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JCB 525 Telehander - No foward drive

Discussion in 'Forklifts/Telehandlers' started by cj-525hl, Apr 10, 2011.

  1. cj-525hl

    cj-525hl Active Member

    Joined:
    Apr 5, 2011
    Messages:
    37
    Location:
    France
    Hi All,

    I've got a JCB 525b-2hl telehandler which I've steadily been going over repairing bits and pieces. Whilst using it today, I completely lost forward drive on a hill. It just dropped out. I’ve checked the two terminals which plug into the solenoids which sit on the torque converter and they are showing 12volts when the rev/forward lever is selected. I’m still able to select and run it in reverse, in all gears.

    I was wondering if anyone has any suggestions as to the problem, or were to start looking.

    Colin
     
  2. cps

    cps Senior Member

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    Jul 13, 2008
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    Occupation:
    plant mechanic
    Location:
    Ireland
    Hi there, You could try swapping the solenoids as you could have a bad one! Also the valve itself can give bother!
     
  3. cj-525hl

    cj-525hl Active Member

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    Location:
    France
    Hi cps,

    Many thanks for the quick reply. If you can please bear with me as I'm kind of new to plant, however it's definately getting adictive.

    I've had a look at removing the forward solenoid, as it's the conclusion I came to, but I'm not completely sure how to remove it. I peeled back the metal tab which sits in the black plastic end cap and tried to unscrew the cap. The cap moves fractionally but felt as though it would break if forced any further. Do you know if that's the correct way to remove it, or is there another way?
     
  4. cps

    cps Senior Member

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    Occupation:
    plant mechanic
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    No Problem, yea they that is how you remove it, you may need to turn it back and forth a few time but it should screw of ok!
     
  5. cj-525hl

    cj-525hl Active Member

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    Location:
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    Many thanks cps,

    I'll give it another go tomorrow. Try swapping them over.

    cj
     
  6. cj-525hl

    cj-525hl Active Member

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    Messages:
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    Location:
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    Just a quick update,

    Tried swapping the solenoids over and they both work, so no joy there.

    Any other suggestions would be helpful.

    cj
     
  7. cps

    cps Senior Member

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    Occupation:
    plant mechanic
    Location:
    Ireland
    Hi cj, it could be the spool in the valve itself, they can stick some times! Remove the solenoids and there should be 4 screws each side, take the covers of and check the springs and spool!
     
  8. cj-525hl

    cj-525hl Active Member

    Joined:
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    Location:
    France
    Hi cps,

    Hope you've had a good day.

    I removed the forward side solenoid, 4 screws, cover and checked the spool (now I know what it's called) and all seemed to be operating fine, refitted and still no forward drive.

    The forward drive went on my return from the village down the road, about 3 miles away. I reversed it home today, some funny looks from the locals. I told them I was reversing to save on deisel, should have a full tank by the time I get back. Some weren't sure if I was joking or not!

    When I got back I then tried swapping out the spools to test the reverse spool on the forward side to double check, but I couldn't remove one of the bolts on the cover. So I've descided to remove the whole valve assembly as I don't think it's ever been removed since new. Some of the bolts are well and truely corroded in so I might have to drill out some of the bolt heads on the top of the body and remove bolt shafts after.

    Interesting little project. I'll let you know how I get on.

    cj
     
  9. Reel hip

    Reel hip Well-Known Member

    Joined:
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    Occupation:
    owner operator bobcat"s and dump truck"s
    Location:
    San Diego
    But at least you now have a full tank of diesel! hahaha. good luck
     
  10. cj-525hl

    cj-525hl Active Member

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    Location:
    France
    Hi Reel Hip,

    Yah, the locals where a little confused.

    I've ordered a new gasket and 4no. new bolts which hold the shuttle body (I think that's it's name) assembly on the top of the gearbox. The supplier ordered the wrong ones so it's taken awhile.

    Still, I've done some further research and it could be a number of things. The first thing to check once the shuttle is back on is the oil level. I replaced the filter just before the problem occured. I did check the oil level after, but I'm not sure if it was the right procedure. So that will be the next thing. I'm hoping it's the oil as it's a quick fix

    If not oil, I'll check the oil strainer to see if it's caught any metal from broken internal parts. It could be a forward clutch pack that's let go, but I presume they weaken over time and not just let go all of a sudden.

    I've also managed to locate a JCB 3cx workshop manual which I think has the same gearbox so I now have diagrams etc. Makes all the difference.

    cj
     
  11. JayP

    JayP New Member

    Joined:
    May 11, 2011
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    1
    Location:
    Edmonton
    Sorry I can't start a new topic yet. My th63 Telehandler slips out of gear when the machine's been running for about an hour. I shut it down and a few hours after it cools it runs fine again. My transmission
    Fluid level is high not sure if it gets too hot. I appreciate any ideas as to why this happens.
    Thanks
    Jay
     
  12. newty

    newty Member

    Joined:
    May 10, 2009
    Messages:
    13
    Location:
    UK
    Hi,

    These can strip the splines which hold the drive gear onto the clutch basket. Normally happens when people go from fwd / rev without stopping. If the clutch plates have broken up the friction material will be in the strainer in the bottom of the gearbox.
     
  13. cj-525hl

    cj-525hl Active Member

    Joined:
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    Messages:
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    Location:
    France
    Hi Newty,

    I've remounted the shuttle body with no luck, still no forward drive.

    I was only driving up hill when I lost forward drive. Could this have stripped a spline? if so would there be debris in the stainer too?

    I'll drain the oil from gearbox and have a look in the strainer. I'll post up the findings.

    Many thanks Newty.

    Colin
     
  14. newty

    newty Member

    Joined:
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    Messages:
    13
    Location:
    UK
    Hi Colin,

    If it has stripped the splines there may not be debris in the bottom of the box. If its the clutch pack there will be debris.

    I see you have a workshop manual, the fwd clutch basket has a drive gear fasterned to it, The two are held together by a spline and then crimped so they are one unit. The spline gets worn away over the years so the gear spins in the clutch basket, thus no drive. Ive seen a couple do this.

    I think that you are going to have to bite the bullet and get the box out and split but check the strainer first.

    Hope this helps.
    Adam
     
  15. cps

    cps Senior Member

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    Occupation:
    plant mechanic
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    Good advise there Adam, like you say he may have to bite the bullet!

    let us know what you find Colin

    Aiden
     
  16. cj-525hl

    cj-525hl Active Member

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    Location:
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    Just a bit more information, selecting gears is now not possible when the engine is running. If I switch the engine off I can select gears to my hearts content. Does this mean anything or shed more light on the problem? I'm wondering if it might just be too much oil in the gearbox.

    I've looked at the manual I downloaded to check ATF level. It says to run the engine for 10 minutes to fill filter etc. after filter change and then stop and let settle for 20 seconds and then check the level. Is this procedure correct as the level is above the max mark whilst the engine is running. I normally check ATF level whilst the engine is running.
     
  17. newty

    newty Member

    Joined:
    May 10, 2009
    Messages:
    13
    Location:
    UK
    Hi,

    Thats the correct way to check the oil level. But running it for a min the dip will be ok rather than 10. Too much oil will not cause drive problems from cold.

    Its difficult to diagnose faults over the internet, all i can do is use my experience to help guide you...

    If you select a gear then start the machine does it TRY to creep with the fwd/rev lever in neutral?

    If so...

    I'd go for the fwd clutch pack friction material being in the strainer in the bottom of the box and the steel plates eating themselves and causing the box to be being driven all the time which is why you cant select gears with the engine running. I think its time to pull the strainer from the box. 5 mins, a drain tray and a 13mm spanner and you will have a better idea of the condition of the internals.
     
  18. cj-525hl

    cj-525hl Active Member

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    37
    Location:
    France
    Hi Newty,

    Many thanks for taking the time to help. It's very much appreciated.

    I'll drain the oil and remove the strainer to see what's in there. From memory it used to creep forward everso slightly when started in gear and selector set to neutal. Does not do that now.

    I'll drain the oil and have a look in the strainer.
     
  19. cj-525hl

    cj-525hl Active Member

    Joined:
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    Messages:
    37
    Location:
    France
    Just drained ATF and removed strainer. There was about 2 tablespoons of black flakes in there. I presume thats clutch material.
     
  20. newty

    newty Member

    Joined:
    May 10, 2009
    Messages:
    13
    Location:
    UK
    Hi,

    Im affraid you are correct. Time to pull the box.
    I have made a cradle from some 12mm flat plate and some pieces of old box section that sits on my trolley jack to aid removal and replacement, just helps if im on my own in the workshop.
    Its also a good idea to reverse the machine onto some wooden blocks/planks under each wheel just to give you some more room under the machine and so you have enough height to wheel the gearbox out from under the machine on the trolley jack. I remove the offside front wheel and drag the box out that way.