jcb 1CX, Service Manual

Page: 167 / 242

13 - 9
Dismantling and Assembly
from machine number 807173
Dismantling
Drain the oil from the motor.
Mark the relative positions of the front case 19, rear case 16
and brake housing 13.
Unscrew capscrews 1 in a progressive manner then remove
end cover 2 from brake housing 13. Remove and discard
gasket 3. Withdraw spring disc 4.
Remove the brake piston 5 from brake housing 13 using low
pressure compressed air. Take care to collect piston as it is
being ejected.
Remove and discard seal 6 from the brake piston.
Unscrew capscrews 11 and remove with washers 12 then
separate brake housing 13 from rear case 16. Remove and
discard ‘O’ ring 14.
Remove seal 7 from interior of brake housing 13. Withdraw
brake pack 8 from brake housing 13 together with shims 9
and 10 (if fitted).
Remove capscrews 15 and separate the rear case 16 from
the front case and cam assembly.
Support the front case and cam assembly on blocks.
Separate cam assembly 18 from front case 19.
Remove and discard ‘O’ rings 17 and 20.
Tap rear case 16 lightly with a rubber mallet to release
distributor ring 21.
Make a note of the position of stop pin 23 in the slot in rear
case 16 then remove the stop pin.
Note: To ensure that motor rotation is correct on re-
assembly, the slots in the rear case are identified ‘L’ or ‘R’.
Remove seal rings 24, 25, and 26 from distributor ring 21.
Discard the seal rings.
Remove springs 22 from their bores in distributor ring 21.
Separate cylinder block 27 from cam 18.
Remove circlips 28 and retaining rings 29 from cylinder block
18.
Withdraw pistons 30 and rollers 31 from cylinder block 27. If
difficulty is experienced, low pressure air can be applied to
the ports in the cylinder block.
Remove and discard ‘O’ rings 32 fitted to pistons 30.
Using a soft steel drift, remove split ring 33 and washer 34.
Support the front case on blocks and press shaft 35 out of
bearings 36 and 38.
Remove the cone from bearing 36. Using a soft steel drift,
remove bearing cups 36 and 38 from front casing 19.
Remove bearing cone 38 from shaft 35 using a puller. This
action may damage the bearing cone, in which case it
should be replaced.
Remove and discard shaft seal 37 from front casing 19.
Assembly
Clean all components and oil before assembly. All new seals
and ‘O’ rings should be greased with petroleum jelly.
Warm bearing cone 38 and press onto shaft 35 using a
bench press.
Press shaft seal 37 into front case 19 using a bench press.
Take care not to damage the seal. Fill the space between
the lips of the seal with grease.
Press bearing cup 38 into front case 19 using a bench press.
Turn the front case over and press bearing cup 36 into the
front casing using a bench press.
Cover the splines of shaft 35 with tape to protect the shaft
seal. Fit the completed front casing assembly to the shaft
assembly. Check that the shaft seal 37 is undamaged then
remove the tape from the shaft splines.
Warm bearing cone 36 and, while rotating the front case,
press onto shaft 35 using a bench press to a load of 4
tonnes.
Using a bench press, apply a pre-load of 1.5 tonnes to the
bearing cone 36 while rotating the front case. Fit split ring 33
onto shaft 35 and measure the gap between bearing 36 and
the split ring.
Remove split ring 33 and fit washer 34 with a thickness of
between 0.05 to 0.1 mm (0.002 to 0.004 in.) greater than the
measured gap. Refit the split ring and remove the pre-load.
Check that shaft 35 runs freely and without binding, but with
a slight stiffness, in the front case.
The remainder of the assembly is a reversal of the dismantling
procedure.
Examine pistons 31 and their bores in cylinder block 27 for
signs of damage. Replace as necessary.
Inspect springs 22 for signs of damage and/or distortion.
Replace as necessary.
Section E Hydraulics
9803/8550
Section E
13 - 9
Issue 1
Drive Motors
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