jcb TM320 User manual

SERVICE MANUAL
LOADER
TM320, TM420
EN - 9813/6850 - ISSUE 2 - 04/2018
This manual contains original instructions, verified by
the manufacturer (or their authorized representative).
Copyright 2018 © JCB SERVICE
All rights reserved. No part of this publication may
be reproduced, stored in a retrieval system, or
transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise,
without prior permission from JCB SERVICE.
www.jcb.com
Foreword
The Operator's Manual
You and others can be killed or seriously injured
if you operate or maintain the machine without
first studying the Operator's Manual. You must
understand and follow the instructions in the
Operator's Manual. If you do not understand
anything, ask your employer or JCB dealer to
explain it.
Do not operate the machine without an Operator's
Manual, or if there is anything on the machine you
do not understand.
Treat the Operator's Manual as part of the machine.
Keep it clean and in good condition. Replace the
Operator's Manual immediately if it is lost, damaged
or becomes unreadable.
Contents
01 - Machine
03 - Attachments, Couplings and Load
Handling
06 - Body and Framework
09 - Operator Station
12 - Heating, Ventilating and Air-
Conditioning (HVAC)
15 - Engine
18 - Fuel and Exhaust System
21 - Cooling System
24 - Brake System
25 - Steering System
27 - Driveline
30 - Hydraulic System
33 - Electrical System
72 - Fasteners and Fixings
75 - Consumable Products
78 - After Sales

27 - Driveline
06 - Semi-Automatic Gearbox
12 - Clutch - Ratio
27 - 126 9813/6850-2 27 - 126
12 - Clutch - Ratio
Disassemble and Assemble
Special Tools
Description Part No. Qty.
Circlip Assembly Tool 998/11334 1
Main shaft clutch
Disassembly
The numerical sequence is a guide to the
disassembly procedure.
1. Remove and discard the O-ring seals 1.
2. To check the clutch plates.
2.1. Remove the circlip1 from the clutch drum.
2.2. Lift off the thick pressure counter plate then
the seven friction plates and seven counter
plates.
3. Remove and check the roller bearing race. If
necessary discard it.
4. Use either the circlip assembly tool or a tube of
suitable diameter to install over the top spring
cup.
Special Tool: Circlip Assembly Tool (Qty.: 1)
Figure 567.
A
ATube
5. Cut out a small portion of the tube, to allow
access, to release the circlip 2.
6. With the clutch drum located in the press,
compress the spring sufficiently to allow the
circlip 2 to be released.
7. When the circlip 2 is released, remove it from the
shaft with the spring cup, spring and the lower
spring cup.
8. If necessary the clutch operating piston may be
removed by compressed air blown through the
drilling in the end of the clutch shaft.
9. Remove and discard the clutch piston O-ring seal
2 and seal 3.

27 - Driveline
06 - Semi-Automatic Gearbox
12 - Clutch - Ratio
27 - 127 9813/6850-2 27 - 127
Figure 568.
B
R
S
M
Q
P
N
K
G
F
D
C
L
J
H
E
Table 242.
Item Description
B Circlip 1
C Thick pressure counter
plate
D Friction plate
E Counter plate
F Roller bearing race
Item Description
G Upper spring cup
H Circlip 2
J Spring
K Lower spring cup
L Piston
M Clutch shaft
N O-ring seal 2

27 - Driveline
06 - Semi-Automatic Gearbox
12 - Clutch - Ratio
27 - 128 9813/6850-2 27 - 128
Item Description
P O-ring seal 3
Q Housing
R Gallery port
S O-ring seal 1
Assembly
Assembly is the opposite of the disassembly
procedure with the following precautions.
1. Install the new clutch piston O-ring seals 2 and
seal 3 to the piston.
2. Lubricate the new seals and push the piston into
the housing by hand.
3. Put the lower spring cup over the central spigot
of the piston.
4. Replace the spring and the top spring cup.
5. Keep the circlip 2 on the top cup ready for
installation.
6. Use the tube with a cutout to compress the
spring.
7. Locate the cutout to give access for circlip 2.
8. Install the circlip 2 and make sure that it is seated
correctly in the groove.
9. New clutch friction plates must be soaked in oil
before assembly.
10. Install the first counter plate to the clutch drum
followed by the friction plate.
11. Alternately install all fourteen plates.
12. Use a scrap splined drive hub to align the splines
of the friction plates.
13. Install the thick counter plate at the top of the
assembly followed by the circlip 1.
14. Check the free play clearance of the clutch plates
and it must be within the specified limit.
Dimension: 3 –3.5 mm
15. You can adjust the clearance by either changing
the thick pressure plate from 6.0mm (0.24in)
thick version to 6.5mm (0.26in) thick or by
the addition of a shim counter plate installed
immediately under the thick pressure plate.
16. Once the clutch is assembled completely then
apply compressed air to the gallery port in the
end of the shaft to check the clutch operation.
Ratio Clutches
Disassembly
1. For the remaining two ratio clutches follow the
same disassembly procedure as above.
2. The only difference is the retention of the support
taper roller bearing which for each clutch is held
in place by a machined cap.
Assembly
1. Clutch 1 and clutch 2 assembly.
1.1. Use a mandrel to carefully push the taper
bearing 1 into its position.
1.2. Rotate the roller cage as the bearing is
pushed into place to make sure that the
mandrel does not foul and distort the cage.
1.3. Put the new O-ring seal 4 into the grooves
in the cap 1.
Figure 569.
W
V
U
T
X
TTaper bearing 1
UO-ring sea l4
VCap 1
WCapscrews 1
XO-ring seals 5
1.4. Two capscrews 1 hold the cap 1 in place.
1.5. Tighten the capscrews 1 to the correct
torque value.
1.6. Put two new O-ring seals 5 into the groves
in cap 1.

27 - Driveline
06 - Semi-Automatic Gearbox
12 - Clutch - Ratio
27 - 129 9813/6850-2 27 - 129
2. Clutch 3 and clutch 4 assembly.
2.1. Use a mandrel to carefully push the taper
bearing 2 into its position.
2.2. Rotate the roller cage as the bearing is
pushed into the place to make sure that the
mandrel does not foul and distort the cage..
2.3. Put the new O-ring seal 6 into the grooves
in the cap 2.
Figure 570.
Y
Z
AA
AC
AB
YTaper bearing 2
ZO-ring seal 6
AA Cap 2
AB Capscrews 2
AC O-ring seals 7
2.4. Two capscrews 2 hold the cap 2 in place.
2.5. Tighten the capscrews 2 to the correct
torque value.
2.6. Put two new O-ring seals 7 into the groves
in cap 2.
Table 243. Torque Values
Item Description Nm
W Capscrews1 18
AB Capscrews2 45

27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 130 9813/6850-2 27 - 130
13 - Clutch - Master
Remove and Install ..................................... 27-130
Disassemble and Assemble ........................ 27-136
Remove and Install
Special Tools
Description Part No. Qty.
Clutch Pack Retainers 892/01048 2
Mandrel 892/01050 1
Locking Plates 892/01052 2
Consumables
Description Part No. Size
JCB Multi-Gasket 4102/1212 0.05 L
Remove
1. Put the gearbox on a suitable manipulator.
Rotate the gearbox until the clutch is in the top
position.
2. Remove all the cover attaching bolts and then
install the M10 jacking bolts1 (x3).
3. Screw all the jacking bolts evenly until the cover
is clear of its spigot.
Figure 571.
G
A
B
C
E
B
F
D
ACover attaching bolts (x18)
BM10 jacking bolts1 (x3)
CCover
DM10 threaded lifting eye (x2)
EOil seal2
FCover O-ring seal
GO-ring1 seal
4. Install the M10 threaded lifting eyes to lift the
cover.

27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 131 9813/6850-2 27 - 131
5. Carefully lift off the cover and make sure that you
keep it square to the housing.
6. Make sure that you remove and discard all the
O-ring1 seals.
7. Remove the jacking bolt.
8. Remove and discard the cover O-ring seal.
9. Prise out and discard the oil seal2 carefully and
make sure that the seal housing in the cover is
not damaged.
10. Install the special locking plates to prevent the
clutch assembly from rotating.
Special Tool: Locking Plates (Qty.: 2)
Figure 572.
A
H
H
J
K
L
ACover attaching bolts (x18) HSpecial screws
JClutch assembly KSpecial locking plate
LHousing
11. Use the cover attaching bolts and the special
screws that are supplied with the locking plates,
to lock the clutch assembly to the housing.
12. Remove all the clutch drum bolts.

27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 132 9813/6850-2 27 - 132
Figure 573.
M
N
P
Q
MClutch drum bolts (x12)
NPlug1
PM8 threaded lifting eye (x2)
QClutch drum
13. Remove the locking plate.
14. Install the M8 threaded lifting eyes to the clutch
drum.
15. Attach suitable lifting equipment to the clutch
drum.
16. Carefully remove the clutch drum, hub and the
pressure plate assembly.
17. Install the special pack retainers to the clutch
plate carrier.
Special Tool: Clutch Pack Retainers (Qty.: 2)
Figure 574.
R
U
T
S
V
RSpecial pack retainers (x2)
SClutch plates
TThrust washer1
UPlate carrier
VThrust washer2
18. Remove the carrier together with the clutch
plates and the thrust washer1.
19. Remove the thrust washer2.
20. Remove the button head capscrews.
21. Remove the oil baffle plate.
22. Rotate the drum carrier to align the five holes with
countersunk capscrews.
23. Remove the countersunk capscrews.

27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 133 9813/6850-2 27 - 133
Figure 575.
Y
M
W
M
Z
L
X
Z
AA
AB
MClutch drum bolts (x12)
LHousing
WButton head capscrews (x5)
XOil baffle plate
YCountersunk capscrews
ZJCB multigasket
AA Drum carrier
AB M10 jacking bolts2 (x3)
24. Install the M10 jacking bolts2 and jack the drum
carrier to remove it from the housing.
25. Make sure that you install the drum bolts that
will assist you to lift the drum carrier clear of the
housing.
26. The drum carrier will be removed completely with
the PTO (Power Take-Off) input gear and the
bearing.
27. It is not necessary to remove the clutch housing
unless it is damaged or the PTO/splitter gearbox
needs to be disassembled.
Figure 576.
L
Z
AD
AC
AB
LHousing
ZJCB multigasket
AB Verbus-ripp bolts (x12)
AC O-ring2
AD Cross drilling blanking plug2
28. The clutch house removal.
28.1. Remove and discard all the Verbus-ripp
bolts.
28.2. Use a soft faced hammer to separate the
housing from the PTO/splitter gearbox.
28.3. Remove the clutch housing.
29. After you remove the clutch from the housing
there will be three main sub assemblies.
29.1. Remove the Clutch drum, hub and
pressure plate sub-assembly. Refer to
Figure 577.

27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 134 9813/6850-2 27 - 134
Figure 577.
29.2. Remove the clutch plates and plate carrier
sub-assembly. Refer to Figure 578.
Figure 578.
29.3. Remove the clutch drum carrier and input
gear PTO sub-assembly.
Figure 579.
Install
Installation is the opposite of the removal procedure
but make sure that additionally you follow the
instructions below.
1. If it is necessary to replace the clutch housing
with a new one then make sure that the cross
drilling blanking plug2 is installed to the new
housing.
2. Tighten the plug2 to the correct torque value.
3. Make sure that the oil feed cross drillings are
clear.
4. Carefully clean all the traces of the sealing
compound from the clutch and the smoothshift
gearbox housing mating surfaces.
5. Lightly lubricate with oil and install a new O-ring2.
6. Apply even beads of JCB Multigasket to the
Smoothshift Gearbox housing (around the outer
diameter and around each threaded bolt hole).
Consumable: JCB Multi-Gasket
7. Make sure that you install new Verbus-ripp bolts.
8. Tighten the Verbus-ripp bolts to the correct
torque value.
9. Make sure that the clutch components are
carefully checked for any signs of wear or
damage.
10. If any of the friction or counter plates are
damaged or if any of the friction plates are
excessively worn (thickness less than 3.5 mm or
oil grooves less than 0.1 mm deep) replace the
complete set of plates.

27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 135 9813/6850-2 27 - 135
11. Make sure that the new friction plates are soaked
in transmission oil before you install them.
12. Check the thrust washer2 for any signs of wear.
13. If the thickness (3.9mm) or the outside diameter
(110.0mm) is less then the mentioned value then
install a new thrust washer2.
14. Before you install the new thrust washer2 soak it
in the transmission oil for at least an hour.
15. Do not apply any kind of thread locking
compound to any of the bolts or screws.
16. Tighten the plug1s to the correct torque value to
prevent oil gallery leakage.
17. It is not possible to locate the clutch drum over
the clutch plates and carrier assembly inside the
housing.
18. First sub-assemble the components on the
bench and then use the retainers to hold the
assembly together.
19. Before you replace the drum, plates, carrier and
hub assembly install the two guide pins to the
M10 threaded holes in the drum carrier.
20. Use a special mandrel to install the new oil seal2.
Special Tool: Mandrel (Qty.: 1)
21. If the clutch plates are replaced with new ones,
check to make sure that the clutch is disengaged
before installing the cover 2.
22. Lightly apply oil and install a new O-ring1 and the
cover O-ring.
Table 244. Torque Values
Item Description Nm
A Cover attaching bolt 56
M Clutch drum bolt 52
W Button head capscrews 12
Y Countersunk capscrews 38
N Plug1(Black) 22
N Plug1(Gold) 12
AB Verbus-ripp bolt 75
AD Cross drilling blanking plug2 15

27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 136 9813/6850-2 27 - 136
Disassemble and Assemble
Special Tools
Description Part No. Qty.
Peg Socket 892/01045 1
Mandrel 892/01046 1
Clutch Jig 892/01047 1
Clutch Pack Retainers 892/01048 2
Guide Rods 892/01049 2
Slide Hammer Kit 993/68100 1
Consumables
Description Part No. Size
4101/0250 0.01 LJCB Threadlocker
and Sealer (Medium
Strength) 4101/0251 0.05 L
Master Clutch- Clutch Drum and Hub
Disassembly
1. Remove the lubrication nozzles.
2. Remove the bolts.
3. Remove the release springs and the spring
pillars then discard the springs.
4. Remove the oil baffle plate from the locating
dowel 1.
5. Remove the pressure plate.
6. Make sure that you do not lose the dowel 1 and
dowel 2
7. Remove the piston from the drum.
8. Use M6 bolt (x2) and suitable levers to help in
removal of the piston.
9. Remove and discard the outer seal from the
piston.
10. Remove the socket head capscrews (x8).
11. Use a suitable bar to prevent drum rotation.
12. Use a soft faced hammer to tap out the hub from
the drum.
13. Remove and discard the O-ring 1 from the drum.
14. Remove the circlip.
15. Use a suitable drift to tap out the blanking disc
together with the inner bearing.
16. Remove and discard the O-ring 2.
17. Remove and discard the iron sealing ring.
18. Remove and discard the inner piston seal from
the hub.
19. Do not remove the outer bearing unless it is to be
replaced with a new one.
20. At the time of removal the bearing can be
damaged. When the bearing is removed it must
be replaced.
21. To remove the outer bearing, screw in two jacking
bolts at their correct location on the hub.
22. If the bronze bush is to be replaced, then remove
it with a suitable puller and slide hammer.
Special Tool: Slide Hammer Kit (Qty.: 1)

27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 137 9813/6850-2 27 - 137
Figure 580.
A
H
K
L
K
H
Y
X
B
V
N
Q
R
P
L
Z
Z
T
S
U
Y
W
D
C
E
F
L
J
M
W
G

27 - Driveline
06 - Semi-Automatic Gearbox
13 - Clutch - Master
27 - 138 9813/6850-2 27 - 138
Table 245.
Item Description
A Lubrication nozzles
B Bolts
C Springs
D Spring pillars
E Oil baffle plate
F Pressure plate
G Piston
H Drum
J Outer seal
K Socket head capscrews
(x8)
L Hub
M O-ring 1
N Circlip
P Blanking disc
Q Inner bearing
R O-ring 2
S Sealing ring
Item Description
T Inner piston seal
U Outer bearing
V Bronze bush
W M8 bolt (x2)
X Dowel 1
Y Dowel 2
Z Jacking bolts (x2)
Assembly
Assembly is the opposite of the disassembly
procedure but additionally follow the steps below.
1. Check that the oil feed slots and drillings are
clear.
2. Check the condition of the pressure plate, if it is
excessively scored then replace with a new one.
3. If it is necessary to replace the pressure plate,
dowel 1 and dowel 2 must be installed to the plate
before assembly.

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