 Drive shaft PL. 20•4-49/FS
1 27721364 1 Drive shaft PL. 20•6,3-49/FS
1 27721368 1 Drive shaft PL. 20•8-49/FS
1 27721370 1 Drive shaft PL. 20•9-49/FS
1 27721372 1 Drive shaft PL. 20•11,2-49/FS
R003-003/07.96

1 27721374 1 Drive shaft PL. 20•14-49/FS
1 27721376 1 Drive shaft PL. 20•16-49/FS
1 27721378 1 Drive shaft PL. 20•20-49/FS
1 27721380 1 Drive shaft PL. 20•25-49/FS
1 22721382 1 Drive shaft PL. 20•31,5-49/FS
001 1.17
Polaris 20
POLARIS 20
CORPO PER VERSIONE BOCCHE POSTERIORI

GEAR HOUSING FOR REAR PORTS VERSION
Lato coperchio posteriore Lato coperchio anteriore

Side rear cover Side front cover

Pos.
Anello toroidale PH 2-145
1 39350000 1 O-Ring seal PH 2-145
Corpo PL. 20•4
2 17677426 1 Gear housing PL. 20•4
Corpo PL. 20•6,3
2 17677428 1 Gear housing PL. 20•6,3
R003-009/07.96
Corpo PL. 20•8

2 17677430 1 Gear housing PL. 20•8
Corpo PL. 20•9
2 17677431 1 Gear housing PL. 20•9
Corpo PL. 20•11,2
2 17677432 1 Gear housing PL. 20•11,2
Corpo PL. 20•14
2 17677434 1 Gear housing PL. 20•14
Corpo PL. 20•16
2 17677436 1 Gear housing PL. 20•16
Corpo PL. 20•20
2 17677438 1 Gear housing PL. 20•20
Corpo PL. 20•25
2 17677440 1 Gear housing PL. 20•25
Anello toroidale PH 2-150
3 39073000 1 O-Ring seal PH 2-150
001 1.41
Polaris 20
COPERCHIO POSTERIORE
POLARIS 20 REAR END COVER
PER POMPE E MOTORI UNIDIREZIONALI (S-D) E REVERSIBILI (B) CON BOCCHE LATERALI
FOR UNIDIRECTIONAL (S-D) AND REVERSIBLE (B) PUMPS AND MOTORS WITH SIDE PORTS

Pos.
Coperchio posteriore in ghisa
21915750 1 Cast iron rear end cover
1
Coperchio posteriore in alluminio
21915751 1 Aluminium rear end cover
R003-010/07.96
1.42 001
Polaris 20
POLARIS 20 82 E2
KIT VITI PER UNITÁ SINGOLE
TIE BOLTS KIT FOR SINGLE UNIT
Per coperchi in alluminio

45 [Nm] For aluminium covers
Per coperchi in ghisa
70 [Nm] For cast iron covers
Pompa o motore tipo Codice Q.tà Descrizione Prezzo cadauno

Pump or motor type code Q.ty Description Cost each
Kit vite M 10x85 UNI 5737-10.9
PL 20.4 64503085 1 Screw kit M 10x85 UNI 5737-10.9
PL 20.6,3 64503085 1 Screw kit M 10x85 UNI 5737-10.9
R003-011/07.96

Kit vite M 10x100 UNI 5737-10.9
Kit vite M 10x105 UNI 5737-10.9
Kit vite M 10x115 UNI 5737-10.9
Kit vite M 10x125 UNI 5737-10.9
1.50 001
Polaris 20
POLARIS 20 54 B2-12 B2


R003-011/07.96

Kit vite M 10x100 UNI 5737-10.9
Kit vite M 10x100 UNI 5737-10.9
Kit vite M 10x110 UNI 5737-10.9
Kit vite M 10x115 UNI 5737-10.9
001 1.51
Polaris 20
POLARIS 20 54 B4-54 B5


Kit vite M 10x80 - M 10x100 UNI 5737-10.9
PL 20.4 64700000 1 Screw kit M 10x80 - M 10X100 UNI 5737-10.9
Kit vite M 10x85 - M 10x100 UNI 5737-10.9
PL 20.6,3 64700005 1 Screw kit M 10x85 - M 10x100 UNI 5737-10.9
Kit vite M 10x85 - M 10x105 UNI 5737-10.9
PL 20.8 64700010 1 Screw kit M 10x85 - M 10x105 UNI 5737-10.9
R003-011/07.96
Kit vite M 10x90 - M 10x110 UNI 5737-10.9

PL. 20.11,2 64700015 1 Screw kit M 10x90 - M10x110 UNI 5737-10.9
Kit vite M 10x95 - M 10x115 UNI 5737-10.9
PL20.14 64700020 1 Screw kit M 10x95 - M 10x115 UNI 5737-10.9
Kit vite M 10x100 - M 10x120 UNI 5737-10.9
PL. 20.16 64700025 1 Screw kit M 10x100 - M 10x120 UNI 5737-10.9
Kit vite M 10x105 - M 10x125 UNI 5737-10.9
PL.20.20 64700030 1 Screw kit M 10x105 - M 10x125 UNI 5737-10.9
Kit vite M 10x115 - M 10x130 UNI 5737-10.9
PL. 20.25 64700035 1 Screw kit M 10x115 - M 10x130 UNI 5737-10.9
1.52 001
Polaris 20
POLARIS 20 95 B6


Kit vite M 10x100 UNI 5737-10.9
Kit vite M 10x105 UNI 5737-10.9
Kit vite M 10x105 UNI 5737-10.9
R003-011/07.96
Kit vite M 10x105 UNI 5737-10.9

Kit vite M 10x110 UNI 5737-10.9
PL. 20.11,2 64503110 1 Screw kit M 10x110 UNI 5737-10.9
Kit vite M 10x115 UNI 5737-10.9
PL20.14 64503115 1 Screw kit M 10x115 UNI 5737-10.9
Kit vite M 10x120 UNI 5737-10.9
PL. 20.16 64503120 1 Screw kit M 10x120 UNI 5737-10.9
Kit vite M 10x125 UNI 5737-10.9
PL.20.20 64503125 1 Screw kit M 10x125 UNI 5737-10.9
Kit vite M 10x135 UNI 5737-10.9
PL. 20.25 64503135 1 Screw kit M 10x135 UNI 5737-10.9
001 1.53
Polaris 20
POLARIS 20 03 S1-31 S1-49 S1



R003-011/07.96

Kit vite M 10x100 UNI 5737-10.9
Kit vite M 10x105 UNI 5737-10.9
Kit vite M 10x115 UNI 5737-10.9
Kit vite M 10x125 UNI 5737-10.9
1.54 001
Polaris 20
POLARIS 20
KIT VITI PER UNITÁ SINGOLE CON BOCCHE POSTERIORI

TIE BOLTS KIT FOR REAR PORTS SINGLE UNIT

COME ORDINARE IL KIT VITI

HOW TO ORDER THE TIE BOLTS KIT
R003-011/07.96
PL 20 • 4 - 82 E2 - P
Cilindrata
Displacement
Codice albero di trascinamento

Drive shaft code
Codice coperchio anteriore

Front cover code
001 1.55
Polaris 20
POLARIS 20
ALBERO CONDUTTORE PER POMPE MULTIPLE

DRIVE SHAFT FOR MULTIPLE PUMPS
Codice Q.tà * Descrizione Prezzo cadauno

Pos.
Code Q.ty * Description Cost each
Albero conduttore PL. 20•4/III/FS
1 27720820 1 Drive shaft PL. 20•4/III/FS
Albero conduttore PL. 20•6,3/III/FS
1 27720822 1 Drive shaft PL. 20•6,3/III/FS
R003-013/07.96

2.8 001 * Le quantità sono riferite a una sezione

* Quantities refer to one section
Polaris 20
POLARIS 20 KIT PL20

KIT VITI PER POMPE MULTIPLE
TIE BOLTS KIT FOR MULTIPLE PUMPS

COME ORDINARE IL KIT VITI

R003-014/07.96
HOW TO ORDER THE TIE BOLTS KIT
PL 20 • / 20 • / 20 •
Cilindrata sezione anteriore (A)

Front section displacement (A)
Cilindrata sezione intermedia (I)

Intermediate section displacement (I)
Cilindrata sezione posteriore (P)

Rear section displacement (P)
001 2.9
CASAPPA S.p.A. - Parma - Italy - Tel.: + 39 0521 304111 - Fax: + 39 0521 804600
CASAPPA Corp. - Batavia, IL 60510 U.S.A. - Phone: 630 761-0041 - Fax: 630 761-0048
CASAPPA GmbH - Stuttgart - Germany - Tel.: + 49 711 7811770 - Fax: + 49 711 7811771
CASAPPA SARL - Janneyrias - France - Tel.: + 33 4 72462112 - Fax: + 33 4 72462100
www.casappa.com
e-mail: info@casappa.com
HYDROMOTOR SPARE
PART
Mixer
SPARE PARTS FOR
HYDRAULIC MOTORS TYPE MP... series 4, 41513830XX
Number Stock per
Item Spare Parts Code No NOTES
per Motor 1000 Motors
1 SCREW
For MP (F)...(D) M6x20-12.9 MP08V019 6 100
For MPQ… M5x16-12.9 MP08V017 6 100
For MPQ…U M5x16-12.9 MP08V017 8 100
2 SPRING WASHER 6H (without MPQ…) MP023V001 6 100
3 DUST SEAL 28,5x35x2 MP013V021 1 *
4 SPIGOT FLANGE
For MP(F)… 43162 027 00 1 10
For MP(F)…U, MP(F)…D 43162 025 00 1 10
For MPQ... 43162 028 00 1 10
For MPQ...D 43162 026 00 1 10
For MPQ...U 43162 029 00 1 10
5 SHAFT SEAL
For MP(F,Q)… QUAD-RING QRAR 04217 MP014V002 1 *
For MP(F,Q)… D 28,56x42x5,5/4,8 HP20 MP015V048 1 *
For MP(F,Q)… U 28,56x42x5,5/4,8 HP20 MP015V048 1 *
6 "O" RING
For MP (F)... "O" RING 48x2 MP011V016 1 *
For MPQ... CANT SEAL 47,35x1,68x1,68 MP012V007 1 *
7 THRUST WASHER
For MP(F)… 49891 596 00 1 15
For MPQ... 49891 972 00 1 15
For MP(F)…U 49891 597 00 1 15
For MPQ...U 49891 598 00 1 15
8 AXIAL NEEDLE BEARING
For MP... AXK 28,6x45,75x3 MP10V002 1 50
For MP... U ARK 28,65x42x4,5 MP10V003 1 50
9 CASTELLATED NUT M20x1,5 (For MP...K only) MP07V014 1 5
10 WASHER (For MP...K only) 49891 027 00 1 20
11 KEY
For MP...CO straight key ¼ "x ¼ "x1 ¼" 56231 002 00 1 50
For MP...C straight key A8x7x32 MP13V001 1 50
For MP...K straight key B5x5x14 MP13V052 1 50
12 SHAFT **
For MP…C ø25 k6, straight key 41344 253 10 1 10
For MP…CO ø1", straight key 41344 254 10 1 10
For MP...SH splined BS 2059 (SAE 6B) 41344 255 10 1 10
For MP…K tapered 1:10 41344 256 10 1 10
For MP…SA splined B25x22 DIN 5482 41344 257 10 1 10
For MP…VC ø25 k6, straight key 129 5400 201 1 10
For MP…VCO ø1", straight key 129 5400 301 1 10
For MP...VSH splined BS 2059 (SAE 6B) 129 5400 401 1 10
For MP…VSA splined B25x22 DIN 5482 129 5400 501 1 10
MP-E-MP -ser4 -1- 05.2006

Hydraulic Motors Type MP - series 4
Spare Parts List
Number Stock per
12.1 SHAFT **
For MP…C -RS ø25 k6, straight key 41344 253 11 1 10
For MP…CO -RS ø1", straight key 41344 254 11 1 10
For MP...SH -RS splined BS 2059 (SAE 6B) 41344 255 11 1 10
For MP…K -RS tapered 1:10 41344 256 11 1 10
For MP…SA -RS splined B25x22 DIN 5482 41344 257 11 1 10
For MP…VC -RS ø25 k6, straight key 129 5400 211 1 10
For MP…VCO -RS ø1", straight key 129 5400 311 1 10
For MP...VSH -RS splined BS 2059 (SAE 6B) 129 5400 411 1 10
For MP…VSA -RS splined B25x22 DIN 5482 129 5400 511 1 10
13 CHECK VALVE (not for MP...U) 138 0001 100 2 20
14 HOUSING**
Housing SAE A, two holes,
For MP... 51142 829 20 1 10
side ports, G1/2
For MP...M 51142 830 20 1 10
side ports, M22x1,5
Housing magneto, four
For MPF... 51142 831 20 1 10
holes, side ports, G1/2
Housing magneto,four
For MPF...M 51142 832 20 1 10
holes, side ports, M22x1,5
Housing square, four bolts,
For MPQ... 51142 833 20 1 10
side ports, G1/2
For MPQ...M 51142 834 20 1 10
side ports, M22x1,5
For MPE...(M) 51142 835 20 1 10
rear ports
For MPFE...(M) 51142 837 20 1 10
holes, rear ports
For MPQE... (M) 51142 839 20 1 10
rear ports
For MP...U 51142 829 00 1 10
side ports, G1/2
For MP...UM 51142 830 00 1 10
side ports, M22x1,5
For MPF...U 51142 831 00 1 10
For MPF...UM 51142 832 00 1 10
For MPQ... U 51142 981 00 1 10
side ports, G1/2
For MPQ...U M 51142 982 00 1 10
side ports, M22x1,5
For MPE...U(M) 51142 835 00 1 10
rear ports
For MPFE...U(M) 51142 837 00 1 10
holes, rear ports
For MPQE...U (M) 51142 983 00 1 10
rear ports
14.1 HOUSING-RS**
For MP... RS 51142 829 21 1 10
side ports, G1/2
For MP...M RS 51142 830 21 1 10
side ports, M22x1,5
For MPF... RS 51142 831 21 1 10
For MPF...M RS 51142 832 21 1 10
MP-E-MP-ser 4 -2- 05.2006

Spare Parts List
Number Stock per
For MPQ... RS 51142 833 21 1 10
side ports, G1/2
For MPQ...M RS 51142 834 21 1 10
side ports, M22x1,5
For MPE...(M) RS 51142 835 01 1 10
rear ports
For MPFE...(M) RS 51142 837 01 1 10
holes, rear ports
For MPQE... (M) RS 51142 839 01 1 10
rear ports
For MP...U RS 51142 829 01 1 10
side ports, G1/2
For MP...UM RS 51142 830 01 1 10
side ports, M22x1,5
For MPF...U RS 51142 831 01 1 10
For MPF...UM RS 51142 832 01 1 10
For MPQ... U RS 51142 981 01 1 10
side ports, G1/2
For MPQ...U M RS 51142 982 01 1 10
side ports, M22x1,5
For MPE...U(M) RS 51142 835 01 1 10
rear ports
For MPFE...U(M) RS 51142 837 01 1 10
holes, rear ports
For MPQE...U (M) RS 51142 983 01 1 10
rear ports
15 PLUG G ½ - DIN (for MP...E) MP17V014 2 100
16 WASHER 21x26 (for MP...E) 49891 564 00 2 100
17 CARDAN SHAFT
For MP... 25 L=73,8 mm 46457 151 00 1 10
For MP... 32, 40, 50 L=74,3 mm 46457 152 00 1 10
For MP... 80 L=78,7 mm 46457 155 00 1 10
For MP...100 L=81,3 mm 46457 156 00 1 10
For MP...125 L=84,6 mm 46457 157 00 1 10
For MP...160 L=89 mm 46457 160 00 1 10
For MP...200 L=94,5 mm 46457 161 00 1 10
For MP...250 L=99,5 mm 46457 162 00 1 10
For MP...315 L=110,5 mm 46457 163 00 1 10
For MP...400 L=121,5 mm 46457 165 00 1 10
For MP... 500 L=133,5 mm 46457 166 00 1 10
For MP... 630 L=152,0 mm 46457 168 00 1 10
18 CANT SEAL 77,7x81,06x1,68 MP012V010 3 *
19 DISTRIBUTOR PLATE 43142 021 00 1 10
20 GEROTOR SET MP
For MP 25 W=5,2 mm 129 6450 600 1 10
For MP 32 W=6,3 mm 129 6450 610 1 10
For MP 40 W=7,4 mm 129 6450 620 1 10
For MP 50 W=6,67 mm 129 6450 100 1 10
For MP 80 W=10,67 mm 129 6450 110 1 10
For MP 100 W=13,33 mm 129 6450 120 1 10
For MP 125 W=16,67 mm 129 6450 130 1 10
MP-E-MP-ser 4 -3- 05.2006

Spare Parts List
Number Stock per
For MP 160 W=21,33 mm 129 6450 140 1 10
For MP 200 W=26,67 mm 129 6450 150 1 10
For MP 250 W=33,33 mm 129 6450 160 1 10
For MP 315 W=42,67 mm 129 6450 170 1 10
For MP 400 W=53,33 mm 129 6450 180 1 10
For MP 500 W=66,63 mm 129 6450 700 1 10
For MP 630 W=84,0 mm 129 6450 710 1 10
21 END COVER
For MP .... 25, 32, 40, 50... side ports 43312 008 00 1 10
For MP ....80,100,125,160,200,250,315,400,500, 630
43312 007 00 1 10
... side ports
For MP .... 25, 32, 40, 50...M side ports 43312 013 00 1 10
For MP ....80,100,125,160,200,250,315,400,500,
43312 009 00 1 10
630...M side ports
For MP ....E 25, 32, 40, 50... rear ports, G 1/2 48443 024 00 1 10
For MP ....E 80,100,125,160,200,250,315,400,500,
48443 023 00 1 10
630... rear ports, G 1/2
For MP ....E 25, 32, 40, 50...M rear ports, M22x1,5 48443 028 00 1 10
For MP ....E 80,100,125,160,200,250,315,400,500,
48443 027 00 1 10
630...M rear ports, M22x1,5
22 END COVER (only for version “1”)
For MP .... 25, 32, 40, 50...1 side ports 43312 015 00 1 10
For MP ....80,100,125,160,200,250,315,400,500,
43312 014 00 1 10
630...1 side ports
For MP ....E 25,32,40,50...1 rear ports, G1/2 48443 036 00 1 10
For MP ....E 80,100,125,160,200,250,315,400,500,
48443 034 00 1 10
630...1 rear ports, G 1/2
For MP ....E 25, 32, 40, 50...1 M rear ports, M22x1,5 48443 037 00 1 10
For MP ....E 80,100,125,160,200,250,315,400, 500,
48443 035 00 1 10
630...1 M rear ports, M22x1,5
23 WASHER 8x12
For MP... 49891 500 00 7 1200
For MP...E 49891 500 00 5 1000
For MP... U 49891 992 00 7 1200
For MP...EU 49891 992 00 5 1000
24 SCREW M8x1xL
For MP... 25... L=35 mm MP08V002 7 40
For MP... E 25... L=35 mm MP08V002 5 40
For MP... 32... L=35 mm MP08V002 7 40
For MP... E 32... L=35 mm MP08V002 5 40
For MP... 40... L=40 mm MP08V003 7 40
For MP... E 40... L=40 mm MP08V003 5 40
For MP... 50... L=40 mm MP08V003 7 40
For MP... E 50... L=40 mm MP08V003 5 30
For MP... 80... L=40 mm MP08V003 7 40
For MP... E 80... L=45 mm MP08V004 5 30
For MP...100... L=45 mm MP08V004 7 40
For MP...E 100... L=45 mm MP08V004 5 30
For MP...125... L=50 mm MP08V005 7 40
For MP...E 125... L=50 mm MP08V005 5 30
MP-E-MP-ser 4 -4- 05.2006

Spare Parts List
Number Stock per
For MP...160... L=55 mm MP08V006 7 40
For MP...E 160... L=55 mm MP08V006 5 30
For MP...200... L=60 mm MP08V007 7 40
For MP...E 200... L=60 mm MP08V007 5 30
For MP...250... L=65 mm MP08V008 7 40
For MP...E 250... L=65 mm MP08V008 5 30
For MP...315... L=75 mm MP08V010 7 40
For MP...E 315... L=75 mm MP08V010 5 30
For MP...400... L=85 mm MP08V012 7 40
For MP...E 400... L=85 mm MP08V012 5 30
For MP...500... L=100 mm MP08V014 7 40
For MP...E 500... L=100 mm MP08V014 5 30
For MP...630... L=115 mm MP08V154 7 40
For MP...E 630... L=115 mm MP08V154 5 30
25 NAME PLATE 49961 888 00 1 10
26 RIVET 2x5 MP08B057 2 100
27 WASHER (not for version “1”)
For MP... 13x17 49891 566 00 1 100
For MP...M 14x18 MP021B003 1 100
28 PLUG (not for version “1”)
For MP... G 1/4 MP17V001 1 100
For MP...M M14x1,5 MP17V004 1 100
29 SPACER (for MP...E only) 49891 940 00 1 40
30 PLUG 9 (for MP-RS only) MP065014 1 10
NOTES: * - Contained in Seal Kit. Code 41 5127 0001, 41 5127 0487, 415127 0667, 41 5127 0109, 41
5127 0010 и 41 5127 0118.
** -Separate housing or shaft not available.
Seal Kit for MP(F) …- series 4
Code No Number Stock per

Item Spare Parts NOTES
41 5127 0487 per Motor 1000 Motors
3 DUST SEAL 28,5x35x2 1
5 QUAD-RING QRAR 04217 1
30
6 "O" RING 48x2 1
18 CANT SEAL 77,7x81,06x1,68 3
Seal Kit for MPQ …- series 4

5 QUAD-RING QRAR 04217 1
30
6 CANT SEAL 47,35x1,68x1,68 1
18 CANT SEAL 77,7x81,06x1,68 3
MP-E-MP-ser 4 -5- 05.2006

Spare Parts List
Seal Kit for MP(F) … D- series 4

5 SHAFT SEAL 28,56x42x5,5/4,8 HP20 1
30
6 "O" RING 48x2 1
18 CANT SEAL 77,7x81,06x1,68 3
Seal Kit for MPQ …D- series 4

5 SHAFT SEAL 28,56x42x5,5/4,8 HP20 1
30
6 CANT SEAL 47,35x1,68x1,68 1
18 CANT SEAL 77,7x81,06x1,68 3
Seal Kit for MP(F) ... U- series 4

5 SHAFT SEAL 28,56x42x5,5/4,8 HP20 1
30
6 "O" RING 48x2 1
18 CANT SEAL 77,7x81,06x1,68 3
Seal Kit for MPQ...U- series 4

5 SHAFT SEAL 28,56x42x5,5/4,8 HP20 1
30
6 CANT SEAL 47,35x1,68x1,68 1
18 CANT SEAL 77,7x81,06x1,68 3
Tightening Torques
Item Tightening, daNm

1 0,6÷0,8 (1,0÷1,2 for “U”)
9 9÷11
15 3÷3,5
24 3÷3,5 (4,0÷4,2 for “U”)
28 2÷2,5
1 for MPQ...[SCREW M5x16]
0,6÷0,8
are sticked
MP-E-MP-ser 4 -6- 05.2006

Hydraulic Motors Type MP, MPF and MPQ- series 4
Spare Parts List
Version “RS”
Version “1”
MP-E-MP -ser4 -7- 05.2006

SPARE PARTS FOR
HYDRAULIC MOTORS TYPE MT..., 4151297XXX
Number Stock per
1 DUST SEAL 45x52x3 MP013V025 1 ***
2 SCREW M8x25-10.9 MP08V251 6 60
3 FRONT CAP 43362 019 00 1 10
4 SHAFT SEAL
For MT... 45x65x7 MP015V005 1 ***
For MT... U 45x65x5,5/4,8 HP-20 MP015V047 1 ***
5 "O" RING 90x2 MP011B028 1 ***
6 CASTELLATED NUT M30x2 [SHAFT "K"] MP07V016 1 10
7 WASHER ø56 [SHAFT "K"] 49891 570 00 1 10
8 PARALLEL KEY
For MT...C A12x8x70 DIN 6885 56231 009 00 1 10
For MT...CO 3/8"x3/8"x2 1/4" 56231 010 00 1 10
For MT...K B 12x8x28 DIN 6885 56231 012 00 1 10
9 SHAFT*
For MT...C cylindrical ø40, straight key 41344 099 00 1 10
For MT...CO cylindrical ø1 1/2", straight key 41344 103 00 1 10
For MT...SH 17T splined, ANSI B92.1-1976 41344 100 00 1 10
For MT...K 1:10 tapered ø45 under seal 41344 101 00 1 10
For MT...SL splined DIN 9611 Form 1 41344 102 00 1 10
10 RADIAL TAPERED ROLLER BEARING* [55x90x23] MP10V011 2 60
11 SPACER BUSHING MT* 43141 435 00 1 10
12 SUPPORT BUSHING MT* 43141 783 00 1 10
13 LOCK NUT* M50x1.5 49813 702 00 1 30
14 CONICAL SEAL RING MT 49891 569 00 1 30
15 PLUG
For MT... G1/4 MP17V001 1 40
For MT...M M14x1.5 MP17V004 1 20
16 WASHER
For MT... 13x17 49891 566 00 1 40
For MT...M 14x18 MP021B003 1 20
17 HOUSING
For MT... Standard G1/4 51162 150 00 1 10
For MT...M Standard M14x1.5 51162 152 00 1 5
For MTW... Wheel, mounting flange G1/4 51162 705 00 1 10
For MTW...M Wheel, mounting flange, M14x1.5 51162 710 00 1 5
18 CARDAN SHAFT I
For MT...160 L=103.5 mm 46457 041 00 1 10
For MT...200 L=108 mm 46457 042 00 1 10
For MT...250 L=114 mm 46457 043 00 1 10
For MT...315 L=124 mm 46457 044 00 1 10
For MT...400 L=134.5 mm 46457 045 00 1 10
For MT...500 L=148.5 mm 46457 046 00 1 10
For MT...630 L=143 mm 46457 115 00 1 10
For MT...725 L=153.5 mm 46457 222 00 1 10
SP-E-MT -1- 01.2008

Hydraulic Motors MT...
Spare Parts List
Number Stock per
19 "O" RING 96x3 MP011V028 2 ***
20 GEAR WHEEL SET MT...
For MT[W][S] 160 W=20 mm 129 7000 200 1 10
For MT[W][S] 200 W=25 mm 129 7000 300 1 10
For MT[W][S] 250 W=31.3 mm 129 7000 400 1 10
For MT[W][S] 315 W=40.5 mm 129 7000 500 1 10
For MT[W][S] 400 W=51 mm 129 7000 600 1 10
For MT[W][S] 500 W=65 mm 129 7000 700 1 10
For MT [W][S] 630 W=61 mm 129 7000 800 1 10
For MT [W][S] 725 W=70 mm 129 7000 810 1 10
For MTV 160 W=20 mm 129 7150 100 1 5
For MTV 200 W=25 mm 129 7150 200 1 5
For MTV 250 W=31.3 mm 129 7150 300 1 5
For MTV 315 W=40.5 mm 129 7150 400 1 5
For MTV 400 W=51 mm 129 7150 500 1 5
For MTV 500 W=65 mm 129 7150 600 1 5
For MTV 630 W=61 mm 129 7150 700 1 5
For MTV 725 W=70 mm 129 7150 800 1 5
21 PIN 4x9.8 MP11006 1 10
22 VALVE DRIVE
For МТ 46457 047 00 1 30
For МТ...Т 46453 003 00 1 30
23 CHANNEL PLATE
For MT… 43142 710 00 1 30
For MT…LSV 43142 836 00 1 30
24 VALVE PLATE 43142 711 00 1 30
24.1 VALVE PLATE MT…RS 43142 798 00 1 15
25 BALANCE PLATE 45342 046 00 1 30
26 PIN 5x24 MP08V182 1 20
27 SPRING WASHER 59263 012 00 1 10
28 "O" RING 62x2 MP011V037 1 ***
29 SPACER****
b=33.7 mm For MT [W] [S] 41111 031 00 1 15
b=35 mm For MTV only 41111 039 00 1 15
30 "O" RING 40x2 MP011V036 1 ***
31 END COVER
For MT... 51141 038 00 1 20
For MT...RS 51141 038 01 1 20
For MT...M 51141 040 00 1 20
For MT...M…RS 51141 040 01 1 20
For MT...E 51141 039 00 1 20
For MT...E…RS 51141 039 01 1 20
For MT...EM 51141 041 00 1 20
For MT...EM…RS 51141 041 01 1 20
For MT...Т 51141 060 00 1 20
For MT...Т…M 51141 132 00 1 20
For MTV... 51141 048 00 1 20
SP-E-MT -2- 01.2008
Spare Parts List
Number Stock per
For MTV...RS 51141 048 01 1 20
For MTV...M 51141 049 00 1 20
For MTV...M…RS 51141 049 01 1 20
For MTV...E 51141 050 00 1 20
For MTV...E..RS 51141 050 01 1 20
For MTV...EM 51141 051 00 1 20
For MTV...EM…RS 51141 051 01 1 20
For MTV...Т 51141 048 02 1 20
For MTV... M Т 51141 049 02 1 20
32 BALL ø6.35 MP09V012 2 20
33 GUIDE PIN 44323 001 00 2 20
34 SPRING 59111 005 00 2 20
35 WASHER 10x14 MP021B001 2 20
36 PLUG M10x1 MP17V003 2 10
37 SCREW M14xL** ** 4 40
38 NAME PLATE
For MT... 49961 887 00 1 10
For MT...T 49961 886 00 1 10
39 RIVET 2x5
For MT... MP08B057 4 200
For MT...T MP08B057 2 100
40 PLUG
For MT...E G3/4 49561 240 00 2 10
For MT...EM M27x2 49561 245 00 2 10
41 WASHER 27x33 [For MT…E only] MP021B007 2 10
42 SHAFT CUP
For MT...C 48472 017 00 1 10
For MT...CO, SH 48472 015 00 1 20
For MT...SL 48472 706 00 1 10
For MT...K 48472 016 00 1 10
For MTS 48472 019 00 1 10
For MTV 48472 022 00 1 10
43 "O" RING
For MTS... 124,5x3 MP011V089 1 ***
For MTV... 100x3 MP011V029 1 ***
44 SCREW M5x30 [For MTV] MP08B006 2 20
45 SPRING RING 5H [For MTV] MP023B007 4 80
46 FRONT CAP [For MTV only] 43142 118 00 1 10
47 SCREW
For MTV 160 M5x20 MP08V018 2 20
For MTV 200 M5x25 MP08V067 2 20
For MTV 250 M5x30 MP08B006 2 20
For MTV 315 M5x40 MP08V068 2 20
For MTV 400 M5x50 MP08V076 2 20
For MTV 500 M5x65 MP08V144 2 20
For MTV 630 M5x60 MP08V248 2 20
For MTV 725 M5x70 MP08V145 2 20
SP-E-MT -3- 01.2008
Spare Parts List
Number Stock per
48 FLANGE
For MTS... 51162 154 00 1 5
For MTS...M 51162 155 00 1 5
49 SEAL PLUG-SET
For MT... G3/4 4153000010 2 100
For MT...M M27x2 4153000011 2 100
50 PIN MTT 49715 013 00 1 10
51 TACHOMETER MT...T 129 7000 001
51.1 WASHER MTT 49891 580 00 1 10
51.2 “О” RING 42х1.5 МР011B088 1 ***
51.3 “О” RING 23х1.5 МР011V112 1 ***
51.4 HOUSING EPMTT 51162 239 00 1 10
51.5 AXLE MTT 41344 300 00 1 10
51.6 ROTO GLYDE RING 8х12.9х2.2 МР016022 1 ***
51.7 SPACER 49891 584 00 1 10
51.8 RETAINING RING В8 /2170/ МР022B022 1 10
51.9 RADIAL BALL BEARING 8х22х7 МР10V029 1 10
51.10 RETAINING RING В8 /5300/ МР022B040 1 10
51.11 RETAINING RING А22 МР022B023 1 10
51.12 WASHER А5х9 МР021B028 4 10
51.13 SCREW М5х16 МР08V232 4 10
52 CUP EPMST 48472 715 00 1 5
53 PLUG 9 [for MT…RS only] MP065014 1 10
NOTES:
* - BEARING UNIT contains items 9, 10,11,12 and 13. These parts are not separately available.
** - The lenght "L" and Code No are specified in a Table (see page 6).
*** - Contained in Seal Kit Code No 41 5129 7000, 41 5169 1010, 41 5129 7096, 41 5129 7150,
41 5168 1170, 41 5169 2700 and 41 5129 7137.
**** - The length "b" is definable by mounting.
SPARE PARTS FOR

HYDRAULIC MOTORS TYPE MT...HD
Number Stock per
54 BALANCE PLATE MT-HD 45342 080 00 1 30
55 BACK-UP RING 66,5x1,25x1 MP062V030 2 *
56 “О” RING 64х1,5 MP011V155 1 *
57 “О” RING 41,5х1,5 MP011V156 1 *
58 BACK-UP RING 44x1,25x1 MP062V031 1 *
59 END COVER MT-HD
For MT...HD 51141 143 00 1 20
For MTE...HD 51141 144 00 1 20
SP-E-MT -4- 01.2008

Spare Parts List
Seal Kit for MT and MTW...

1 DUST SEAL 45x52x3 1
4 SHAFT SEAL 45x65x7 1
5 "O" RING 90x2 1
14 CONICAL SEAL RING MT /No49891 569 00/ 1 30
19 "O" RING 96x3 2
28 "O" RING 62x2 1
30 "O" RING 40x2 1
Seal Kit for MT…U and MTW...U

4 SHAFT SEAL 45x65x5,5/4,8 HP-20 1
5 "O" RING 90x2 1
14 CONICAL SEAL RING MT /No49891 569 00/ 1 30
19 "O" RING 96x3 2
28 "O" RING 62x2 1
30 "O" RING 40x2 1
Seal Kit for MT...T

5 "O" RING 90x2 1
14 CONICAL SEAL RING MT /No49891 569 00/ 1
19 "O" RING 96x3 2
30
28 "O" RING 62x2 1
30 "O" RING 40x2 1
51.2 “О” RING 42х1.5 1
51.3 “О” RING 23х1.5 1
51.6 ROTO GLYDE RING 8х12.9х2.2 1
SP-E-MT -5- 01.2008

Spare Parts List
Seal Kit for MT...U…T

4 SHAFT SEAL 45x65x5,5/4,8 HP-20 1
5 "O" RING 90x2 1
19 "O" RING 96x3 2
30
28 "O" RING 62x2 1
30 "O" RING 40x2 1
51.2 “О” RING 42х1.5 1
51.3 “О” RING 23х1.5 1
51.6 ROTO GLYDE RING 8х12.9х2.2 1
Seal Kit for MT…HD and MTW...HD

5 "O" RING 90x2 1
19 "O" RING 96x3 2 30
55 BACK-UP RING 66,5x1,25x1 2
56 “О” RING 64х1,5 1
57 “О” RING 41,5х1,5 1
58 BACK-UP RING 44x1,25x1 1
Seal Kit for MTS...

19 "O" RING 96x3 2
28 "O" RING 62x2 1
30
30 "O" RING 40x2 1
43 "O" RING 124,5x3 1
Seal Kit for MTS...HD

19 "O" RING 96x3 2
55 BACK-UP RING 66,5x1,25x1 2
56 “О” RING 64х1,5 1
30
57 “О” RING 41,5х1,5 1
58 BACK-UP RING 44x1,25x1 1
43 "O" RING 124,5x3 1
SP-E-MT -6- 01.2008

Spare Parts List
Seal Kit for MTV...

19 "O" RING 96x3 2
28 "O" RING 62x2 1 30
30 "O" RING 40x2 1
43 "O" RING 100x3 1
Tightening Torques
Item Tightening, daNm

2 2.5÷3.0
6 47÷53
13 10÷11
15 2.0÷2.5
36 1.0÷1.5
37 10÷11
40 3.0÷3.5
44 0.5÷0.7
47 0.5÷0.7
Screw Lenghts "L" for Motors MT...
DISPLACEMENT MOUNTING FLANGE

cu.cm/rev W S V
L,mm
MT 160 120 120 120 115
Code No MP08V037 MP08V037 MP08V037 MP08V210
MT 200 120 120 120 120
MT 250 130 130 130 125
MT 315 140 140 140 135
MT 400 150 150 150 145
MT 500 160 160 160 160
MT 630 160 160 160 155
MT 725 170 170 170 165
SP-E-MT -7- 01.2008

Hydraulic Motors MT…, MTW…
Spare Parts List
SP-E-MT -8- 01.2008

Hydraulic Motors MTS…, MTV…
Spare Parts List
SP-E-MT -9- 01.2008

Hydraulic Motors MT…T, MT…HD
Spare Parts List
MT…T
MT…HD
SP-E-MT - 10 - 01.2008
DIESEL ENGINE SPARE
PART
320/40515
TRANSMISSION SPARE
PART
FRONT AXLE SPARE
PART
REAR AXLE SPARE
PART

2018-182 IS21 Concrete Spraying Machine Operating Manual - Spare Parts - DRAFT

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2018-182 IS21 Concrete Spraying Machine Operating Manual - Spare Parts - DRAFT

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MODEL : IS21

1. IS21 CONCRETE SPRAYING MACHINE OPERATING

2. ELECTRICAL CIRCUIT DIAGRAM AND REMOTE

3. HYDRAULIC CIRCUIT DIAGRAM AND PARTS

4. AIR COMPRESSOR OPERATING MANUAL

5. DOSAGE PUMP OPERATING MANUAL AND DOSING

6. HYDRAULIC PUMP OPERATING MANUAL

7. HYDRAMOTOR OPERATING MANUAL

8. DIESEL ENGINE OPERATING MANUAL

9. TRANSMISSION OPERATING MANUAL

10. FRONT AND REAR AXLES OPERATING MANUAL

11. DROPBOX OPERATING MANUAL

12. IS26 CONCRETE SPRAYING MACHINE SPARE PART

13. MANIPULATOR SPARE PART

14. AIR COMPRESSOR SPARE PART

16. HYDRAULIC PUMP SPARE PART

17. HYDROMOTOR SPARE PART

18. DIESEL ENGINE SPARE PART

19. TRANSMISSION SPARE PART

20. FRONT AXLE SPARE PART

21. REAR AXLE SPARE PART

TİTAN MAKİNA LTD. ŞTİ.

Address :1160. Sokak No: 9 Ostim 06370 Ankara Türkiye

2. APPLIED DIRECTIVES AND STANDARDS ............................................ 5

3. GENERAL SAFETY INSTRUCTIONS ...................................................... 6

5. DESCRIPTION AND OPERATION OF THE MACHINE ...............................31

6. TECHNICAL DATA ..................................................................................50

6.6. Operator’s Cabin.......................................................................................55

7. LAYOUT PLAN AND TECHNICAL DRAWINGS .....................................62

8. USE OF CONTROL PANEL AND STARTING THE MACHINE ...............66

9. MAINTENANCE INSTRUCTIONS ...........................................................77

10. SCOPE of DELIVERY ............................................................................128

11. CE DECLARATION ..................................................................................129

1.1. Terms and Definitions

Titan : Titan Makina Ltd. Şti.

The intended use of this machine is concrete spraying. Any

The safety devices on the machine are installed in order to

The mechanical parts of the machine are under warranty for 1

2. APPLIED DIRECTIVES AND STANDARDS

2006/42/EC Machinery Directive

Safety of machinery - General principles for design

3. GENERAL SAFETY INSTRUCTIONS

1. This manual is prepared by Titan to provide safety information on installation,

3.1. Safety Signs and Instructions

Symbols include important technical information not to be ignored.

Symbol Indicates Description

This symbol indicates the risk of

This symbol indicates the

This symbol indicates the fuel

This symbol indicates the water

Protective This symbol indicates that

Symbol Indicates Description

This symbol indicates that the

In case of emergency, break the

Tyre This symbol indicates the ideal

While fixing the machine by

Ear This symbol indicates that ear

Symbol Indicates Description

This symbol indicates the drop

In Case of This symbol indicates the actions

Main This symbol indicates the main

This symbol indicates that the

This symbol indicates that the

Symbol Indicates Description