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jcb 214e Service Manual

Backhoe loader
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Table Of Contents
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Table of Contents

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www.WorkshopManuals.co.uk
Service
Manual
3CX, 4CX, 214e, 214, 215,
217 & VARIANTS
Backhoe
Loader
From M/c No. 930000 Onwards
From M/c No. 903000 Onwards (USA)
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; © WORLD PARTS CENTRE,
WATERLOO PARK, UTTOXETER, ST14 5PA
ENGLAND
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9803/3280 Issue 4
Purchased from www.WorkshopManuals.co.uk
General Information
Care & Safety
Attachments
Body & Framework
1
2
3
A
B
C
D
E
F
G
H
K

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Summary of Contents for jcb 214e

  • Page 1 From M/c No. 930000 Onwards Brakes From M/c No. 903000 Onwards (USA) Steering PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © WORLD PARTS CENTRE, WATERLOO PARK, UTTOXETER, ST14 5PA Engine ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND Publication No.
  • Page 2 Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment.
  • Page 3 Colour Coding The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service publications. Full Pressure Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and M.R.V. operating pressure.

  • Page 4: Table Of Contents

    www.WorkshopManuals.co.uk Section 1 General Information Section 1 Contents Page No. Machine Identification Plate 1 - 1 Typical Vehicle Identification Number (VIN) 1 - 1 Typical Engine Identification Number 1 - 1 Serial Plates 1 - 2 Torque Settings 2 - 1 Service Tools Numerical List 3 - 1 Service Tools...

  • Page 5: Machine Identification Plate

    www.WorkshopManuals.co.uk Section 1 General Information Section 1 1 - 1 1 - 1 Machine Identification Plate Typical Vehicle Identification Number (VIN) Your machine has an identification plate mounted on the loader tower. The serial numbers of the machine and its 930000 major units are stamped on the plate.

  • Page 6: Serial Plates

    www.WorkshopManuals.co.uk Section 1 General Information Section 1 1 - 2 1 - 2 Serial Plates A Front Axle (2WS machine) B Front Axle (4WS machine) C Rear Axle (2WS machine) D Rear Axle (4WS machine) E Synchro Shuttle Transmission F Powershift Transmission S259110 G Engine S257580...
  • Page 7 0.12 10.0 24.0 18.0 (10) 48.0 35.5 (12) 82.0 60.5 Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 8 Pressure Test Kit 4 - 6 4104/1310 Hand Cleaner 4 - 1 892/00255 Pressure Test Adapter 4 - 6 4104/1538 JCB Cleaner & Degreaser 5 - 1 892/00256 Pressure Test Adapter 4 - 6 4104/1557 Cleaner/Degreaser (400 ml) 5 - 1 892/00257...
  • Page 9 www.WorkshopManuals.co.uk Section 1 General Information Section 1 3 - 2 3 - 2 Service Tools Numerical List Page No. Page No. 892/00282 Shunt 4 - 4 Shaft Lock Screw 4 - 13 892/00283 Tool Kit Case 4 - 4 892/00284 Tachometer 4 - 4 892/01078...
  • Page 10 www.WorkshopManuals.co.uk Section 1 General Information Section 1 3 - 3 3 - 3 Service Tools Numerical List 7216/0002 6 Way Pin Housing 4 - 5 The following parts are replacement items for kits and would 7216/0003 6 Way Socket Retainer 4 - 5 normally be included in the kit numbers quoted on pages 7216/0004...
  • Page 11 West Midlands, WV13 2JW S261210 Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc. JCB part number - 892/00845 Hand Cleaner - special blend for the removal of polyurethane adhesives. JCB part number - 4104/1310 (454g;...
  • Page 12 'L' Blades - 25 mm (1 in) cut - replacement blades for cut-out knife (above). JCB part number - 992/12801 (unit quantity = 5 off) Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass.
  • Page 13 Long Knife - used to give extended reach for normally Braided Cutting Wire - consumable heavy duty cut-out inaccessible areas. wire used with the glass extraction tool (above). JCB part number - 892/00844 JCB part number - 892/00849 (approx 25 m length) S186360...

  • Page 14: Electrics

    www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 4 4 - 4 Service Tools (cont'd) Section C - Electrics AVO Test Kit 892/00283 Tool Kit Case 892/00298 Fluke Meter 85 892/00286 Surface Temperature Probe 892/00284 Venture Microtach Digital Tachometer 892/00282 100 amp Shunt - open type 892/00285...
  • Page 15 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 5 4 - 5 Service Tools (cont'd) Section C - Electrics Electrical Repair Kit 6A :7216/0002 6 Way Pin Housing 2A :7212/0002 2 Way Pin Housing 6B :7216/0004 6 Way Pin Retainer 2B :7212/0004 2 Way Pin Retainer 6C :7216/0003...

  • Page 16: Hydraulics

    www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 6 4 - 6 Service Tools (cont'd) Section E - Hydraulics Hydraulic Circuit Pressure Test Kit 892/00253 Pressure Test Kit :892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in :892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in :892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in :892/00254...
  • Page 17 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 7 4 - 7 Service Tools (cont'd) Section E - Hydraulics Components for Valve Block A.R.V. Testing For 4CX Variable Flow machines use 25/201103 892/00309 A.R.V. Pressure Test Kit 892/00881 Valve Spool : 892/00340 Test Block Body Seal Fitting Tool...
  • Page 18 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 8 4 - 8 Service Tools (cont'd) Section E - Hydraulics Female Cone Blanking Plug 892/00055 1/4 in. BSP Male Cone Blanking Cap 892/00056 3/8 in. BSP 816/00294 1/4 in. BSP 892/00057 1/2 in.
  • Page 19 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 9 4 - 9 Service Tools (cont'd) Section E - Hydraulics 11 o S216230 10mm 20mm 892/00180 Seal Fitting Tool for fitting 'O' ring and kin ring to Hydraulic Steer Unit 892/00181 Replacement Plastic Boss 110mm...
  • Page 20 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 10 4 - 10 Service Tools (cont'd) Section F - Transmission 892/00920 Flow Test Adapter 892/00301 Flow Test Adapter 892/00812 Drive Coupling Spanner for front 892/00302 Flow Test Adapter axle and gearbox yoke couplings S196720 S266880...
  • Page 21 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 11 4 - 11 Service Tools (cont'd) Section F - Transmission 892/00224 Impulse Extractor Set for Hub Bearing Seals S216290 892/00817 17 mm A/F x 3/4in. square drive 892/00818 22 mm A/F x 3/4in. square drive 892/00819 15 mm A/F x 1/2in.
  • Page 22 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 12 4 - 12 Service Tools (cont'd) Section F - Transmission 992/04800 Flange Spanner - for locking pinion flange while pinion nut is slackened or torque set S216310 892/00182 Bearing Pad Driver S197040 992/04000 Torque Multiplier (use in conjunction with a torque wrench to give a...
  • Page 23 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 13 4 - 13 Service Tools (cont'd) Section F - Transmission 892/01077 Synchro Shuttle Gearbox - Selector 892/01078 Synchro Shuttle Gearbox - Mainshaft Shaft Lock Screw Adjuster A395350 A396510 Synchro Shuttle Gearbox - Setting ring socket spanners Powershift Gearbox Flow Test Adaptor 892/01079...
  • Page 24 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 14 4 - 14 Service Tools (cont'd) Section F - Transmission 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/in :892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in :892/00203...
  • Page 25 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 15 4 - 15 Service Tools (cont'd) Section F - Transmission A396960 A396930 A396950 A396940 8, 9 A396580 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 26 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 16 4 - 16 Service Tools (cont'd) Section F - Transmission 921/53400 Spacer Kit - Sychro Shuttle Gearbox, Solid Spacer Setting Kit SD70, SD80 Axles Synchro Shuttle Gearbox, SD70, SD80 Axles Comprises of: Spacer thickness mm 892/00918...
  • Page 27 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 17 4 - 17 Service Tools (cont'd) Section F - Transmission 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...
  • Page 28 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 18 4 - 18 Service Tools (cont'd) Section F - Transmission Powershift Gearbox - 6 Speed (ShiftMaster) Electronic Service Tool Kit 892/01033 Kit comprises: Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable ShiftMaster diagnostics software.
  • Page 29 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 19 4 - 19 Service Tools (cont'd) Section K - Engine 892/00836 Lifting Wire Assembly (for engine removal) S192390 892/00041 De-glazing Tool for Cylinder Bores (to S219080 assist bedding-in of new piston rings) A314530 892/00936 Timing pin for fuel injection pump...
  • Page 30 25-65mm diameter. 4102/1212 50ml JCB High Strength Threadlocker A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important.
  • Page 31 www.WorkshopManuals.co.uk Section 2 Care & Safety Section 2 Contents Page No. Safety Notices 1 - 1 General Safety 2 - 1 Operating Safety 3 - 1 Maintenance Safety 4 - 1 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 32 www.WorkshopManuals.co.uk Section 2 Care & Safety Section 2 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.
  • Page 33 2 - 1 All construction and agricultural equipment can be hazardous. When a JCB machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others.
  • Page 34 www.WorkshopManuals.co.uk Section 2 Care & Safety Section 2 3 - 1 3 - 1 Operating Safety ! WARNING ! WARNING Machine Condition ROPS/FOPS Structure A defective machine can injure you or others. Do not operate The machine is fitted with a Roll Over Protection Structure a machine which is defective or has missing parts.
  • Page 35 Do not weld cast Make sure there is good ventilation in closed areas where iron. Contact your JCB distributor for advice before batteries are being used or charged. Do not check the modifying the machine.
  • Page 36 www.WorkshopManuals.co.uk Section 2 Care & Safety Section 2 4 - 2 4 - 2 Maintenance Safety (cont'd) ! CAUTION ! WARNING Rams Diesel Fuel The efficiency of the rams will be affected if they are not Diesel fuel is flammable; keep naked flames away from the kept free of solidified dirt.
  • Page 37 ! WARNING loader arm safety strut. Fluoroelastomeric Materials 2-1-1-6 Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton, ! WARNING Fluorel and Technoflon. Fluoroelastomeric materials subjected to high temperatures can produce highly A raised and badly supported machine can fall on you.

  • Page 38: Table Of Contents

    www.WorkshopManuals.co.uk Section 3 Section 3 Routine Maintenance Contents Page No. Lubricants - Health and Safety Hygiene 2 - 1 Storage 2 - 1 Handling 2 - 1 First Aid - Oil 2 - 1 Spillage 2 - 1 Fires 2 - 1 3 - 1 Service Schedules Loader Arm Safety Strut...

  • Page 39: Table Of Contents

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 Contents Page No. Engine Oil and Filter Checking the Oil Level 13 - 1 Changing the Oil and Filter 13 - 1 Engine Cooling System Checking the Coolant 14 - 1 Changing the Coolant 14 - 1 Adjusting the Fan Belt 14 - 2...

  • Page 40: Table Of Contents

    www.WorkshopManuals.co.uk Section 3 Section 3 Routine Maintenance Contents Page No. Hydraulic Oil Cooler Cleaning the Tubes/Fins 23 - 1 Stabiliser Legs Wear Pads 25 - 1 Wear Pad Adjustment 25 - 1 Air Conditioning Adjusting the Compressor Drive Belt 26 - 1 Hose Burst Protection Valve (if fitted) Checking Hose Burst Protection Valve 27 - 1...

  • Page 41: Hygiene

    Hygiene a Wash your skin thoroughly with soap and water. b Using a nail brush will help. JCB lubricants are not a health risk when used properly for their intended purposes. c Use special hand cleansers to help clean dirty hands.

  • Page 42: Service Schedules

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 3 - 1 Service Schedules 3 - 1 A badly maintained machine is a danger to the operator and Apart from the daily jobs, the schedules are based on the people working around him. Make sure that the regular machine running hours.
  • Page 43 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 3 - 2 Service Schedules 3 - 2 Pre-start Cold Checks Operation † 100 1000 2000 Service Points and Fluid Levels Hydraulic Oil Cooler - Clean Hydraulic Oil Strainer - Clean Hydraulic Tank Filler Cap (with integral filter) - Change Hydraulic Pump Drive Shaft - Examine/Grease...
  • Page 44 Note: The axles and driveshafts are factory greased with a high performance grease, if during service a standard grease is used, then the interval must be reduced to every 50 hours, contact your JCB Distributor for advice. Note: After a major transmission repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair.
  • Page 45 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 4 - 1 Loader Arm Safety Strut 4 - 1 Installing Install the loader arm safety strut as detailed below before working underneath raised loader arms. ! WARNING Raised loader arms can drop suddenly and cause serious injury.

  • Page 46: Checking For Damage

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 5 - 1 Checking for Damage 5 - 1 Inspect steelwork for damage. Note damaged paintwork for future repair. Make sure all pivot pins are correctly in place and secured by their locking devices. Ensure that the steps and handrails are undamaged and secure.

  • Page 47: Cleaning The Machine

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 6 - 1 Cleaning the Machine 6 - 1 Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Lower the attachments to the ground and stop the engine. Clean the machine using water and/or steam.

  • Page 48: Removing And Fitting A Side Panel

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 7 - 1 Engine Panels 7 - 1 Opening and Closing the Bonnet Removing and Fitting a Side Panel ! WARNING To release the bonnet, pull handle A, the bonnet will automatically open and be supported on gas struts. The loader arms must be raised and locked before you remove an engine side panel.
  • Page 49 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 8 - 1 Seat Belt 8 - 1 Checking the Seat Belt Condition and Security ! WARNING When a seat belt is fitted to your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident.

  • Page 50: Loader Arms

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 9 - 1 Greasing 9 - 1 You must grease the machine regularly to keep it working Greasing should be done with a grease gun. Normally, two efficiently. Regular greasing will also lengthen the machine's strokes of the gun should be sufficient.

  • Page 51: Backhoe Quickhitch

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 9 - 2 Greasing 9 - 2 Backhoe & Quickhitch 22 Grease Points Note: Figure shows a typical boom and dipper arrangement. & £ ⁄ ¤ A340900 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...

  • Page 52: Front Axle (2 Wheel Drive Machines)

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 9 - 3 Greasing 9 - 3 Front Axle (2 Wheel Drive Machines) Note: Grease point 5 is a remote grease point mounted on 9 Grease Points the side of the mainframe chassis (near the left front wheel). S260200 Front Axle (4 Wheel Drive Machines) Note: Grease point 5 is a remote grease point mounted on...

  • Page 53: Front Axle (All Wheel Steer Machines)

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 9 - 4 Greasing 9 - 4 Front Axle (All Wheel Steer Machines) 5 Grease Points Note: Grease point 5 is a remote grease point mounted on the side of the front nose (near the left front wheel). S260220 Rear Axle (All Wheel Steer Machines) 4 Grease Points...

  • Page 54: Extending Dipper

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 9 - 5 Greasing 9 - 5 Extending Dipper Driveshafts Front Driveshaft ! CAUTION 3 Grease Points Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period.

  • Page 55: In - 1 Clamshovel

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 9 - 6 Greasing 9 - 6 6 - In - 1 Clamshovel Loader Quickhitch 3 grease points each end - 2 grease points each end - Total 6 Grease Points Total 4 Grease Points S089961 S257250 Stabilisers (Centremount Machines)

  • Page 56: Power Sideshift

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 9 - 7 Greasing 9 - 7 Power Sideshift Kingpost Total 4 Grease Points 9 Grease Points Note: Release the kingpost clamps and lower the excavator Note: Figure shows a centremount kingpost, greasing is to the ground before greasing.

  • Page 57: Knuckle (If Fitted)

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 9 - 8 Greasing 9 - 8 Knuckle (if fitted) Backhoe Quickhitch (Hydraulic) ! CAUTION Refer to Backhoe greasing for the boom and dipper grease points. Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl. Total 2 Grease Points.

  • Page 58: Checking The Wheel Nut Torques

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 10 - 1 Tyres and Wheels 10 - 1 Tyre Inflation Checking the Wheel Nut Torques These instructions are for adding air to a tyre which is On new machines, and whenever a wheel has been already inflated.

  • Page 59: Checking The Foot Brake Fluid Level

    Faulty brakes can kill. If you have to add oil to the brake Turn handle grip E clockwise, half a turn. reservoir regularly get the brake system checked by your JCB Dealer. Do not use the machine until the fault has Test the parking brake, see Section G, Service been put right.
  • Page 60 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 12 - 1 Engine Air Filter 12 - 1 Changing the Elements ! CAUTION Depress clips B and lift off cover C. Remove outer element D. Take care not to tap or knock the element. If The outer element must be renewed immediately if the the inner element is to be changed, lift up pulls E and warning light on the instrument panel illuminates.

  • Page 61: Checking The Oil Level

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 13 - 1 Engine Oil and Filter 13 - 1 Checking the Oil Level Make sure the park brake is engaged and the Make sure the park brake is engaged and the transmission set to neutral. Lower the loader arms and transmission set to neutral.

  • Page 62: Changing The Coolant

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 14 - 1 Engine Cooling System 14 - 1 Checking the Coolant Make sure the park brake is engaged and the transmission set to neutral. Lower the loader arms and ! WARNING backhoe to the ground, switch OFF the engine and remove the starter key.

  • Page 63: Adjusting The Fan Belt

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 14 - 2 Engine Cooling System 14 - 2 Adjusting the Fan Belt Cleaning the Cab Heater Filter ! WARNING Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Make sure the engine cannot be started.

  • Page 64: Fuel Standards

    Is the resistance to flow. If this is outside limits, the engine present. performance can be affected. Consult your JCB distributor for advice about the use of Fatty Acid Methyl Ester fuels, as improper application may Density impair engine performance.

  • Page 65: Filling The Tank

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 15 - 2 Fuel System 15 - 2 Filling the Tank ! WARNING Lower the loader arms and switch off the engine before refuelling. Do not permit operation of the machine controls while refuelling. 2-3-3-9 At the end of every working day, fill the tank with the correct type of fuel.

  • Page 66: Draining The Sediment Bowl

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 15 - 3 Fuel System 15 - 3 Draining the Sediment Bowl Bleed the System ! CAUTION Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Running the engine with air in the system could damage Lower the loader arms and backhoe to the ground, stop the fuel injection pump.
  • Page 67 Clean the strainer with a suitable solvent. Follow the solvent manufacturer's instructions on safety. Fit the strainer E and a new gasket F. Apply JCB Threadlocker and Sealer to bolts D before fitting and tightening them. Torque tighten the bolts to 10 Nm (7 lbf ft).
  • Page 68 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 17 - 1 Powershift Gearbox 17 - 1 Checking the Oil Level Make sure the park brake is engaged and the transmission set to neutral. Lower the loader arms and backhoe to the ground, switch OFF the engine and remove the starter key.
  • Page 69 Note: When the cover is removed oil will gush out. Keep to one side when you remove the cover plate. Fit cover plate A and a new gasket C. Apply JCB Threadlocker and Sealer to bolts B before fitting them.

  • Page 70: Hydraulic Tank Cap

    If the fluid in the tube appears cloudy, then water or air has entered the system. The hydraulic pump could be severely damaged if the machine is operated. Contact your JCB distributor immediately. 2-3-4-3 If the oil level is low, remove filler cap B and replenish with recommended hydraulic oil as required.

  • Page 71: Changing The Filter Element

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 18 - 2 Hydraulic System 18 - 2 Changing the Filter Element ! WARNING Remove the element from its canister. Fine jets of hydraulic fluid at high pressure can penetrate a Hold canister F. the skin.

  • Page 72: Changing The Suction Strainer

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 18 - 3 Hydraulic System 18 - 3 Changing the Suction Strainer ! WARNING Make the machine safe before getting beneath it. Lower the attachments to the ground; engage the parking brake; remove the starter key, disconnect the battery. 2-3-2-2 Position the machine on level ground.

  • Page 73: Changing The Differential Oil

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 19 - 1 Front and Rear Axle (All Wheel Steer Machines) 19 - 1 Checking the Differential Oil Level Changing the Differential Oil ! WARNING ! WARNING Make the machine safe before getting beneath it. Lower Make the machine safe before getting beneath it.

  • Page 74: Checking The Hub Oil Levels

    Engage the parking brake. Set the transmission to neutral. Lower the attachments to the ground. Stop the Consult your JCB distributor for advice if necessary. engine and remove the starter key. Change the oil in each hub separately Clean the area around the fill/level plug C.

  • Page 75: Changing The Oil

    - the lubricating properties of the oil will quantity and recommended type of oil. Clean and refit reduce as a result of brake wear. fill/level plug A. Consult your JCB distributor for advice if necessary. S145210 S209320 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 76 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 21 - 1 Battery 21 - 1 ! CAUTION Warning Symbols The following warning symbols may be found on the battery. Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged.

  • Page 77: First Aid - Electrolyte

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 21 - 2 Battery 21 - 2 ! WARNING Checking the Electrolyte Level Batteries give off an explosive gas. Do not smoke when Maintenance free batteries used in normal temperate climate handling or working on the battery. Keep the battery away applications should not need topping up.

  • Page 78: Battery Isolator

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 21 - 3 Battery 21 - 3 Battery Isolator To disconnect the battery from the machine electrics a battery isolator has been fitted. ! CAUTION Except in an emergency, do not use the battery isolator to switch OFF the engine.

  • Page 79: Cleaning The Tubes/Fins

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 23 - 1 Hydraulic Oil Cooler 23 - 1 Cleaning the Tubes/Fins The hydraulic oil cooler is in front of the engine radiator. If the hydraulic oil cooler tubes/fins get clogged (by dirt and flies etc) the radiator and cooler will be less efficient.

  • Page 80: Wear Pad Adjustment

    (contact your JCB Distributor). To adjust the clearance, screw pad B fully in until it just It is important to note that lower pads C are designed to touches the inner leg and then back the pad off by one take most of the ‘loading’...
  • Page 81 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 26 - 1 Air Conditioning (if fitted) 26 - 1 ! WARNING The air conditioning system is a closed loop system and contains pressurised refrigerant. No part of the system should be disconnected until the system has been discharged by a refrigeration engineer or a suitably trained person.

  • Page 82: Lowering A Load

    If there is any movement, get the hydraulic system Do not stand underneath the raised load during the checked by your JCB distributor. lowering procedure. Stand clear and to one side until the load has been safely lowered. Make sure that the area is clear of other people before lowering the load.
  • Page 83 (Below 40 ° C, 104 ° F) Front Axle (4WD) JCB HD90 Gear Oil (without LSD) API-GL-5 Housing (2WS) 2.86 JCB Special Gear Oil Plus (with LSD) API-GL-4 Housing (4WS) 3.96 Must be suitable for use with limited slip differentials (LSD). Hubs (x2) 0.44...
  • Page 84 Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart.
  • Page 85 www.WorkshopManuals.co.uk Section A Attachments Section A Contents Page No. 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 86 www.WorkshopManuals.co.uk Section B Body & Framework Section B Contents Page No. Service Tools 1 - 1 Slide Hammer Kit Procedure 1 - 4 Rivet Nut Tool Procedure 1 - 5 Technical Data Air Conditioning (Option) 2 - 1 Basic Operation Air Conditioning - R-134a Refrigerant 3 - 1...
  • Page 87 www.WorkshopManuals.co.uk Section B Body & Framework Section B Contents Page No. Loader Arms - Removal and Replacement 35 - 1 Stabiliser Legs - Removal and Replacement 36 - 1 Kingpost - Removal and Replacement 37 - 1 Boom & Dipper - Removal and Replacement 38 - 1 Hydraulic Tank - Removal and Replacement 39 - 1...
  • Page 88 2 required to handle large panes of glass. No plug supplied. Note: 110V models available upon Ensure suction cups are protected from damage request - contact JCB Technical Service. during storage. JCB part number: JCB part number - 892/00842...
  • Page 89 'L' Blades - 25 mm (1 in) cut - replacement blades for cut-out knife (above). JCB part number - 992/12801 (unit quantity = 5 off) Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass.
  • Page 90 1 - 3 Service Tools 1 - 3 Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame. JCB part number - 926/15500 Nylon Spatula (unit quantity = 500 off) general tool used...
  • Page 91 www.WorkshopManuals.co.uk Section B Body & Framework Section B 1 - 4 Service Tools 1 - 4 Slide Hammer Kit Procedure The slide hammer kit is used to remove pivot pins that must be extracted, i.e. cannot be 'knocked through'. The purpose of this description is to explain how the kit and the various components are used to remove the pivot pins.
  • Page 92 www.WorkshopManuals.co.uk Section B Body & Framework Section B 1 - 5 Service Tools 1 - 5 Rivet Nut Tool Procedure A 'Rivet Nut' is a one piece fastener installed 'blind' from one side of the machine body/framework. The rivet nut is compressed so that a section of its shank forms an 'upset' against the machine body/framework, leaving a durable thread (see illustrations).
  • Page 93 www.WorkshopManuals.co.uk Section B Body and Framework Section B 2 - 1 Technical Data 2 - 1 Air Conditioning (Option) Binary Pressure Switch Settings Low Pressure 1.96 bar (2.0 kgf/cm 28.4 lbf/in High Pressure 27.5 bar (28 kgf/cm 400 lbf/in Thermostatic Switch Settings Cut out -0.6 °...
  • Page 94 www.WorkshopManuals.co.uk Section B Section B Body & Framework 3 - 1 Basic Operation 3 - 1 A401370 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 95 www.WorkshopManuals.co.uk Section B Section B Body & Framework 3 - 2 Basic Operation 3 - 2 Air Conditioning To operate the air conditioning, press switch F to switch the system on. Press switch G to operate the 3-speed heater fan. Rotate H to select the desired temperature. Control J R-134a Refrigerant enables the operator to select either recirculating air or fresh air from outside the machine.
  • Page 96 www.WorkshopManuals.co.uk Section B Section B Body & Framework 3 - 3 Basic Operation 3 - 3 Air Conditioning System Operation (cont'd) System Control The refrigerant is drawn through the evaporator matrix E by Control of the system is achieved by the cyclic action of the the suction of the compressor.
  • Page 97 www.WorkshopManuals.co.uk Section B Section B Body & Framework 3 - 4 Basic Operation 3 - 4 Safety Procedures The air conditioning system includes a pressurised closed When checking the state of the refrigerant at the circuit containing a non-CFC, environmentally friendly receiver drier sight glass, it is necessary to run the refrigerant, Type R-134a.
  • Page 98 www.WorkshopManuals.co.uk Section B Section B Body & Framework 10 - 1 Fault Finding 10 - 1 Air Conditioning The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment. It is recommended that, to locate faults on the system accurately and quickly, an electronic leak detector and a refrigerant pressure gauge should be used.
  • Page 99 www.WorkshopManuals.co.uk Section B Section B Body & Framework 10 - 2 Fault Finding 10 - 2 Air Conditioning (cont’d) No Air Conditioning CHECK ACTION Are the controls set correctly, i.e. air conditioning YES: Check 2 selected, thermostat switch set to coldest position Reset controls and retest.
  • Page 100 www.WorkshopManuals.co.uk Section B Body & Framework Section B 10 - 3 Fault Finding 10 - 3 Air Conditioning - System Diagnosis Note: Normal gauge readings will depend on system This section gives an overview of the following conditions: components and ambient conditions, make sure that the valves are closed and the readings are stable and that the Normally Functioning A/C System system has a full charge.
  • Page 101 www.WorkshopManuals.co.uk Section B Body & Framework Section B 10 - 4 Fault Finding 10 - 4 Air Conditioning - System Diagnosis (cont'd) Low R-134a Charge LOW SIDE (Blue) HIGH SIDE (Red) Gauge Readings: Low Side Gauge - Low. High Side Gauge - Low. Other symptoms: Sight Glass - Bubbles continuously visible.
  • Page 102 www.WorkshopManuals.co.uk Section B Body & Framework Section B 10 - 5 Fault Finding 10 - 5 Air Conditioning - System Diagnosis (cont'd) No Refrigerant Circulation LOW SIDE (Blue) HIGH SIDE (Red) Gauge Readings: Zero to negative Low Side Gauge - Zero to negative. High Side Gauge - Low.
  • Page 103 www.WorkshopManuals.co.uk Section B Body & Framework Section B 10 - 6 Fault Finding 10 - 6 Air Conditioning - System Diagnosis (cont'd) Air in System LOW SIDE (Blue) HIGH SIDE (Red) Gauge Readings: High High Low Side Gauge - High. High Side Gauge - High.
  • Page 104 www.WorkshopManuals.co.uk Section B Body & Framework Section B 10 - 7 Fault Finding 10 - 7 Air Conditioning - System Diagnosis (cont'd) Compressor Malfunction LOW SIDE (Blue) HIGH SIDE (Red) Gauge Readings: High Low Side Gauge - High. High Side Gauge - Low. Diagnosis: Internal compressor...
  • Page 105 www.WorkshopManuals.co.uk Section B Section B Body & Framework 10 - 8 Fault Finding 10 - 8 Air Conditioning (cont'd) Wiring Continuity Checks Use the illustration below to complete continuity checks on the HVAC/air conditioning system and heater harness wires.The harness connects to the main machine harness via connector 1. Refer also to the main machine circuit diagram in Section C Electrics.
  • Page 106 www.WorkshopManuals.co.uk Section B Section B Body & Framework 20 - 1 20 - 1 Service Procedures Checking Refrigerant Charge Level Air Conditioning The pressure in the system, i.e. the refrigerant charge level Leak Testing can be determined by checking the state of refrigerant at the receiver drier sight glass.
  • Page 107 If the high pressure warning light on the ‘Javac’ unit comes on, throttle back the manifold low pressure valve to provide a restriction. The JCB recommended ‘Javac’ unit only recovers refrigerant as a gas. Other units can recover refrigerant as a liquid and/or gas. ALWAYS check manufacturers instructions before using.
  • Page 108 www.WorkshopManuals.co.uk Section B Section B Body & Framework 20 - 3 Service Procedures 20 - 3 Air Conditioning - Refrigerant Charging and Discharging Note: The procedures for refrigerant charging and discharging must only be carried out by qualified service personel who have received specialist training on the air conditioning system.
  • Page 109 www.WorkshopManuals.co.uk Section B Section B Body & Framework 20 - 4 Service Procedures 20 - 4 A396790 Electronic Vacuum Gauge The CPS VG100 vacuum gauge is an electronic type using LED’s to indicate various states of vacuum. It is used in place of or to supplement the gauge on the vacuum pump.
  • Page 110 www.WorkshopManuals.co.uk Section B Section B Body & Framework 20 - 5 Service Procedures 20 - 5 Air Conditioning - Refrigerant Charging and Discharging Note: The procedures for refrigerant charging and discharging must only be carried out by qualified service personel who have received specialist training on the air conditioning system.
  • Page 111 www.WorkshopManuals.co.uk Section B Section B Body & Framework 20 - 6 Service Procedures 20 - 6 Air Conditioning - Refrigerant Charging and Discharging Note: The procedures for refrigerant charging and discharging must only be carried out by qualified service personel who have received specialist training on the air conditioning system.
  • Page 112 www.WorkshopManuals.co.uk Section B Section B Body & Framework 20 - 7 Service Procedures 20 - 7 Air Conditioning Binary Pressure Switch Testing The binary pressure switch assembly comprises a low pressure switch designed to open at 1.96 bar (28.4 lbf/in and a high pressure switch designed to open at 27.5 bar (400 lbf/in When the refrigerant pressure is within the 1.96 and 27.5 bar...
  • Page 113 www.WorkshopManuals.co.uk Section B Section B Body & Framework 20 - 8 Service Procedures 20 - 8 Air Conditioning Condenser Matrix Remove the starter key. It is likely that over a period of time, because of the Remove the front grille. machine' s working environment, the airflow around the condenser matrix will become restricted due to a build up of Remove both side panels.
  • Page 114 www.WorkshopManuals.co.uk Section B Section B Body & Framework 20 - 9 Service Procedures 20 - 9 Air Conditioning Filters - Changing and Cleaning Air Intake Filter Stop the engine and remove the starter key. Remove Screws D, air intake cover E and filter F. Clean filter element using compressed air.
  • Page 115 www.WorkshopManuals.co.uk Section B Body & Framework Section B 20 - 10 Service Procedures 20 - 10 Air Conditioning Compressor Drive Belt - Adjusting Park the machine on firm level ground. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine.
  • Page 116 Reference is made to the tools in the text. The majority of these tools can Always wear safety glasses during both removal and be obtained locally and the remainder from JCB Service replacement. (see Service Tools).
  • Page 117 www.WorkshopManuals.co.uk Section B Body & Framework Section B 21 - 2 Service Procedures 21 - 2 Direct Glazing (cont'd) Removing the Broken Glass and Old Sealant (cont'd) Position the machine on level ground and apply the parking brake. Stop the engine. Put protective covers over the cab seat and control pedestals.
  • Page 118 www.WorkshopManuals.co.uk Section B Body & Framework Section B 21 - 3 Service Procedures 21 - 3 Direct Glazing (cont'd) Removing the Broken Glass and Old Sealant (cont'd) c Cut-out Knife F. The cut-out knife can be used as a left handed or right handed tool. For the knife and its replaceable blades, refer to Service Tools.
  • Page 119 www.WorkshopManuals.co.uk Section B Body & Framework Section B 21 - 4 Service Procedures 21 - 4 Direct Glazing (cont'd) Preparing the New Glass ! CAUTION The laminated front screen must be handled with extra care to prevent breakage. Wherever possible, store and handle it in a vertical attitude.
  • Page 120 www.WorkshopManuals.co.uk Section B Body & Framework Section B 21 - 5 Service Procedures 21 - 5 Direct Glazing (cont'd) Preparing the New Glass (cont'd) Install the Ultra Fast Adhesive cartridge (see Sealing and Retaining Compounds and Note 2 below) into a suitable applicator gun: 10-15mm a Remove the aluminium disc cover from the base of...
  • Page 121 www.WorkshopManuals.co.uk Section B Body & Framework Section B 21 - 6 Service Procedures 21 - 6 Direct Glazing (cont'd) Installing the New Glass (cont'd) Make the inside seal smooth: a Wearing surgical gloves, dip your finger in a soapy water solution. Use your finger to make the inside seal smooth.
  • Page 122 www.WorkshopManuals.co.uk Section B Body & Framework Section B 22 - 1 Service Procedures 22 - 1 Cab ROPS/FOPS Structure - Checks ! WARNING The machine is fitted with a Roll Over Protection Structure (ROPS) and a Falling Objects Protection Structure (FOPS). You could be killed or seriously injured if you operate the machine with a damaged or missing ROPS/FOPS.
  • Page 123 www.WorkshopManuals.co.uk Section B Section B Body & Framework 23 - 1 Service Procedures 23 - 1 Engine Panels - Removing and Fitting Instructions for removing and fitting the engine panels are described in the routine maintenance section, refer to Section 3 Routine Maintenance - Engine Panels. 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...

  • Page 124: Stabiliser Legs Wear Pads

    www.WorkshopManuals.co.uk Section B Body & Framework Section B 24 - 1 Service Procedures 24 - 1 Stabiliser Leg Wear Pad Adjustment Instructions for adjusting the wear pads are described in the maintenance section, refer to Section 3 Stabiliser Legs - Wear Pad Adjustment.
  • Page 125 www.WorkshopManuals.co.uk Section B Body and Framework Section B 25 - 1 Service Procedures 25 - 1 Extending Dipper - Wear Pad Adjustment The Extradig dipper wear pads are bolt-on replaceable Inspecting the Top Wear Pads items. They support and guide the inner dipper section during extension and retraction.
  • Page 126 www.WorkshopManuals.co.uk Section B Body and Framework Section B 25 - 2 Service Procedures 25 - 2 Extending Dipper If the gap is greater than in (1.5 mm) then adjust as follows: - Wear Pad Adjustment (Cont’d) Remove one adjusting bolt H and discard one Adjusting the Bottom Wear Pads washer J.
  • Page 127 www.WorkshopManuals.co.uk Section B Body & Framework Section B 26 - 1 Service Procedures 26 - 1 Sideshift - Hydraclamp Clearance Setting If the kingpost clearance D is not set correctly leaks may occur or the seal could become dislodged, use the procedure below to set the clearance.
  • Page 128 www.WorkshopManuals.co.uk Section B Body & Framework Section B 26 - 2 Service Procedures 26 - 2 Power Sideshift - Wear Pad Renewal Inspection (1000 hours) Assembly When the wear pads are worn to 6 mm (0.23 in) or below Fit wear pad H, plate J and bolt D. they should be replaced.
  • Page 129 www.WorkshopManuals.co.uk Section B Body & Framework Section B 26 - 3 Service Procedures 26 - 3 Power Sideshift - Chain Adjustment The chain tension should be checked at the initial 100 hours Removal service and every 500 hours. Park the machine on firm level ground, engage the parking brake and set the transmission to neutral.
  • Page 130 www.WorkshopManuals.co.uk Section B Body & Framework Section B 30 - 1 Air Conditioning 30 - 1 A401280 Component Key: A/C Controls Expansion Valve Re-circ Air Inlet Water Valve HVAC Unit Bulkhead Plate 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 131 www.WorkshopManuals.co.uk Section B Body & Framework Section B 30 - 2 Air Conditioning 30 - 2 HVAC/Air Conditioning Unit - Removal and Replacement Note: Before removing the HVAC/Air Conditioning Unit, discharge the system. Refer to Service Procedures, Air Conditioning - Refrigerant Charging and Discharging. The HVAC/air conditioning unit is located in the cab beneath the right hand side console.
  • Page 132 www.WorkshopManuals.co.uk Section B Body & Framework Section B 30 - 3 Air Conditioning 30 - 3 A401270 Component Key: HVAC Unit Top Cover Heat Exchanger (Heater and Evaporator) Expansion Valve Freeze Protection Thermostat Blower Unit HVAC Unit Housing 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 133 www.WorkshopManuals.co.uk Section B Body & Framework Section B 30 - 4 Air Conditioning 30 - 4 Blower Unit - Removal and Replacement Evaporator Matrix - Removal and Replacement The blower W is located inside the HVAC/air conditioning unit and can be removed without having to remove the HVAC Note: Before removing the Evaporator Matrix, discharge unit from the machine.
  • Page 134 www.WorkshopManuals.co.uk Section B Body & Framework Section B 30 - 5 Air Conditioning 30 - 5 A401280 Component Key: A/C Controls Expansion Valve Re-circ Air Inlet Water Valve HVAC Unit Bulkhead Plate 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 135 www.WorkshopManuals.co.uk Section B Body & Framework Section B 30 - 6 Air Conditioning 30 - 6 Binary Pressure Switch - Removal and Replacement The pressure switch is located adjacent to the expansion valve S on the HVAC/air conditioning unit, beneath the right hand side console.
  • Page 136 www.WorkshopManuals.co.uk Section B Body & Framework Section B 35 - 1 Loader Arms 35 - 1 S265931 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 137 www.WorkshopManuals.co.uk Section B Body & Framework Section B 35 - 2 Loader Arms 35 - 2 Removal and Replacement Removal ! WARNING Park the machine on firm level ground. Engage the The loader arm interlevers are potentially dangerous, parking brake and set the transmission to neutral. when pivoting about their centre they form a 'scissor' point with the loader arm.
  • Page 138 www.WorkshopManuals.co.uk Section B Body & Framework Section B 36 - 1 Stabiliser Legs 36 - 1 S261790 S216810 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 139 www.WorkshopManuals.co.uk Section B Body & Framework Section B 36 - 2 Stabiliser Legs 36 - 2 Removal and Replacement - (Centremount Machines) Removal Remove the stabiliser leg: Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. ! CAUTION Lower the backhoe and loader end to the ground and stop the engine.
  • Page 140 www.WorkshopManuals.co.uk Section B Body & Framework Section B 36 - 3 Stabiliser Legs 36 - 3 S271850 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 141 When the inner leg is in position adjust the bottom pads, refer to Section 3 Stabiliser Legs - Wear Pad Adjustment. Apply a grease such as JCB slew grease (part number 4003/1601) to the threads of pad B. 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 142 www.WorkshopManuals.co.uk Section B Body & Framework Section B 37 - 1 Kingpost 37 - 1 Removal and Replacement m 14 Item 14 Item 15 om Pivot Bearing - 15ft 6in / 17ft Backhoe) (Boom Pivot Bearing - 14ft Backhoe) (Kingpost Pivot Bearing) A261800 A252870 A252880...
  • Page 143 www.WorkshopManuals.co.uk Section B Body & Framework Section B 37 - 2 Kingpost 37 - 2 Removal and Replacement Removal Replacement Slew the kingpost to the centre and remove the boom Replacement is generally a reversal of the removal and dipper. procedures, however note the following: ! WARNING To assist with the identification of 15ft 6in and 17ft...
  • Page 144 www.WorkshopManuals.co.uk Section B Body & Framework Section B 38 - 1 Boom and Dipper 38 - 1 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 145 www.WorkshopManuals.co.uk Section B Body & Framework Section B 38 - 2 Boom and Dipper 38 - 2 Boom - Removal and Replacement Removal Replacement ! WARNING The procedures describe the removal of the boom with the boom and dipper rams still installed. If required, these items Hydraulic Fluid can be removed separately before removing the boom, refer Fine jets of hydraulic fluid at high pressure can penetrate...
  • Page 146 www.WorkshopManuals.co.uk Section B Body & Framework Section B 38 - 3 Boom and Dipper 38 - 3 S266170 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 147 www.WorkshopManuals.co.uk Section B Body & Framework Section B 38 - 4 Boom and Dipper 38 - 4 Dipper - Removal and Replacement Removal Replacement ! WARNING The procedures describe the removal of the dipper with the extradig (if fitted) and the bucket ram still installed. If Hydraulic Fluid required, these items can be removed separately before Fine jets of hydraulic fluid at high pressure can penetrate...
  • Page 148 Chock both sides of all four wheels. Apply JCB Threadlocker and Sealer to drain plug B. Disconnect the battery, to prevent the engine being When refitting the suction hose G make sure it is correctly started while you are beneath the machine.
  • Page 149 www.WorkshopManuals.co.uk Section B Body & Framework Section B 40 - 1 Power Sideshift Ram 40 - 1 Removal and Replacement Removal Replacement Park the machine on firm level ground, engage the Locate the ram at one end with pin C. Adjust the ram parking brake and set the transmission to neutral.
  • Page 150 www.WorkshopManuals.co.uk Section B Body and Framework Section B 50 - 1 Cab Panels 50 - 1 Removal and Replacement Side Console Removal Park the machine on firm level ground, apply the parking brake. Lower the loader arms and excavator to the ground, switch OFF the engine and remove the starter key.
  • Page 151 www.WorkshopManuals.co.uk Section B Body and Framework Section B 51 - 1 Cab Panels 51 - 1 Removal and Replacement Front/Steering Console Removal Park the machine on firm level ground, apply the parking brake. Lower the loader arms and excavator to the ground, switch OFF the engine and remove the starter key.
  • Page 152 Fuse Link Box 2 - 3 Relays 2 - 3 Basic System Operation Circuit Schematics Basic Machine - 3CX, 4CX, 214, 215, 217 (Not 214e) 4 - 1 Synchro Shuttle and Powershift 4 - 5 Options - Steer Mode (4x4x4)
  • Page 153 www.WorkshopManuals.co.uk Section C Electrics Section C Contents Page No. Alternator Removal and Replacement 30 - 1 Starter Motor Removal and Replacement 40 - 2 Inspection 40 - 2 Dismantling and Assembly 40 - 2 Earth Points 145 - 1 Harness Data Drawings 150 - 1 Harness Interconnection...
  • Page 154 www.WorkshopManuals.co.uk Section C Electrics Section C 1 - 1 Service Tools 1 - 1 AVO Test Kit 892/00283 Tool Kit Case 892/00298 Fluke Meter 85 892/00286 Surface Temperature Probe 892/00284 Venture Microtach Digital Tachometer 892/00282 100 amp Shunt - open type 892/00285 Hydraulic Temperature Probe S188231...
  • Page 155 www.WorkshopManuals.co.uk Section C Electrics Section C 2 - 1 Technical Data 2 - 1 General Electrical Data System Type 12 Volt, negative earth Battery (Heavy Duty) - Cold crank amps for 1 minute to 1.4 volts per cell at -18 deg C (0 deg F) - Reserve capacity (minutes) for 25 amp load Battery (Temperate) - Cold crank amps for 1 minute to...
  • Page 156 www.WorkshopManuals.co.uk Section C Electrics Section C 2 - 2 Technical Data 2 - 2 Fuses and Relays Fuses ! CAUTION Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5 The relays and fuses are located in the side console underneath cover A.
  • Page 157 www.WorkshopManuals.co.uk Section C Electrics Section C 2 - 2 Technical Data 2 - 2 Fuses and Relays Fuses ! CAUTION Always replace fuses with ones of correct ampere rating to avoid electrical system damage. 8-3-3-5 The relays and fuses are located in the side console underneath cover A.
  • Page 158 www.WorkshopManuals.co.uk Electrics Section C Section C 2 - 3 Technical Data 2 - 3 Fuses and Relays (continued) Link Box Fuses Relays To further protect the machine wiring harnesses and 4 speed Powershift / Synchro Shuttle electrical circuits, a fuse link box is fitted to the battery, as The relays listed below are located in the side console The relays listed below are located in the front console as shown at B.
  • Page 159 www.WorkshopManuals.co.uk Electrics Section C Section C 4 - 1 Basic System Operation 4 - 1 Circuit Schematic - Basic Machine EARTH 51 52 53 54 55 SPEAKER SPEAKER FRONT CONSOLE INSTRUMENTS 43 43 43 43 45 46 47 48 49 50 32 33 34 35 36 37 38 39 SIDE CONSOLE INSTRUMENTS...
  • Page 160 www.WorkshopManuals.co.uk Section C Electrics Section C 4 - 2 Basic System Operation 4 - 2 Circuit Schematic - Basic Machine Refer to pages C/4-1 and C/4-4. The basic circuit shows a standard machine. The remaining pages in section C/4 show machine circuits that differ from the ‘basic’.
  • Page 161 www.WorkshopManuals.co.uk Section C Electrics Section C 4 - 3 Basic System Operation 4 - 3 Circuit Schematic - Basic Machine (cont’d) Main Components: Connections: Cigar Lighter From C on page C/4-1 Face Level Fan To E on page C/4-1 Face Level Fan Switch To F on page C/4-1 Heated Seat To G on page C/4-1...
  • Page 162 www.WorkshopManuals.co.uk Electrics Section C Section C 4 - 4 Basic System Operation 4 - 4 Circuit Schematic - Basic Machine (cont’d) INTEGRAL INTERMITTENT ROAD LIGHTS SWITCH 1853 PRIMARY FUSE 2 A409181 852/30241sht2 Iss1 Issue 3* 9803/3280 Purchased from www.WorkshopManuals.co.uk...
  • Page 163 www.WorkshopManuals.co.uk Electrics Section C Section C 4 - 5 Basic System Operation 4 - 5 Circuit Schematic - Synchro Shuttle Circuit Schematic - Powershift Note: For further details on Powershift gearbox electrical circuits and connections, refer to Section F - Electrical Connections. MANUAL POWERSHIFT TRANSMISSION...
  • Page 164 www.WorkshopManuals.co.uk Section C Electrics Section C 4 - 6 Basic System Operation 4 - 6 Circuit Schematic - Synchro Shuttle and Powershift Synchro Shuttle Transmission 4 Speed Powershift Transmission Parking Brake Warning Light Relay Parking Brake Warning Light Relay Parking Brake Relay Parking Brake Relay Parking Brake Switch Parking Brake Switch...
  • Page 165 www.WorkshopManuals.co.uk Section C Electrics Section C 4 - 7 Basic System Operation 4 - 7 Circuit Schematics - Options Steer Mode - 4CX and 3CX Super (4x4x4) Front Axle Proximity Switch Rear Axle Proximity Switch Steer Mode Selector Switch Steer Mode Printed Circuit Board Crab Relay Crab/4 Wheel Steer Relay 2 Wheel Steer Relay...
  • Page 166 www.WorkshopManuals.co.uk Electrics Section C Section C 4 - 8 Basic System Operation 4 - 8 4CX STEERMODE Circuit Schematics - Options MODE 3CX SUPER (4X4X4) 2 Wheel Steer/Brake Mode 2 Wheel Steer/Brake Mode (Germany) Steer Mode - 4CX and 3CX Super (4x4x4) STEERMODE STEER MODE P.C.B.
  • Page 167 www.WorkshopManuals.co.uk Electrics Section C Section C 4 - 9 Basic System Operation 4 - 9 Circuit Schematics - Options All Wheel Steer/Brake Mode Auxiliary and Hydraclamp Hydraulics Speedometer 1830 A409183 852/30241sht4 Iss1 Issue 2* 9803/3280 Purchased from www.WorkshopManuals.co.uk...
  • Page 168 www.WorkshopManuals.co.uk Section C Electrics Section C 4 - 10 Basic System Operation 4 - 10 Circuit Schematics - Options All Wheel Steer/Brake Mode LH Brake Light RH Brake Light Brake Light Switch 4 Wheel Braking Relay 4 Wheel Drive Solenoid Auto 2 Wheel Drive Relay 4 Wheel Drive Selector Switch Connections:...
  • Page 169 www.WorkshopManuals.co.uk Section C Electrics Section C 4 - 11 Basic System Operation 4 - 11 Circuit Schematics - Options Hand Held Tools 1 Selector Switch 2 Indicator Lamp 3 Roadbreaker Solenoid Dedicated Quickhitch 1 Hitch Enable Switch 2 Quick-Hitch Relay 3 Warning Buzzer 4 Lever ‘hold-in’...
  • Page 170 www.WorkshopManuals.co.uk Electrics Section C Section C 4 - 12 Basic System Operation 4 - 12 Circuit Schematics - Options A409185 A409185 852/30241sht6 Iss1 852/30241sht6 Iss1 Hand Held Tools Smooth Ride System Return To Dig Hydraulic Speed Control Dedicated Quick-Hitch Pole Planter (HSC) (SRS) (Shovel Reset)
  • Page 171 www.WorkshopManuals.co.uk Electrics Section C Section C 4 - 13 Basic System Operation 4 - 13 Circuit Schematics - 6 Speed Powershift (Shiftmaster) Note: For further details on Powershift gearbox electrical circuits and connections, refer to AUTOSHIFT TRANSMISSION Section F - Electrical Connections. 120 Ohm 120 Ohm RESISTOR...
  • Page 172 www.WorkshopManuals.co.uk Section C Electrics Section C 4 - 14 Basic System Operation 4 - 14 Circuit Schematic - 6 Speed Powershift (Shiftmaster) 6 Speed Powershift Transmission Parking Brake Warning Light Relay Parking Brake Relay Parking Brake Switch Reverse Alarm Reverse Alarm Relay Speed Sensor Electronic Control Unit Forward/Reverse Selector Lever...
  • Page 173 Section C Electrics Section C 4 - 15 Basic System Operation 4 - 15 Circuit Schematic - 214e Machines Refer to pages C/4-16 and C/4-17. Main Components: Thermostart Engine Coolant Temperature Gauge Battery Engine Coolant Temperature Sender Starter Switch...
  • Page 174 Electrics Section C Section C 4 - 16 Basic System Operation 4 - 16 Circuit Schematic - 214e Machines 2 2 2 2 2 7 10 9 8 7 3 4 5 6 FUSE P3 BATTERY FEED FUSE P2...
  • Page 175 Electrics Section C Section C 4 - 17 Basic System Operation 4 - 17 Circuit Schematic - 214e Machines (cont’d) OPTIONS 60 62 64 66 68 90 91 57 58 59 61 63 65 67 SIDE CONSOLE INSTRUMENTS 'SRS'...
  • Page 176 Section C Electrics Section C 4 - 18 Basic System Operation 4 - 18 Circuit Schematic - 214e Machines (cont’d) Main Components: Connections: Alternator Warning Indicator Light From A on page C/4-16 Parking Brake Indicator Light To B on page C/4-16...
  • Page 177 www.WorkshopManuals.co.uk Section C Electrics Section C 19 - 1 Service Procedures 19 - 1 Electrical Testing Methods - Using a Multimeter These instructions are intended to cover the use of the recommended multimeters. A171900 S153070 Make sure that the test leads are plugged into the correct sockets. The black test lead should be plugged into the black socket (sometimes, this socket is also marked by a "...
  • Page 178 www.WorkshopManuals.co.uk Section C Electrics Section C 19 - 2 Service Procedures 19 - 2 S153070 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 179 www.WorkshopManuals.co.uk Section C Electrics Section C 19 - 3 Service Procedures 19 - 3 Electrical Testing Methods - Using a Multimeter Measuring DC Voltage On the FLUKE 85 Turn the switch to position B. On the AV0 2003 Move the right slider switch to position A, and the left hand slider switch to the appropriate range. On an analogue meter Turn the dial to the appropriate DC Volts range.
  • Page 180 www.WorkshopManuals.co.uk Section C Electrics Section C 19 - 4 Service Procedures 19 - 4 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 181 www.WorkshopManuals.co.uk Section C Electrics Section C 19 - 5 Service Procedures 19 - 5 Electrical Testing Methods - Using a Multimeter Testing a Diode or a Diode Wire A diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end. The diode is sealed in heatshrink sleeving.
  • Page 182 www.WorkshopManuals.co.uk Section C Electrics Section C 20 - 1 Service Procedures 20 - 1 Battery Maintenance Safety ! WARNING To ensure that the battery provides optimum performance Batteries give off an explosive gas. Do not smoke when the following steps should be observed: handling or working on the battery.
  • Page 183 www.WorkshopManuals.co.uk Section C Electrics Section C 20 - 2 Service Procedures 20 - 2 Battery (cont’d) Testing This test is to determine the electrical condition of the Set the CHECK/LOAD switch A to LOAD and hold down battery and to give an indication of the remaining useful for 5 - 10 seconds until the meter reading stabilises.
  • Page 184 www.WorkshopManuals.co.uk Section C Electrics Section C 21 - 1 Service Procedures 21 - 1 Alternator Connect the leads to the meter and set the meter to the relevant range as follows. General Description AVO 2002 Red lead to volts (middle) socket on meter. Black lead to negative on meter.
  • Page 185 www.WorkshopManuals.co.uk Section C Electrics Section C 22 - 1 Service Procedures 22 - 1 Starter Motor Starting Circuit Test Test 3 Before carrying out the voltmeter tests, check the battery Connect the voltmeter between the solenoid terminal C and condition (see Battery Testing) and ensure that all a good earth.
  • Page 186 www.WorkshopManuals.co.uk Section C Electrics Section C 22 - 2 Service Procedures 22 - 2 Starter Motor (cont’d) Starting Circuit Test (cont'd) Test 5 Connect the voltmeter between battery positive and the Test 3b starter main terminal A. With the starter switch ' off' , the If the reading between terminal D and earth is below 8.0V, voltmeter should indicate battery voltage, but it should fall to connect the voltmeter between terminal E and earth.
  • Page 187 Cut the wire and remove the protective insulation for a Note that JCB harnesses have an International Protection suitable distance dependent upon the size of wire and rating of 67 (I.P.67).
  • Page 188 www.WorkshopManuals.co.uk Section C Electrics Section C 23 - 2 Service Procedures 23 - 2 Wiring Harness - Repair Procedure (cont'd) With the Butane Heater assembly 892/00350, seal the connection using the following procedure. Remove the cap A from the end of the disposable gas cartridge B.
  • Page 189 www.WorkshopManuals.co.uk Section C Electrics Section C 23 - 3 Service Procedures 23 - 3 Wiring Harness - Repair Procedure (cont'd) Turn the red ring D to the right (in the direction of the plus sign) in order to turn on the gas. IMPORTANT: Before turning the heater on, make sure that the cartridge is not hotter than the reflector element.
  • Page 190 www.WorkshopManuals.co.uk Section C Electrics Section C 30 - 1 Alternator 30 - 1 Removal and Replacement Disconnect cables from rear of alternator, remove bolts A, B and C and withdraw unit from machine. Replace by reversing the removal sequence. Position the alternator until belt deflection is approximately 10mm (3/8 in) before tightening bolts B and C.
  • Page 191 www.WorkshopManuals.co.uk Section C Electrics Section C 40 - 1 Starter Motor 40 - 1 S02043C 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 192 Smear drive shaft splines and operating collar bearing withdrawal of ring 22. surface with JCB MPL Grease before assembly. Assemble operating fork 19 with curved face toward the armature. Allow brake shoes 28 to remain in the end plate 11 unless requiring renewal.
  • Page 193 www.WorkshopManuals.co.uk Section C Electrics Section C 145 - 1 Harness Data 145 - 1 Earth Points A405010 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 194 www.WorkshopManuals.co.uk Section C Electrics Section C 145 - 2 Harness Data 145 - 2 Earth Points Introduction The illustartion opposite shows the machine electrical earth point locations. This can be useful when tracing electrical faults, typically when several electrical devices are malfunctioning.
  • Page 195 www.WorkshopManuals.co.uk Section C Electrics Section C 150 - 1 Harness Data 150 - 1 Drawings Introduction The following drawings are reproduced from production electrical harness drawings. Each harness drawing includes tables showing wire connections and destinations for all the connectors on the harness. Harness Interconnection The harness number refers to and corresponds with the annotations in the schematic drawing on the adjacent page.
  • Page 196 www.WorkshopManuals.co.uk Section C Electrics Section C 150 - 2 Harness Data 150 - 2 Harness Interconnection (continued) SIDE CONSOLE HARNESS - Main components connected to this harness: Side console instruments Side console switches Side console warning lamps Starter switch Heater controls Fuses and Relays Immobiliser (if fitted) ENGINE/MAINFRAME...
  • Page 197 www.WorkshopManuals.co.uk Section C Electrics Section C 151 - 1 Harness Data 151 - 1 Harness Drawing - Front Console, 4 speed Powershift, Synchro Shuttle, page 1 of 2 - CAD 721/10940 Issue 1 Key to Connectors: Column Switch - Powershift Bulkhead Plug Footbrake Switch Front Cab Earth...
  • Page 198 www.WorkshopManuals.co.uk Section C Electrics Section C 151 - 2 Harness Data 151 - 2 Harness Drawing - Front Console, 4 speed Powershift, Synchro Shuttle, page 2 of 2 - CAD 721/10940 Issue 1 BULKHEADPLUG STEERMODEUNIT WIPERMOTOR STEERMODESW FOGLIGHT SWITCH AX,AY AX,AY TERM WIRE...
  • Page 199 www.WorkshopManuals.co.uk Section C Electrics Electrics Section C 151 - 3 Harness Data Harness Data 151 - 3 Harness Drawing - Front Console, 6 speed Powershift (ShiftMaster) page 1 of 2 - CAD 721/10937 Issue 1 Key to Connectors: Bulkhead Plug Speedometer Illumination Front Cab Earth Steer Mode Switch...
  • Page 200 www.WorkshopManuals.co.uk Section C Electrics Electrics Section C 151 - 4 Harness Data Harness Data 151 - 4 Harness Drawing - Front Console, 6 speed Powershift (ShiftMaster) page 2 of 2 - CAD 721/10937 Issue 1 BULKHAEDPLUG COLUMNSWITCH-RH HAZARDSWITCH ECUII'A'PLUG AX,AZ AX,AY TERM WIRE...
  • Page 201 www.WorkshopManuals.co.uk Section C Electrics Section C 153 - 1 Harness Data 153 - 1 Harness Drawing - Side Console, page 1 of 4* - CAD 721/10936 Issue 1 (Machines up to serial no. 933756) 721/10936_1 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 202 www.WorkshopManuals.co.uk Section C Electrics Electrics Section C 153 - 2 Harness Data Harness Data 153 - 2 Harness Drawing - Side Console, page 2 of 4* - CAD 721/10936 Issue 1 (Machines up to serial no. 933756) Key to Connectors: Mainframe Plug Rear Worklight Switch Cab Link...
  • Page 203 www.WorkshopManuals.co.uk Section C Electrics Electrics Section C 153 - 3 Harness Data 153 - 3 Harness Drawing - Side Console, page 3 of 4 - CAD 721/10936 Issue 1 (Machines up to serial no. 933756) 721/10936_3 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 204 www.WorkshopManuals.co.uk Section C Electrics Electrics Section C 153 - 4 Harness Data Harness Data 153 - 4 Harness Drawing - Side Console, page 4 of 4 - CAD 721/10936 Issue 1 (Machines up to serial no. 933756) 721/10936_4 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 205 www.WorkshopManuals.co.uk Section C Electrics Electrics Section C 153 - 5 Harness Data Harness Data 153 - 5 Harness Drawing - Side Console, page 1 of 5 - CAD 721/10970 Issue 2 (Machines from serial no. 933757) 721/10970_1 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 206 www.WorkshopManuals.co.uk Section C Electrics Section C 153 - 6 Harness Data 153 - 6 Harness Drawing - Side Console, page 2 of 5 - CAD 721/10970 Issue 2 (Machines from serial no. 933757) Key to Connectors: Main Frame Plug Fusebox A Fusebox B Fusebox C Ignition 1...
  • Page 207 www.WorkshopManuals.co.uk Section C Electrics Section C 153 - 7 Harness Data 153 - 7 Harness Drawing - Side Console, page 3 of 5 - CAD 721/10970 Issue 2 (Machines from serial no. 933757) Key to Connectors: Cab Link Ignition Switch (CU1) Instrument Panel Fuel Gauge Fuel Gauge Illium...
  • Page 208 www.WorkshopManuals.co.uk Section C Electrics Electrics Section C 153 - 8 Harness Data Harness Data 153 - 8 Harness Drawing - Side Console, page 4 of 5 - CAD 721/10970 Issue 2 (Machines from serial no. 933757) 721/10970_2 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 209 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 210 www.WorkshopManuals.co.uk Harness Drawing - Cab Roof (USA only) page 1 of 2 - CAD 721/10966 Issue 1 721/10966_1 Purchased from www.WorkshopManuals.co.uk...
  • Page 211 www.WorkshopManuals.co.uk Harness Drawing - Cab Roof (USA only) page 2 of 2 - CAD 721/10966 Issue 1 Key to Connectors: LH Worklight Beacon Socket LH Front Indicators RH Worklight LH Headlights RH Headlights RH Front Indicators Cab Horn Earth RH Rear Lights RH RR/Out Worklight RH RR/In Worklight LH RR/In Worklight...
  • Page 212 www.WorkshopManuals.co.uk Harness Drawing - Cab Roof (not USA) page 1 of 2 - CAD 721/10965 Issue 1 RH HEADLIGHTS EARTH RH WORKLIGHT CAB HRN LH WORKLIGHT AUX BEACON SOCKET BEACON SOCKET 721/10965_1 LH HEADLIGHTS Purchased from www.WorkshopManuals.co.uk...
  • Page 213 www.WorkshopManuals.co.uk Harness Drawing - Cab Roof (not USA) page 2 of 2 - CAD 721/10965 Issue 1 Key to Connectors: LH Worklight Beacon Socket RH Worklight LH Headlights RH Headlights Cab Horn Earth RH RR/Out Worklight RH RR/In Worklight LH RR/In Worklight LH RR/Out Worklight Auxiliary Beacon Socket FWL O...
  • Page 214 www.WorkshopManuals.co.uk Harness Drawing - Interior Light, Radio Speakers page 1 of 1 - CAD 721/11050 Issue 1 LH SPEAKER RH SPEAKER TERM WIRE SIZE DEST TYPE TERM WIRE SIZE DEST TYPE CP 2 CP 2 CP 3 CP 3 CP 5 CP 5 CP 6 CP 6...
  • Page 215 www.WorkshopManuals.co.uk Harness Drawing - Steer Controls, page 1 of 1- CAD 721/10968 Issue 1 Key to Connectors: Cab Connector Rear Proximity Switch Steer Mode Feed Steer Mode Feed 721/10968_1 Purchased from www.WorkshopManuals.co.uk...
  • Page 216 www.WorkshopManuals.co.uk Harness Drawing - Steer Controls, page 1 of 1 - CAD 721/10967 Issue 1 Key to Connectors: 4WS com Crab Cab Connector Rear Proximity Switch Steer Mode Feed DEST 721/10967_1 Purchased from www.WorkshopManuals.co.uk...
  • Page 217 www.WorkshopManuals.co.uk Harness Drawing - Transmission, page 1 of 2 - CAD 721/10943 Issue 1 Key to Connectors: Front Console Harness Side Console Harness Gearbox Transmission Oil Temperature Switch Kickdown Switch Transmission Fused Splice Earth Splice Transmission Oil P Splice 721/10943_1 Purchased from www.WorkshopManuals.co.uk...
  • Page 218 www.WorkshopManuals.co.uk Harness Drawing - Transmission, page 2 of 2 - CAD 721/10943 Issue 1 721/10943_2 Purchased from www.WorkshopManuals.co.uk...
  • Page 219 www.WorkshopManuals.co.uk Harness Drawing - Transmission, page 1 of 2 - CAD 721/10942 Issue 1 Key to Connectors: Front Console Harness Side Console Harness Gearbox Transmission Oil Temperature Switch Dump Splice Transmission Feed Splice Earth Splice Transmission OIl P Splice CELLS 1-30 CELLS 1-30 DATUM 13mm WIDE (NOM)
  • Page 220 www.WorkshopManuals.co.uk Harness Drawing - Transmission, page 2 of 2 - CAD 721/10942 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 221 www.WorkshopManuals.co.uk Harness Drawing - Transmission, page 1 of 2 - CAD 721/10941 Issue 1 SOLENOID IDENTIFICATION HSG ID FUNCTION ID CHAR FORWARD HIGH FORWARD LOW MAINSHAFT LAYSHFT REVERSE LOW REVERSE HIGH 2/4 WHEEL DRIVE 6TH SPEED 721/10941_1 Purchased from www.WorkshopManuals.co.uk...
  • Page 222 www.WorkshopManuals.co.uk Harness Drawing - Transmission - *Powershift 6 speed, page 2 of 2 - CAD 721/10941 Issue 1 Key to Connectors: CAB PANEL MAIN SHAFT Cab Panel TERM WIRE SIZE DEST TYPE TERM WIRE SIZE DEST TYPE WIRE SIZE DEST XMSN Oil Press Switch 600Z 1865...
  • Page 223 www.WorkshopManuals.co.uk Harness Drawing - Transmission - Sychro Shuttle, page 1 of 1 - CAD 721/10938 Issue 2* CAB PANEL TRANS DUMP SW TERM WIRE SIZE DEST TYPE TERM WIRE SIZE DEST TYPE 600Z 934B GA 12 GF 1 600FL GC 1 4 W/D GB 1 TERM...
  • Page 224 www.WorkshopManuals.co.uk Harness Drawing - Transmission - Powershift 4 speed, page 1 of 1 - CAD 721/10939 Issue 1 Solenoid Identification Function Identification SOLENOID IDENTIFICATION Forward High HSGID FUNCTION IDCHAR Forward Low FORWARD HIGH FORWARD LOW Mainshaft MAINSHAFT Layshaft LAYSHAFT Reverse Low REVERSE LOW Reverse High REVERSE HIGH...
  • Page 225 www.WorkshopManuals.co.uk Harness Drawing - Engine Mainframe, page 1 of 2 - CAD 721/10935 Issue 2* 721/10935_1 Purchased from www.WorkshopManuals.co.uk...
  • Page 226 www.WorkshopManuals.co.uk Harness Drawing - Engine Mainframe, page 2 of 2 - CAD 721/10935 Issue 2* Key to Connectors: ENG OIL PRESS REAR WASH PUMP HSC SOLENOID CAB PANEL BLK HD H,AZ Engine Oil Pressure TERM WIRE SIZE DEST TYPE TERM WIRE SIZE DEST...
  • Page 227 www.WorkshopManuals.co.uk Harness Drawing - Rear Lights / Hydraclamp - Sideshift, page 1 of 1 - CAD 721/10944 Issue 1 Key to Connectors: Cab Plug Hydraclamp RH Rear Lights LH Rear Lights Earth Brake Lights 721/19044 Purchased from www.WorkshopManuals.co.uk...
  • Page 228 www.WorkshopManuals.co.uk Harness Drawing - Rear Horn / Alarm - Sideshift, page 1 of 1 - CAD 721/10946 Issue 1 REVERSE ALARM REVERSE ALARM TERM WIRE SIZE DEST TYPE 847A C103 600CD REARSOCKET TERM WIRE SIZE DEST TYPE REARFOGLIGHT NOPLA TELIGHT NOPLA TELIGHT TERM WIRE...
  • Page 229 www.WorkshopManuals.co.uk Harness Drawing - Rear Horn / Alarm - Centre Mount page 1 of 1 - CAD 721/10947 Issue 1 REVERSE ALARM REVERSE ALARM TERM WIRE SIZE DEST TYPE 847A C103 600CD REARSOCKET NOPLA TELIGHT NOPLA TELIGHT TERM WIRE SIZE DEST TYPE REARFOGLIGHT...
  • Page 230 www.WorkshopManuals.co.uk Harness Drawing - Auxiliary - Excavator page 1 of 1 - CAD 721/10974 Issue 1 MICROSWITCH TERM WIRE SIZE DEST TYPE JAWC/OSOLENOID JAWC/OSOLENOID 101AA TERM WIRE SIZE DEST TYPE C106 874C C103 600CX Connector Key Cab Connecion JAWC/OSWITCH JAWC/OSWITCH Hammer Solenoid TERM WIRE...
  • Page 231 Contents Page No. Steering Column Removal and Replacement 30 - 1 Dismantling and Assembly 30 - 1 Shovel Reset (214e Machines) 31 - 1 Return To Dig Operation 33 - 1 Adjustment 33 - 1 Precision Control (Servo) Machines up to serial no. 931159...
  • Page 232 www.WorkshopManuals.co.uk Section D Controls Section D Contents Page No. Precision Control (Servo) Machines from January 2003 (continued) Servo Pressure Supply Valve - Removal and Replacement 51 - 1 - Dismantling and Assembly 51 - 2 Control Rods and Linkages Dismantling and Assembly - Loader Valve Controls 60 - 1 - Excavator Valve Controls...
  • Page 233 www.WorkshopManuals.co.uk Section D Controls Section D 30 - 1 Steering Column 30 - 1 A396921 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 234 J. Replacement Replacement is the reverse of the removal sequence. Apply JCB Threadlocker and Sealer to threads of nuts T. Note: The coupling bolt G must engage with the cut-out in the shaft. After re-fitting check that the steering tilt functions correctly, and that the direction indicators and lights operate correctly.
  • Page 235 www.WorkshopManuals.co.uk Section D Controls Section D 31 - 1 Shovel Reset 31 - 1 2065mm A320510 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 236 Controls Section D 31 - 2 Shovel Reset 31 - 2 214e Machines Only Fitting Adjust the feedback link A to 2065mm (81.3in). After The shovel reset system is designed to automatically tilt the adjusting tighten the lock nuts. shovel forward when the loader arms are raised, this prevents a heaped shovel from depositing its contents over Fit cam plate B with the single threaded hole at the top.
  • Page 237 www.WorkshopManuals.co.uk Section D Controls Section D 33 - 1 Return To Dig 33 - 1 A374040 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 238 www.WorkshopManuals.co.uk Section D Controls Section D 33 - 2 Return To Dig 33 - 2 Operation Adjustment This enables you to roll the shovel from the rolled forward Lower the loader arms and position the shovel in the position into the digging position quickly and easily. required ‘Return To Dig’...
  • Page 239 www.WorkshopManuals.co.uk Section D Controls Section D 35 - 1 Precision Control (Servo) 35 - 1 Basic System Operation Component Location A402030 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 240 The following section describes the JCB Precision Control Basic System Operation system fitted to machines up to serial number 931159. There is another JCB Precision Control system fitted to later machines, which is described in a separate section. Refer to Component Identification Precision Control (Servo) - Machines from January 2003.
  • Page 241 www.WorkshopManuals.co.uk Section D Controls Section D 35 - 3 Precision Control (Servo) 35 - 3 SAE + TR TL PR ISO + SAE + Key to Oil Flow & Pressure Full Pressure Servo Exhaust A402070 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 242 Note that the diagram opposite shows the servo hoses valve pilot line in proportion to the joystick position. The connected to give the SAE + (JCB +) control pattern. For further the joystick is moved the greater the pilot pressure ISO + control pattern some servo hoses are connected and the further the associated excavator valve spool moves.
  • Page 243 www.WorkshopManuals.co.uk Section D Controls Section D 36 - 1 Precision Control (Servo) 36 - 1 Electrical Connections 600GT HB HD 101BG 101Y 101Y 101AG 600KH 600KH 875B 1805F 600HX 101BJ 1805C 101N 1805C 101Z A402400 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 244 www.WorkshopManuals.co.uk Section D Controls Section D 36 - 2 Precision Control (Servo) 36 - 2 Electrical Connections On the electrical diagram opposite the electrical connectors (example, CTG to HB) are shown looking on the mating face of each connector when they are disconnected. The wire numbers and colours, where appropriate, are shown as an aid to identification whilst fault finding.
  • Page 245 www.WorkshopManuals.co.uk Section D Controls Section D 37 - 1 Precision Control (Servo) 37 - 1 Fault Finding Introduction 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.
  • Page 246 www.WorkshopManuals.co.uk Section D Controls Section D 37 - 2 Precision Control (Servo) 37 - 2 Fault Finding Chart A - No Servo Controls (system fails to operate) START See Electrical Switches, Seat Mounted Microswitch - Adjustment. Does system function if the 'mode' Check seat mounted micro switch switch is operated? function and condition of associated...
  • Page 247 www.WorkshopManuals.co.uk Section D Controls Section D 37 - 3 Precision Control (Servo) 37 - 3 Fault Finding Chart B - All Backhoe Services Slow to Operate START Renew filter. Remove any Is the pilot supply valve oil filter contamination. Check condition of blocked? hydraulic oil, drain and replace if necessary.
  • Page 248 www.WorkshopManuals.co.uk Section D Controls Section D 37 - 4 Precision Control (Servo) 37 - 4 Fault Finding Chart C - One Backhoe Service fails or is Slow to Operate START Is the associated joystick mechanical Renew or adjust components as linkage worn or wrongly adjusted? applicable.
  • Page 249 www.WorkshopManuals.co.uk Section D Controls Section D 37 - 5 Precision Control (Servo) 37 - 5 Fault Finding Chart D - System Fails to Operate when the ‘Mode Switch’ is Activated (operator seat facing forward) START Does the system operate with the See Fault Finding Chart A - No Servo operator seat set in the rear facing Controls (system fails to operate)
  • Page 250 www.WorkshopManuals.co.uk Section D Controls Section D 38 - 1 Precision Control (Servo) 38 - 1 Service Procedures Testing the Pilot Pressure Position the backhoe to enable access to the pilot supply valve. Before proceeding further the pilot circuit accumulator pressure must be vented. Stop the engine.
  • Page 251 www.WorkshopManuals.co.uk Section D Controls Section D 38 - 2 Precision Control (Servo) 38 - 2 A402430 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 252 www.WorkshopManuals.co.uk Section D Controls Section D 38 - 3 Precision Control (Servo) 38 - 3 Service Procedures Pilot Hose Removal and Replacement Before attempting to remove a servo hose the pilot circuit accumulator pressure must be vented. Stop the engine. With the operator seat set in the rear facing position (for backhoe operation), switch the starter to ON without starting the engine.
  • Page 253 www.WorkshopManuals.co.uk Section D Controls Section D 38 - 4 Precision Control (Servo) 38 - 4 Service Procedures Seat Arms Control Lever - Adjustment In some instances it may be necessary to adjust the operation of the arms raise/lower control lever 1. When the button 2 is depressed upwards fully, the arms are released for raise/lower.
  • Page 254 www.WorkshopManuals.co.uk Section D Controls Section D 40 - 1 Precision Control (Servo) 40 - 1 A402540 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 255 www.WorkshopManuals.co.uk Section D Controls Section D 40 - 2 Precision Control (Servo) 40 - 2 Pilot Control Valves Removal and Replacement Note that the procedure shows the right hand control valve. The removal and replacement procedure for the left hand valve is identical.
  • Page 256 www.WorkshopManuals.co.uk Section D Controls Section D 40 - 3 Precision Control (Servo) 40 - 3 A402440 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 257 Remove the six adaptors 16 from the ports. Note that the adaptors incorporate seals. Note that one way Apply JCB HP Grease to the mating faces of wobble restrictors 4 are fitted to some ports as follows: plate 5 and plungers 6.
  • Page 258 www.WorkshopManuals.co.uk Section D Controls Section D 41 - 1 Precision Control (Servo) 41 - 1 A402410 A402590 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 259 www.WorkshopManuals.co.uk Section D Controls Section D 41 - 2 Precision Control (Servo) 41 - 2 Electrical Switches Joystick Mounted Microswitches, Removal Seat Mounted Microswitch, Removal, Replacement and Replacement Adjustment. Note that the procedure shows the right hand joystick. the Important Note: Some machines may be fitted with two procedure is very similar for the left hand joystick.
  • Page 260 www.WorkshopManuals.co.uk Section D Controls Section D 45 - 1 Precision Control (Servo) 45 - 1 Basic System Operation Component Location 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 261 Operator seat Circuit Description Servo pressure supply valve Isolation valve solenoid The JCB Precision Control system facilitates operation of the Accumulator backhoe (excavator) via joystick controllers A and B Servo pressure regulating valve mounted in the arms of the operator’s seat. Unlike manual...
  • Page 262 www.WorkshopManuals.co.uk Section D Controls Section D 45 - 3 Precision Control (Servo) 45 - 3 Basic System Operation Hydraulic Operation Oil at system pressure flows to the servo pressure supply Component Key: valve C via a hose connected at the excavator valve J. An Left hand joystick controller integral pressure regulating valve F maintains the oil at Right hand joystick controller...
  • Page 263 www.WorkshopManuals.co.uk Section D Controls Section D 45 - 4 Precision Control (Servo) 45 - 4 ISO+ L.H. R.H. ISO+ SAE+ L.H. SAE+ R.H. Key to Oil Flow & Pressure Full Pressure Servo Exhaust A404990 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 264 www.WorkshopManuals.co.uk Section D Controls Section D 45 - 5 Precision Control (Servo) 45 - 5 628C 628D 1875 1876 114C 114E 1874 629A 629D 114G 1877 1857 412C UNLOADER (HSC) SWITCH ALTERNATOR FREQUENCY PUMP DUMP CONTROLLER SIDE CONSOLE LED 8870 921A 921A 921B...
  • Page 265 www.WorkshopManuals.co.uk Section D Controls Section D 45 - 6 Precision Control (Servo) 45 - 6 Basic System Operation Electrical Operation - Joystick Controller Pump Dump Controller (Power Management ECU) There solenoid actuated isolation valves The electronic control unit is mounted in the engine incorporated in the servo pressure supply valve block, which compartment and is used to control engine hydraulic power.
  • Page 266 www.WorkshopManuals.co.uk Section D Controls Section D 45 - 7 Precision Control (Servo) 45 - 7 Basic System Operation Joystick Controllers - Description The joystick controllers operate as direct operated pressure reducing valves and consist of a hand control lever, four pressure reducing valves and the housing.
  • Page 267 www.WorkshopManuals.co.uk Section D Controls Section D 45 - 8 Precision Control (Servo) 45 - 8 Basic System Operation Servo Pressure Supply Valve - Description The servo pressure supply valve is fitted with a pressure regulating valve 1, a pressure relief valve 2 and two solenoid valves 3 for servo pressure isolation.
  • Page 268 www.WorkshopManuals.co.uk Section D Controls Section D 47 - 1 Precision Control (Servo) 47 - 1 Fault Finding Introduction 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.
  • Page 269 www.WorkshopManuals.co.uk Section D Controls Section D 47 - 2 Precision Control (Servo) 47 - 2 Fault Finding Chart A - No Servo Controls (system fails to operate) START Does the system operate if the seat is Check the function of the seat mounted locked in the opposite facing position? proximity switches and condition of Check that the arm rests are...
  • Page 270 www.WorkshopManuals.co.uk Section D Controls Section D 47 - 3 Precision Control (Servo) 47 - 3 Fault Finding Chart B - All Backhoe Services Slow to Operate START Adjust as required. Is the servo pressure low? Refer to Service Procedures - Testing the Servo Pressure. Are the servo pressure isolation valves operating correctly? Remove Clean and renew components as...
  • Page 271 www.WorkshopManuals.co.uk Section D Controls Section D 47 - 4 Precision Control (Servo) 47 - 4 Fault Finding Chart C - One Backhoe Service fails or is Slow to Operate START Inspect the associated joystick Clean and renew components as controller valve capsule for signs of applicable.
  • Page 272 www.WorkshopManuals.co.uk Section D Controls Section D 48 - 1 Precision Control (Servo) 48 - 1 Service Procedures Testing the Servo Pressure 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 273 Replacement Replacement is the reverse of the removal sequence. Note: All hydraulic adaptors that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adaptor. 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 274 www.WorkshopManuals.co.uk Section D Section D Controls 50 - 2 Precision Control (Servo) 50 - 2 Joystick Controllers Dismantling and Assembly A404780 A404770 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 275 Assembly is the reverse of the dismantling sequence. Clean the valve components in an appropriate solvent. Renew all 'O' rings and back-up rings. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. Torque Settings...
  • Page 276 Disconnect the battery, to prevent the engine being Note: All hydraulic adaptors that are installed together with a started while you are beneath the machine. bonded sealing washer must also have JCB Threadseal GEN-1-2 applied to the threads of the adaptor.
  • Page 277 www.WorkshopManuals.co.uk Section D Section D Controls 51 - 2 Precision Control (Servo) 51 - 2 Servo Pressure Supply Valve Dismantling and Assembly A404760 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 278 Turn the starter switch to the OFF Clean the valve components in an appropriate solvent. position and remove the key. Renew all 'O' rings and back-up rings. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. Torque Settings Item...
  • Page 279 www.WorkshopManuals.co.uk Section D Controls Section D 60 - 1 Control Rods and Linkages 60 - 1 Dismantling and Assembly Loader Valve Controls Locking A404660 A404500 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 280 www.WorkshopManuals.co.uk Section D Controls Section D 60 - 2 Control Rods and Linkages 60 - 2 Dismantling and Assembly Thread the transmission dump switch cable through the Loader Valve Controls loader control lever and fit the wires/pins into the electrical connector. Couple the connector to the The illustration on the adjacent page shows the control rods chassis harness and fit the control lever knobs.
  • Page 281 Section D Section D Controls 61 - 1 Control Rods and Linkages 61 - 1 Dismantling and Assembly Excavator Valve Controls (JCB + Pattern) Locking A404810 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 282 The illustration on the adjacent page shows the control rods control lever knobs. and linkages for the excavator control valve and is intended as a guide to the dismantling and assembly. Note JCB + Connect the battery, check that the controls and rear pattern controls shown.
  • Page 283 www.WorkshopManuals.co.uk Section D Controls Section D 70 - 1 Control Cables 70 - 1 Removal and Replacement Cab Heater Controls A404491 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 284 www.WorkshopManuals.co.uk Section D Controls Section D 70 - 2 Control Cables 70 - 2 Removal and Replacement Cab Heater Controls The cab heater controls A and associated cables are housed in the R.H. side console as shown. There are two control cables which operate the re-circulation vent and the hot water valve.
  • Page 285 www.WorkshopManuals.co.uk Section D Controls Section D 71 - 1 Control Cables 71 - 1 Removal and Replacement Stabiliser Controls A404700 A404730 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 286 www.WorkshopManuals.co.uk Section D Controls Section D 71 - 2 Control Cables 71 - 2 Removal and Replacement Stabiliser Controls The stabiliser controls A and associated cables are housed in the R.H. side console as shown. There are two control cables which operate the R.H. and L.H.
  • Page 287 www.WorkshopManuals.co.uk Section D Controls Section D 72 - 1 Control Cables 72 - 1 Removal and Replacement Boom Lock Cable A405180 A394410 A404510 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 288 www.WorkshopManuals.co.uk Section D Controls Section D 72 - 2 Control Cables 72 - 2 Removal and Replacement Boom Stop Setting Boom Lock Cable The boom stop block should be set as follows: The boom lock control A and associated cable is housed in the R.H.
  • Page 289 www.WorkshopManuals.co.uk Section D Controls Section D 73 - 1 Control Cables 73 - 1 Removal and Replacement Engine Throttle Cable A404690 A404680 A404670 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 290 www.WorkshopManuals.co.uk Section D Controls Section D 73 - 2 Control Cables 73 - 2 Removal and Replacement Engine Throttle Cable The engine throttle cable is routed from the L.H. side of the engine compartment to connect with the footpedal A at the engine compartment bulkhead, and to the hand throttle lever B housed in the R.H.
  • Page 291 www.WorkshopManuals.co.uk Section D Controls Section D 74 - 1 Control Cables 74 - 1 Removal and Replacement Auxiliary Footpedal Cable The auxiliary footpedal control A is mounted in the cab floor as shown. The cable operates the auxiliary control valve located adjacent to the excavator valve.
  • Page 292 www.WorkshopManuals.co.uk Section E Hydraulics Section E Contents Page No. Service Tools 1 - 1 Technical Data Hydraulic Pumps Fixed Flow 2 - 1 Variable Flow 2 - 3 Relief Valve Pressures Loader Valve - Fixed Flow 2 - 4 Loader Valve - Precision Control (Servo) - Machines up to serial no.
  • Page 293 www.WorkshopManuals.co.uk Section E Hydraulics Section E Contents Page No. Loader Valve - Variable Flow Operation 7 - 1 Priority Inlet Section Operation 7 - 2 Auxiliary Spool 7 - 4 Loader Shovel Spool 7 - 5 Loader Lift Spool 7 - 6 Shuttle Valve Signal Network 7 - 7 Excavator Valve...
  • Page 294 www.WorkshopManuals.co.uk Section E Hydraulics Section E Contents Page No. Excavator Valve - Precision Control (Servo) - Machines from January 2003 Pressure Testing - Load Sense Relief Valve 23 - 11 Pressure Compensator Network - Testing 23 - 12 Ram Creep Tests - All Services 24 - 1 Quick Release Couplings Connecting &...
  • Page 295 85 - 1 Bucket Ram 85 - 1 Stabiliser Ram 85 - 1 Dipper Ram 86 - 1 Slew Ram 87 - 1 Power Sideshift Ram 88 - 1 JCB Ram Sealing Procedure 89 - 1 9803/3280 Issue 4* Purchased from www.WorkshopManuals.co.uk...
  • Page 296 www.WorkshopManuals.co.uk Section E Hydraulics Section E Contents Page No. Hydraulic Oil Cooler Removal and Replacement 95 - 1 Smooth Ride System Accumulator Removal and Replacement 96 - 1 Dismantling and Assembly 96 - 2 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 297 www.WorkshopManuals.co.uk Section E Section E Hydraulics 1 - 1 Service Tools 1 - 1 Hydraulic Circuit Pressure Test Kit 892/00253 Pressure Test Kit :892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in :892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in :892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in :892/00254 Replacement Hose 993/69800...
  • Page 298 www.WorkshopManuals.co.uk Section E Section E Hydraulics 1 - 2 Service Tools 1 - 2 Components for Valve Block A.R.V. Testing For 4CX Variable Flow machines use 25/201103 892/00309 A.R.V. Pressure Test Kit 892/00881 Valve Spool : 892/00340 Test Block Body Seal Fitting Tool : 892/00341 Setting Body...
  • Page 299 www.WorkshopManuals.co.uk Section E Section E Hydraulics 1 - 3 Service Tools 1 - 3 Female Cone Blanking Plug 892/00055 1/4 in. BSP Male Cone Blanking Cap 892/00056 3/8 in. BSP 816/00294 1/4 in. BSP 892/00057 1/2 in. BSP 816/00189 3/8 in. BSP 892/00058 5/8 in.
  • Page 300 www.WorkshopManuals.co.uk Section E Section E Hydraulics Service Tools 1 - 4 1 - 4 11 o 10mm 20mm 110mm 175mm 892/01027 Piston Seal Assembly Tool 338500 S216250 892/00334 Ram Seal Fitting Tool S338410 Ram Seal Protection Sleeves 892/01016 For 25 mm Rod Diameter 892/01017 For 30 mm Rod Diameter 892/01018...
  • Page 301 www.WorkshopManuals.co.uk Section E Section E Hydraulics 2 - 1 Technical Data 2 - 1 Hydraulic Pumps Fixed Flow Model/Reference Double pump/4070H Mounting Gearbox Theoretical displacement: cc/rev cu in/rev Pump section 1 (mounting flange end) 2.01 Pump section 2 1.40 Flow at 2200 rev/min and system pressure (90% min displacement): litres/min UK gal/min US gal/min Pump section 1 (mounting flange end)
  • Page 302 www.WorkshopManuals.co.uk Section E Section E Hydraulics 2 - 2 Technical Data 2 - 2 Hydraulic Pumps Fixed Flow (continued) Model/Reference Double pump/PGP620/Common outlet Mounting Gearbox Theoretical displacement: cc/rev cu in/rev Pump section 1 (mounting flange end) 1.77 Pump section 2 1.40 Flow at 2200 rev/min and system pressure (90% min displacement): litres/min UK gal/min...
  • Page 303 www.WorkshopManuals.co.uk Section E Section E Hydraulics 2 - 3 Technical Data 2 - 3 Hydraulic Pumps Variable Flow Type Variable Displacement Reference A10VO - 978753 Mounting Gearbox Load Sense Pressure (in neutral position) Maximum permitted - 5 bar; 72.5 lbf/in Load sense pressure relief Valve (if fitted) 230 bar;...
  • Page 304 www.WorkshopManuals.co.uk Section E Section E Hydraulics 2 - 4 Technical Data 2 - 4 Relief Valve Pressures Loader Valve - Fixed Flow kgf/cm lbf/in Main Relief Valve (M.R.V.) 236 - 241 240 - 245 3420 - 3500 Unloader Valve 207 - 214 207 - 211 3000 - 3100 Auxiliary Relief Valves (A.R.V.)
  • Page 305 www.WorkshopManuals.co.uk Section E Section E Hydraulics 2 - 5 Technical Data 2 - 5 Relief Valve Pressures Loader Valve - Precision Control (Servo) (Machines up to serial no. 931159) kgf/cm lbf/in Main Relief Valve (M.R.V.) 227 - 231 232 - 235 3300 - 3350 Unloader Valve 203 - 207...
  • Page 306 www.WorkshopManuals.co.uk Section E Section E Hydraulics 2 - 5A Technical Data 2 - 5A Relief Valve Pressures Loader Valve - Precision Control (Servo) (Machines from January 2003) kgf/cm lbf/in Auxiliary Relief Valves (A.R.V.) Shovel Ram Head Side 4500 Shovel Ram Rod Side 2500 Note: Instructions for pressure testing and adjustment are described in Service Procedures, Loader Valve - Pressure Testing.
  • Page 307 www.WorkshopManuals.co.uk Section E Section E Hydraulics 2 - 7 Technical Data 2 - 7 Relief Valve Pressures Loader Valve - Variable Flow kgf/cm lbf/in Priority Relief Valve† 170 - 176 173 - 179 2450 - 2550 Auxiliary Relief Valves (A.R.V.) @ 0.5gal/min (1.9 litres/min) Shovel Ram Head Side 170 - 174 173 - 177...
  • Page 308 Testing. † System shown is for JCB plus pattern and JCB diagonal pattern. For ISO system, the boom and dipper spools change position, i.e. boom is position 2 and dipper is position 5. The bottom ARV from spool 5 will also be swapped with the bottom ARV from spool 2.
  • Page 309 www.WorkshopManuals.co.uk Section E Section E Hydraulics 2 - 10 Technical Data 2 - 10 Relief Valve Pressures Excavator Valve - Precision Control (Servo) (Machines up to serial no. 931159) kgf/cm lbf/in Boom Ram Head Side 248 - 255 253 - 260 3600 - 3700 Boom Ram Rod Side 345 - 352...
  • Page 310 www.WorkshopManuals.co.uk Section E Section E Hydraulics 2 - 10A Technical Data 2 - 10A Relief Valve Pressures Excavator Valve - Precision Control (Servo) (Machines from January 2003) kgf/cm lbf/in Auxiliary Relief Valves (A.R.V.) Boom Ram Head Side 3550 Boom Ram Rod Side 5000 Bucket Ram Head Side 3700...
  • Page 311 www.WorkshopManuals.co.uk Section E Section E Hydraulics 2 - 11 Technical Data 2 - 11 Relief Valve Pressures Auxiliary Valve - Fixed Flow kgf/cm lbf/in Extradig Ram Head Side 138 - 145 141 - 148 2000 - 2100 Extradig Ram Rod Side 207 - 214 211 - 218 3000 - 3100...
  • Page 312 www.WorkshopManuals.co.uk Section E Section E Hydraulics 2 - 13 Technical Data 2 - 13 Smooth Ride System System Type A piston type accumulator operates as a liquid spring absorbing displaced fluid from the lift rams. Selectable from a switch in the cab. Charging Gas Air Free Dry Nitrogen Accumulator Capacity...
  • Page 313 www.WorkshopManuals.co.uk Component Location A401400 Purchased from www.WorkshopManuals.co.uk...
  • Page 314 www.WorkshopManuals.co.uk Component Location Neutral Circuit Description Component Key: Fixed Flow - Single Pump T Hydraulic Tank P Hydraulic Pump (engine driven) 1B Hose - High Pressure Carry Over Oil is drawn from the hydraulic tank T by the single 3 Loader Valve Block stage hydraulic pump P.
  • Page 315 www.WorkshopManuals.co.uk Component Location A401420 Purchased from www.WorkshopManuals.co.uk...
  • Page 316 www.WorkshopManuals.co.uk Component Location Neutral Circuit Description Component Key: Fixed Flow - Double Pump T Hydraulic Tank P1 Hydraulic Pump (main section) Oil is drawn from the hydraulic tank T by the P2 Hydraulic Pump (secondary section) hydraulic pump. The pump has two sections, P1 1B Hose - High Pressure Carry Over and P2.
  • Page 317 www.WorkshopManuals.co.uk Component Location A401430 Purchased from www.WorkshopManuals.co.uk...
  • Page 318 www.WorkshopManuals.co.uk Component Location Neutral Circuit Description Component Key: Variable Flow T Hydraulic Tank The variable flow displacement pump P is mounted P Hydraulic Pump (engine driven) on the rear of the gearbox and is engine driven via 1A Pump Outlet Pipe/Hose a driveshaft.
  • Page 319 www.WorkshopManuals.co.uk Section E Hydraulics Section E 3 - 10 Basic System Operation 3 - 10 Introduction to Hydraulic Schematic Pumps & Motors Symbols Complex hydraulic components and circuits can be Variable capacity pump described to the engineer by using graphical symbols. The two directions of flow following pages illustrate and give a brief description for some of the more common symbols used.
  • Page 320 www.WorkshopManuals.co.uk Section E Hydraulics Section E 3 - 11 Basic System Operation 3 - 11 Introduction to Hydraulic Schematic Symbols (cont'd) Control Valves One way restrictor Used to enclose several valves indicating that they are supplied as one unit High pressure selector 3-Position, 4-Port (shuttle valve) spring centred pilot...
  • Page 321 www.WorkshopManuals.co.uk Section E Hydraulics Section E 3 - 12 Basic System Operation 3 - 12 Introduction to Hydraulic Schematic Symbols (cont'd) Energy Transmissions and Conditioning Working line, return or feed Reservoir - return line above fluid level Pilot control Reservoir - return line below fluid level Drain lines Flexible pipe...
  • Page 322 www.WorkshopManuals.co.uk Section E Hydraulics Section E 3 - 13 Basic System Operation 3 - 13 Introduction to Hydraulic Schematic Symbols (cont'd) Control Mechanisms Rotating shaft-one direction Solenoid one winding Rotating shaft-two directions Solenoid two winding Detent Electric motor operated Locking device Internal pressure pilot operated Over centre device...
  • Page 323 Port 2 the flow arrows take in their respective operating squares. Port 4 Three typical JCB style spools are known as 'D' spools, 'F' spools and 'N' spools. The 'D' spools generally control rams because when in the FIG 4 neutral position the outlet ports are blocked, preventing ram movement.
  • Page 324 www.WorkshopManuals.co.uk Section E Hydraulics Section E 3 - 15 Basic System Operation 3 - 15 Introduction to Hydraulic Schematic Symbols (cont'd) Example of Schematic Circuit Some of the symbols described on the preceding pages Example Circuit Key have been arranged into a simple schematic circuit shown below.
  • Page 325 3CX, 4CX, 214, 215, 217 & ‘S’ Series Machines Smooth Ride System Selector Valve Assembly Smooth Ride System Accumulator The policy of JCB is one of continuous improvement, Hydraulic Oil Cooler therefore as products develop, there may be variations to Shovel Ram R.H.
  • Page 326 www.WorkshopManuals.co.uk Section E Section E Hydraulics 3 - 21 Circuit Schematics - Fixed Flow 3 - 21 3CX, 4CX, 214, 215, 217 & ‘S’ Series Machines A262643 Issue 1 9803/3280 Purchased from www.WorkshopManuals.co.uk...
  • Page 327 www.WorkshopManuals.co.uk Section E Section E Hydraulics 3 - 22 Circuit Schematics - Fixed Flow 3 - 22 3CX ‘S’ Series & 4CX Gear Pump Options 3CX ‘S’ Series Options This c irc uit sho w s t he Ex t end ing Dip p er and Po w er This circuit shows the Low Flow Hammer, Extending Dipper Sideshift, for the main hydraulic circuit see pages E/3-20 and Power Sideshift, for the main hydraulic circuit see...
  • Page 328 www.WorkshopManuals.co.uk Section E Section E Hydraulics 3 - 23 Circuit Schematics - Fixed Flow 3 - 23 3CX ‘S’ Series Options This circuit shows the Low Flow Hammer and Extending Dipper, for the main hydraulic circuit see pages E/3-20 and E/3-21.
  • Page 329 Section E Section E Hydraulics 3 - 24 Circuit Schematics - Fixed Flow 3 - 24 214e Machines Component Key: Hydraulic Tank Return filter Hydraulic Oil Cooler Hydraulic Pump Twin Check Valve Shovel Rams Quick Release Couplings Lift Rams...
  • Page 330 Section E Hydraulics Section E 3 - 25 Circuit Schematics - Fixed Flow 3 - 25 214e Machines NEUTRAL CIRCUIT H.P.C.O. SLEW SHOVEL BOOM ENGINE LOADER STABILISER STABILISER DIPPER BUCKET H.P.C.O. HAMMERMASTER HAMMERMASTER HAMMERMASTER 260L NEUTRAL CIRCUIT / TANK RETURN...
  • Page 331 www.WorkshopManuals.co.uk Section E Section E Hydraulics 3 - 26 Circuit Schematics - Variable Flow 3 - 26 4CXE, 4CX Super Machines (7 Spool With High Flow Options) PRLS A278942 Issue 1 9803/3280 Purchased from www.WorkshopManuals.co.uk...
  • Page 332 www.WorkshopManuals.co.uk Section E Section E Hydraulics 3 - 27 Circuit Schematics - Variable Flow 3 - 27 4CX, 4CX Super Machines (7 Spool With High Flow Options) Component Key Small letters on the schematic indicate port markings. Refer to Technical Data pages at the beginning of this section for more information.
  • Page 333 www.WorkshopManuals.co.uk Section E Section E Hydraulics 3 - 28 Circuit Schematics - Variable Flow 3 - 28 4CX, 4CX Super Machines (6 Spool With High/Low Flow Options) Component Key Small letters on the schematic indicate port markings. Refer to Technical Data pages at the beginning of this section for more information.
  • Page 334 www.WorkshopManuals.co.uk Section E Section E Hydraulics 3 - 29 Circuit Schematics - Variable Flow 3 - 29 4CXE, 4CX Super Machines (6 Spool With High Flow Options) PRLS A327070 A347590 Issue 1 9803/3280 Purchased from www.WorkshopManuals.co.uk...
  • Page 335 www.WorkshopManuals.co.uk Section E Section E Hydraulics 3 - 30 Circuit Schematics - Variable Flow 3 - 30 4CX, 4CX Super Machines Hand Held Tools Option A322650 Component Key Pump Variable Flow Hydraulic Tank Main Circuit Connection Pressure Flow Regulator High Pressure Flow Spool Relief Valve (2000 lb/in - 138 bar - 146 kgf/cm Load Sense Solenoid...
  • Page 336 www.WorkshopManuals.co.uk Section E Hydraulics Section E 3 - 31 Basic System Operation 3 - 31 Hydraulic Circuit Schematic Precision Control (Servo) (Machines up to serial no. 931159) Component Key: Tank Anti Cavitation Check Valve Breather Hydraulic Oil Cooler Fill Screen Steer Unit Suction Strainer Priority Valve...
  • Page 337 www.WorkshopManuals.co.uk Section E Hydraulics Section E 3 - 32 Circuit Schematics 3 - 32 Precision Control (Servo) (Machines up to serial no. 931159) A396210 Issue 2* 9803/3280 Purchased from www.WorkshopManuals.co.uk...
  • Page 338 www.WorkshopManuals.co.uk Section E Hydraulics Section E 3 - 33 Circuit Schematics 3 - 33 Precision Control (Servo) (Machines from January 2003) POWER SIDESHIFT (OPTION) HAMMER (OPTION) HAMMER HAMMER (OPTION) (OPTION) A403921 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 339 www.WorkshopManuals.co.uk Section E Hydraulics Section E 3 - 34 Basic System Operation 3 - 34 Hydraulic Circuit Schematic Precision Control (Servo) (Machines from January 2003) The schematic shows the main system hydraulics for Precision Control (Servo) machines. For the pilot circuit refer to relevant pages.
  • Page 340 www.WorkshopManuals.co.uk Section E Hydraulics Section E 3 - 35 Basic System Operation 3 - 35 Hydraulic Circuit Schematic Precision Control (Servo) (Machines from January 2003) The schematic shows the pilot circuit for Precision Control (Servo) machines. For the main system hydraulics refer to relevant pages.
  • Page 341 www.WorkshopManuals.co.uk Section E Hydraulics Section E 3 - 36 Circuit Schematics 3 - 36 Precision Control (Servo) (Machines from January 2003) A405700 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 342 www.WorkshopManuals.co.uk Section E Section E Hydraulics 5 - 1 Circuit Descriptions 5 - 1 Hydraulic Pump - Fixed Flow Component Key: Single Pump - Operation Spur Gear - Idler The hydraulic pump is a gear type. The basic principle of the Spur Gear - Driven pump depends on the meshing of the two spur gears A and Channel...
  • Page 343 www.WorkshopManuals.co.uk Section E Section E Hydraulics 5 - 2 Circuit Descriptions 5 - 2 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A396380 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 344 www.WorkshopManuals.co.uk Section E Hydraulics Section E 5 - 3 Circuit Descriptions 5 - 3 Hydraulic Pump - Variable Flow Operation Component Key: The pump is a variable displacement axial piston type. Pump Displacement of oil is achieved by the continuous operation Cylinder Barrel of nine pistons.
  • Page 345 www.WorkshopManuals.co.uk Section E Hydraulics Section E 5 - 4 Circuit Descriptions 5 - 4 Neutral Circuit Pressure Pressure Generated by Operation of a Service Trapped Oil Exhaust A275730 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 346 www.WorkshopManuals.co.uk Section E Hydraulics Section E 5 - 5 Circuit Descriptions 5 - 5 Hydraulic Pump - Variable Flow Pressure/Flow Regulator Valve The pressure and flow regulator valve assembly is mounted to the pump. The valve maintains the pump pressure and flow rate in accordance with demand at the service valve blocks.
  • Page 347 www.WorkshopManuals.co.uk Section E Hydraulics Section E 5 - 6 Circuit Descriptions 5 - 6 Neutral Circuit Pressure Pressure Generated by Operation of a Service Trapped Oil Exhaust A275740 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 348 www.WorkshopManuals.co.uk Section E Hydraulics Section E 5 - 7 Circuit Descriptions 5 - 7 Hydraulic Pump - Variable Flow Pressure/Flow Regulator Valve Load Sensing - Maximum Flow When a service is operated, the signal pressure from the loader (or backhoe) valve 13 increases. The increase in signal pressure combined with the force of spring 6 moves spool 4 down.
  • Page 349 www.WorkshopManuals.co.uk Section E Hydraulics Section E 5 - 8 Circuit Descriptions 5 - 8 Neutral Circuit Pressure Pressure Generated by Operation of a Service Trapped Oil Exhaust A275750 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 350 www.WorkshopManuals.co.uk Section E Hydraulics Section E 5 - 9 Circuit Descriptions 5 - 9 Hydraulic Pump - Variable Flow Pressure/Flow Regulator Valve Load Sensing - Maximum Pressure (no flow) When a service ram reaches the end of its stroke or the service meets resistance (for instance tearing out), the signal pressure from the loader (or backhoe) valve 13 will increase to the same pressure as pump output pressure.
  • Page 351 www.WorkshopManuals.co.uk Section E Section E Hydraulics 6 - 1 Circuit Descriptions 6 - 1 Loader Valve - Neutral Circuit Component Key: The loader valve is mounted on the chassis frame, right hand side (when viewed from the rear). Parallel gallery Gallery It includes the lift ram spool 3C, shovel ram spool 3D and Drilling...
  • Page 352 www.WorkshopManuals.co.uk Section E Section E Hydraulics 6 - 2 Circuit Descriptions 6 - 2 1C(P2) Key to Oil Flow & Pressure Full Pressure 1A(P1) Pressure Servo A401150 Neutral Exhaust Cavitation Lock Up A390630 3N P1 A401160 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 353 www.WorkshopManuals.co.uk Section E Section E Hydraulics 6 - 3 Circuit Descriptions 6 - 3 1C(P2) 1A(P1) A401170 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 354 www.WorkshopManuals.co.uk Section E Section E Hydraulics 6 - 4 Circuit Descriptions 6 - 4 Loader Valve Component Key: - Hydraulic Speed Control (HSC) Parallel gallery Gallery Solenoid valve 3Q allow s t he op erat or t o c ont rol t he Drilling unloader spool movement (to dump flow from the hydraulic Tank Port...
  • Page 355 www.WorkshopManuals.co.uk Section E Section E Hydraulics 6 - 5 Circuit Descriptions 6 - 5 Loader Valve - Load Hold Check Valves Component Key: Operation 1 1A Pump Inlet The illustration shows 'arms raise' being selected by the lift Parallel Gallery ram spool 3C.
  • Page 356 www.WorkshopManuals.co.uk Section E Section E Hydraulics 6 - 6 Circuit Descriptions 6 - 6 A396410 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A396420 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 357 www.WorkshopManuals.co.uk Section E Section E Hydraulics 6 - 7 Circuit Descriptions 6 - 7 A396390 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A396400 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 358 www.WorkshopManuals.co.uk Section E Section E Hydraulics 6 - 8 Circuit Descriptions 6 - 8 Loader Valve Arms Lower Component Key: Spool Waists When a spool is selected as shown at 3C, the central land of Parallel Gallery the spool C blocks the neutral circuit. Oil from the pump, Central Land entering at 1A, is diverted into the parallel gallery B, opens Spool Waist...
  • Page 359 www.WorkshopManuals.co.uk Section E Section E Hydraulics 6 - 9 Circuit Descriptions 6 - 9 Loader Valve - A.R.V. Operation Component Key: Under normal operating conditions, with the shovel in the ' carry' position, the mechanical linkage keeps the shovel 1A Pump Inlet level as the arms are raised, to prevent spillage of the load.
  • Page 360 www.WorkshopManuals.co.uk Section E Section E Hydraulics 6 - 10 Circuit Descriptions 6 - 10 A396370 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 361 www.WorkshopManuals.co.uk Section E Section E Hydraulics 6 - 11 Circuit Descriptions 6 - 11 A401180 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 362 www.WorkshopManuals.co.uk Section E Section E Hydraulics 6 - 12 Circuit Descriptions 6 - 12 Main Relief Valve (MRV) - Operation The main relief valve (M.R.V.) 3B, situated in the loader valve Component Key: b loc k, p rovid es c ont rol of b ot h load er and exc avat or pressures.
  • Page 363 www.WorkshopManuals.co.uk Section E Section E Hydraulics 7 - 1 Circuit Descriptions 7 - 1 Loader Valve - Variable Flow Operation Component Key: The loader valve is mounted on the chassis frame, right Auxiliary (optional) spool hand side (when viewed from rear). Shovel spool Arms lift spool It is a stack type, directional control valve that is configured...
  • Page 364 www.WorkshopManuals.co.uk Section E Section E Hydraulics 7 - 2 Circuit Descriptions 7 - 2 Loader Valve - Variable Flow Priority Inlet Section Operation Component Key: The priority inlet section houses the steering priority valve Pump Inlet and a relief valve assembly. Operation is as follows: Tank Load sense port (to pump) Steering...
  • Page 365 www.WorkshopManuals.co.uk Section E Section E Hydraulics 7 - 3 Circuit Descriptions 7 - 3 Loader Valve - Variable Flow Priority Inlet Section Operation Component Key: Service Selected (no steering demand) Pump Inlet If the steering is not selected, there will be no pressure Tank demand signal in chamber C.
  • Page 366 www.WorkshopManuals.co.uk Section E Section E Hydraulics 7 - 4 Circuit Descriptions 7 - 4 Loader Valve - Variable Flow Auxiliary Spool The auxiliary valve section comprises the spool assembly A, load hold check valve assembly B, primary and secondary shuttles, items L and K respectively. While the spools are in neutral position, the primary shuttles and secondary shuttles are vented to tank.
  • Page 367 www.WorkshopManuals.co.uk Section E Section E Hydraulics 7 - 5 Circuit Descriptions 7 - 5 Loader Valve - Variable Flow Loader Shovel Spool The loader shovel spool operates in the same manner as the auxiliary spool, refer to Auxiliary Spool. The shovel valve section also houses auxiliary relief valves (items 30 and 30A).
  • Page 368 www.WorkshopManuals.co.uk Section E Section E Hydraulics 7 - 6 Circuit Descriptions 7 - 6 Loader Valve - Variable Flow Loader Lift Spool The loader lift spool operates in the same manner as the auxiliary spool, refer to Auxiliary Spool. The lift service spool (item 18) has a ‘float’ detent position. The float facility is provided to allow the arms to move up and down so that the shovel can follow the surface contours as the machine is driven over uneven ground.
  • Page 369 www.WorkshopManuals.co.uk Section E Section E Hydraulics 7 - 7 Circuit Descriptions 7 - 7 Loader Valve - Variable Flow Shuttle Valve Signal Network Each control valve section has two shuttle valves. Each valve compares two pressure signals. One of the shuttles is the primary 18 and the other is the secondary 17.
  • Page 370 Circuit Descriptions 8 - 1 Excavator Valve Manual Control - Neutral Circuit Component Key: (JCB 'X' Control Pattern) Oil from the loader valve enters the excavator valve at A and flows through the neutral gallery and around the waists Inlet of the solid spools.
  • Page 371 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 2 Circuit Descriptions 8 - 2 4C 4D A401190 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 372 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 3 Circuit Descriptions 8 - 3 A401200 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A401210 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 373 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 4 Circuit Descriptions 8 - 4 Excavator Valve - Load Hold Check Valves Component Key: Operation 1 Parallel Gallery Flow to the service via a typical solid spool 4B is controlled Service Line by the load hold check valve 4S which is a spring-loaded 4B Spool non-return valve operating across the pressure feed from the...
  • Page 374 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 5 Circuit Descriptions 8 - 5 Excavator Valve - One Way Restrictor Operation Componet Key: Because of its weight, the excavator end could take over Lower Service Port control when boom lower was selected. The falling boom Upper Service Port would tend to push oil out of the ram faster than the head One Way Restrictor...
  • Page 375 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 6 Circuit Descriptions 8 - 6 A396350 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A401220 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 376 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 7 Circuit Descriptions 8 - 7 Key to Oil Flow & Pressure Full Pressure Pressure A396360 Servo Neutral Exhaust Cavitation Lock Up A390630 A396430 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 377 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 8 Circuit Descriptions 8 - 8 Excavator Valve - Slew A.R.V. and Anti- Cavitation Operation The spool 4A is in neutral but the momentum of the slewing Componet Key: excavator end creates back pressure in the head side of the R.H.
  • Page 378 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 9 Circuit Descriptions 8 - 9 Pilot - Operated Pressure Relief Valve Operation Component Key: Valve at Rest A Service Pressure A.R.V's are positioned in the excavator valve block in order B Poppet to relieve excessive pressure in the services as described in C Piston Excavator Valve - ARV Operation.
  • Page 379 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 10 Circuit Descriptions 8 - 10 A390480 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 380 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 11 Circuit Descriptions 8 - 11 Excavator Valve - Manual Control Hydraclamp Valve Operation (Sideshift Machines) When the backhoe is being used for excavating duties, the kingpost assembly must be 'clamped' to the sideshift 2 - Clamps Released - Not Precision Control Machines rearframe.
  • Page 381 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 13 Circuit Descriptions 8 - 13 Excavator Valve Precision Control (Servo) (Machines up to serial no. 931159) Component Key: Inlet Port Outlet Port Centering Spring Integral Load Sensing Valves (Isolator Compensator Spools) Bypass Compensator Valve Load Sense Drain Regulator and Relief Valve Hydra-clamp Solenoid Valve...
  • Page 382 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 14 Circuit Descriptions 8 - 14 Excavator Valve Precision Control (Servo) (continued) (Machines up to serial no. 931159) When a Service is Selected In the interest of machine efficiency and consistent backhoe operation the excavator valve is of a closed centre design When one or more services are selected the load sense and incorporates load sensing valves D, for each service.
  • Page 383 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 15 Circuit Descriptions 8 - 15 LOAD = 100 bar 20 bar LS = 0 bar PUMP = 20 bar A402770 LOAD = 100 bar 20 bar LS = 20 bar PUMP = 40 bar A402780 LOAD = 100 bar 20 bar...
  • Page 384 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 16 Circuit Descriptions 8 - 16 Excavator Valve Precision Control (Servo) (continued) (Machines up to serial no. 931159) Load Sense (Isolator Compensator) Valve Operation No service is selected (all spools in neutral) With the spools in the neutral position oil from the pump P Any load on the service ram R is held by the main spool S.
  • Page 385 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 17 Circuit Descriptions 8 - 17 Excavator Valve Precision Control (Servo) 2 - Clamps Released - Precision Control Machines Only (Machines up to serial no. 931159) To enable clamps release, the hydraclamp switch A must be in the ON position and an excavator service must be Hydraclamp Valve Operation operated.
  • Page 386 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 18 Circuit Descriptions 8 - 18 Excavator Valve Precision Control (Servo) (continued) (Machines from January 2003) In the interest of machine efficiency and consistent backhoe operation the excavator valve is of a closed centre design and incorporates pressure compensating valves F, for each service.
  • Page 387 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 19 Circuit Descriptions 8 - 19 Excavator Valve Precision Control (Servo) (continued) (Machines from January 2003) Load Sense - Pressure Compensator Valves Operation No service selected (all spools in neutral) With the spools in the neutral position oil from the pump P flows to each service spool S and is dead ended.
  • Page 388 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 20 Circuit Descriptions 8 - 20 Key to Oil Flow & Pressure Full Pressure Pressure Servo A405030 Neutral Exhaust Cavitation Lock Up A390630 A405040 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 389 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 21 Circuit Descriptions 8 - 21 Bucket Actuation Key to Oil Flow & Pressure A405050 Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 Bucket Boom Actuation Actuation A405060 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 390 www.WorkshopManuals.co.uk Section E Section E Hydraulics 8 - 22 Circuit Descriptions 8 - 22 Excavator Valve Precision Control (Servo) (continued) (Machines from January 2003) Load Sense - Pressure Compensator Valves Operation Operating an individual service It must be noted that the load sense gallery LS is connected to all the pressure compensator valves PC (one for each service) as shown.
  • Page 391 www.WorkshopManuals.co.uk Smooth Ride System A391100 S307310 Purchased from www.WorkshopManuals.co.uk...
  • Page 392 www.WorkshopManuals.co.uk Smooth Ride System Component Key: Smoot h Rid e Syst em (SRS) w ill enhanc e t he comfort of the ride by damping out the forces 1 Loader Lift Rams imposed on the machine by the movement of the 2 Accumulator loader arms as the machine travels over uneven 3 Solenoid Valve Block...
  • Page 393 www.WorkshopManuals.co.uk Section E Hydraulics Section E 11 - 1 Circuit Descriptions 11 - 1 Hose Burst Protection Valve Boom & Dipper Operation BOOM RAM The small letter annotations A, B, X, and Y are stamped on the valve. Operation 1 - Load Raise When 'dipper out' is selected, oil from the excavator valve block is fed to port B, the oil opens check valve C against spring D and passes through internal galleries into the rod...
  • Page 394 www.WorkshopManuals.co.uk Section E Hydraulics Section E 11 - 2 Circuit Descriptions 11 - 2 Key to Oil Flow & Pressure Full Pressure Pressure A395760 Servo Neutral Exhaust Cavitation Lock Up A390630 A395770 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 395 www.WorkshopManuals.co.uk Section E Hydraulics Section E 11 - 3 Circuit Descriptions 11 - 3 Key to Oil Flow & Pressure Full Pressure Pressure A395780 Servo Neutral Exhaust Cavitation Lock Up A390630 A395790 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 396 www.WorkshopManuals.co.uk Section E Hydraulics Section E 11 - 4 Circuit Descriptions 11 - 4 Hose Burst Protection Valve Boom & Dipper Operation (Cont’d) BOOM RAM Operation 3 - Relief Valve If during normal operation the pressure in the rod side of the dipper ram increases (for example, by the operation of the bucket against an obstacle), increasing pressure in the ram enters at port Y.
  • Page 397 www.WorkshopManuals.co.uk Section E Hydraulics Section E 11 - 5 Circuit Descriptions 11 - 5 Hose Burst Protection Valve Loader Operation The small letter annotations V2, C2, P, T and E are the same as the port markings found on the HBPV. Operation 1 - Load Raise When lift is selected, oil from the loader valve block 9 is fed to port V2 on the HBPV, the oil opens check valve sleeve A...
  • Page 398 www.WorkshopManuals.co.uk Section E Hydraulics Section E 11 - 6 Circuit Descriptions 11 - 6 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 (C2) (V2) A395800 (C2) (V2) A395810 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 399 www.WorkshopManuals.co.uk Section E Hydraulics Section E 11 - 7 Circuit Descriptions 11 - 7 (C2) (V2) A395820 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 (C2) (V2) A395830 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 400 www.WorkshopManuals.co.uk Section E Hydraulics Section E 11 - 8 Circuit Descriptions 11 - 8 Hose Burst Protection Valve Loader Operation (Cont’d) Operation 3 - Relief Valve If during normal operation the pressure in the ram increases (for example, by the operation of the bucket against an obstacle), increasing pressure in the ram enters the HBPV at C2 and will be sensed on the face of plunger J.
  • Page 401 www.WorkshopManuals.co.uk Section E Section E Hydraulics 15 - 1 Fault Finding 15 - 1 Hydraulic System Introduction - Fixed Flow The purpose of this section is to help you trace hydraulic faults to a faulty unit (valve, actuator, ram etc). Once you Fault Finding Contents have t rac ed t he f ault y unit , ref er t o t he ap p ro p riat e dismantling, inspecting and test instructions given elsewhere...
  • Page 402 www.WorkshopManuals.co.uk Section E Section E Hydraulics 15 - 2 Fault Finding 15 - 2 Fault Probable Cause Action All hydraulic rams slow to operate. Neutral circuit or low pressure Check pipe lines and replace as required. lines leaking, damaged, trapped or kinked.
  • Page 403 www.WorkshopManuals.co.uk Section E Section E Hydraulics 15 - 3 Fault Finding 15 - 3 Fault Probable Cause Action A spool is sticking. Oil temperature abnormally high. Check for correct fluid, see Lubricants and Capacities. Check oil cooler and grille for blockage. The hydraulic fluid is dirty.
  • Page 404 www.WorkshopManuals.co.uk Section E Section E Hydraulics 15 - 4 Fault Finding 15 - 4 Fault Probable Cause Action Hydraulic oil becomes too hot Oil cooler obstructed Remove debris from cooler fins Restriction in neutral circuit Check hoses, replace as necessary lines Hydraulic filter clogged and Change hydraulic filter...
  • Page 405 www.WorkshopManuals.co.uk Section E Section E Hydraulics 15 - 10 Fault Finding 15 - 10 Hydraulic System Introduction - Variable Flow This section details the possible faults that may be found with the loader and backhoe valve blocks. The faults listed Fault Finding Contents only appertain to valve blocks fitted on variable flow hydraulic machine systems (Rexroth valves).
  • Page 406 www.WorkshopManuals.co.uk Section E Section E Hydraulics 15 - 11 Fault Finding 15 - 11 PROBLEM: Leaks between sections. POSSIBLE CAUSE: 1) Missing or cut seals. CORRECTIVE ACTION: 1) Disassemble valve stack and check for missing or cut o-rings. PROBLEM: Sticking spool. POSSIBLE CAUSE: 1) Linkage binding.
  • Page 407 www.WorkshopManuals.co.uk Section E Hydraulics Section E 15 - 12 Fault Finding 15 - 12 Smooth Ride System Fault Probable Cause Action Unable to power down loader arms Rod side solenoid valve open. Check if solenoid operating, replace with system switched OFF. solenoid or selector valve as required.
  • Page 408 www.WorkshopManuals.co.uk Section E Hydraulics Section E 20 - 1 Service Procedures 20 - 1 Hydraulic Contamination Hydraulic Fluid Quality Contaminant Standards Construction machinery uses a large volume of fluid in the Dirt that damages your system is in many cases too small to hyd raulic syst em for p ow er t ransmission, eq uip ment be seen with the eye.
  • Page 409 www.WorkshopManuals.co.uk Section E Section E Hydraulics 21 - 1 Service Procedures 21 - 1 A396190 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 410 www.WorkshopManuals.co.uk Section E Section E Hydraulics 21 - 2 Service Procedures 21 - 2 Fixed Flow Pumps Fitting Pump section 1 - disconnect hose C from the Flow and Pressure Testing pump. Fit the flow meter and load valve (see Note 2) between hose C and the pump.
  • Page 411 www.WorkshopManuals.co.uk Section E Hydraulics Section E 22 - 1 Service Procedures 22 - 1 Variable Flow Pumps Flow and Pressure Testing S315770 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 412 www.WorkshopManuals.co.uk Section E Hydraulics Section E 22 - 2 Service Procedures 22 - 2 Variable Flow Pumps Flow and Pressure Testing Load Sensing Pressure Stand-by Pressure With no services operating, there should be no pressure in With the engine switched off, the pump swashplate is spring the load sense line, this is because hydraulic oil flows loaded to the full flow position.
  • Page 413 www.WorkshopManuals.co.uk Section E Hydraulics Section E 22 - 3 Service Procedures 22 - 3 Variable Flow Pumps Flow and Pressure Testing (Cont’d) Connect a 0 - 400 bar (0 - 6000 lbf/in ) pressure gauge Maximum Hydraulic Stall to pressure test connector B located on the pump pressure out line.
  • Page 414 www.WorkshopManuals.co.uk Section E Hydraulics Section E 22 - 4 Service Procedures 22 - 4 Variable Flow Pumps Flow and Pressure Testing (Cont’d) Pump Flow Load Sense Line Flow It is not possible to test full pump flow at system pressure The load sense line communicates the load pressure whilst the pump is installed on the machine.
  • Page 415 www.WorkshopManuals.co.uk Section E Hydraulics Section E 22 - 5 Service Procedures 22 - 5 Variable Flow Pumps Regulator Valve Adjustment Note: If a new regulator valve is fitted, or a valve stripped, cleaned and rebuilt, then the pressure spool should be backed off to a low pressure.
  • Page 416 www.WorkshopManuals.co.uk Section E Hydraulics Section E 22 - 6 Service Procedures 22 - 6 Variable Flow Pumps Regulator Valve Adjustment (Cont’d) The load sense system is a dynamic type, which means a small flow (0.22 t o 1.1 gall/ 1 t o 5 lit re p er minut e) is circulated through the load sense line.
  • Page 417 Examine the seal running area (driveshaft and housing) for wear or damage. Damage in these areas will require the pump to be further dismantled. Lubricate the new seal with JCB Special MPL Moly Grease. Install the new seal, it is advisable to use a tube or similar located over the driveshaft to ensure the seal enters the housing evenly.
  • Page 418 www.WorkshopManuals.co.uk Section E Hydraulics Section E 22 - 8 Service Procedures 22 - 8 Variable Flow Pumps Shuttle Valve Signal Network - Testing The shuttle network can be easily checked. Start the engine and operate the hydraulic system until the oil is at working temperature.
  • Page 419 www.WorkshopManuals.co.uk Section E Hydraulics Section E 23 - 1 Service Procedures 23 - 1 Loader Valve - Pressure Testing Main Relief Valve (M.R.V.) Make sure that the hydraulic oil is at working temperature, i.e. 50° C (122° F). Lower the backhoe bucket and loader shovel to rest on the ground;...
  • Page 420 www.WorkshopManuals.co.uk Section E Hydraulics Section E 23 - 2 Service Procedures 23 - 2 Loader Valve - Pressure Testing Unloader Valve Make sure that the hydraulic oil is at working temperature, i.e. 50° C (122° F). Lower the backhoe bucket and loader shovel to rest on the ground;...
  • Page 421 www.WorkshopManuals.co.uk Section E Hydraulics Section E 23 - 3 Service Procedures 23 - 3 Loader Valve - Pressure Testing Hydraulic Speed Control (HSC) The following procedure can be used to establish if the hydraulic speed control facility is working correctly. Make sure that the hydraulic oil is at working temperature, i.e.
  • Page 422 www.WorkshopManuals.co.uk Section E Hydraulics Section E 23 - 5 Service Procedures 23 - 5 Loader Valve - Pressure Testing Auxiliary Relief Valves - Using Hand Pump To pressure test and re-set the auxiliary relief valves (A.R.V.'s), service kit 892/00309 must be used. The service kit comprises;...
  • Page 423 Connect a hydraulic hand pump to port 'P' (pump) of S162570F the test block 1. Make sure that the hand pump is filled with JCB Hydraulic fluid. Connect a 0 to 400 bar (0 to 6000 lbf/in ) pressure test gauge to port 'G' (gauge) of the test block 1.
  • Page 424 www.WorkshopManuals.co.uk Section E Hydraulics Section E 23 - 7 Service Procedures 23 - 7 Auxiliary Relief Valves - Using Hand Pump Use the hand pump to raise approximately 172 bar (2500 lbf/in ) pressure at the valve inlet. Note: Raising the pressure at the valve inlet locks the anti- cavitation cone C onto its seat, this allows the A.R.V.
  • Page 425 www.WorkshopManuals.co.uk Section E Hydraulics Section E 23 - 8 Service Procedures 23 - 8 Auxiliary Relief Valves - Using Hand Pump When the correct A.R.V. setting has been attained, release the pressure in the test block. Remove the A.R.V. sub-assembly and its setting body from the test block.
  • Page 426 www.WorkshopManuals.co.uk Section E Hydraulics Section E 23 - 9 Service Procedures 23 - 9 Excavator Valve - Pressure Testing Auxiliary Relief Valves - Using Hand Pump The auxiliary relief valves found in the backhoe valve block are identical in design to those found in the loader valve block.
  • Page 427 www.WorkshopManuals.co.uk Section E Hydraulics Section E 23 - 10 Service Procedures 23 - 10 Excavator Valve - Precision Control (Servo) (Machines up to serial no. 931159) Pressure Testing Load Sense Drain Regulator and Relief Valve Make sure that the hydraulic oil is at working temperature, i.e.
  • Page 428 www.WorkshopManuals.co.uk Section E Hydraulics Section E 23 - 11 Service Procedures 23 - 11 Excavator Valve - Precision Control (Servo) (Machines from January 2003) Pressure Testing Load Sense Relief Valve 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 429 www.WorkshopManuals.co.uk Section E Hydraulics Section E 23 - 12 Service Procedures 23 - 12 Excavator Valve - Precision Control (Servo) Pressure Compensator Network - Testing The pressure compensator valve network can be easily checked as follows: Start the engine and operate the hydraulic system until the oil is at working temperature.
  • Page 430 www.WorkshopManuals.co.uk Section E Hydraulics Section E 24 - 1 Service Procedures 24 - 1 Ram Creep Tests - All Services If ram creep is suspected the following procedures must be 3 Operate the rams to ensure they are full of hot oil. carried out to define if the leakage is within tolerance.
  • Page 431 www.WorkshopManuals.co.uk Section E Hydraulics Section E 24 - 2 Service Procedures 24 - 2 B Test Cylinder/Piston Leakage C Test Spool Leakage 1 Ensure that the oil temperature is at 50° C (122° F) by Note: The following procedure applies only to services fitted using the hydraulic oil temperature probe detailed in A1.
  • Page 432 www.WorkshopManuals.co.uk Section E Hydraulics Section E 24 - 3 Service Procedures 24 - 3 Table 1 Cylinder Total Displacement - mm/10 minutes @ Dia. (mm) Dia. (mm) 69 bar 138 bar 207 bar (1000 lb/in (2000 lb/in (3000 lb/in HEAD SIDE Backhoe S/shift Jack Leg Knuckle...
  • Page 433 www.WorkshopManuals.co.uk Section E Hydraulics Section E 24 - 4 Service Procedures 24 - 4 EXAMPLE - Boom Ram110 x 60 Using the figures given in the table on page 3, plot a graph for the ram to be tested. Check the pressure in the ram (induced by the applied load).
  • Page 434 www.WorkshopManuals.co.uk Section E Hydraulics Section E 24 - 5 Service Procedures 24 - 5 PRESSURE (BAR) 380220 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 435 www.WorkshopManuals.co.uk Section E Hydraulics Section E 25 - 1 Service Procedures 25 - 1 Quick Release Couplings - Connecting and Disconnecting ! WARNING Flat face quick release couplings allow the operator to Hydraulic fluid at pressure can injure you. M ake the remove and install attachments swiftly and efficiently.
  • Page 436 www.WorkshopManuals.co.uk Section E Section E Hydraulics 26 - 1 Service Procedures 26 - 1 Smooth Ride System Charging/Discharging the Accumulator Discharging Charging Park the machine on level ground, lower the loader Park the machine on level ground, lower the loader arms, switch off the engine and chock all four wheels.
  • Page 437 www.WorkshopManuals.co.uk Section E Section E Hydraulics 27 - 1 Service Procedures 27 - 1 Hose Burst Protection Valves The hose burst protection valves (if fitted) prevent the loader or backhoe falling in the event of a hose burst. These valves may be fitted on rams which raise or lower the loader arms, the boom or the dipper.
  • Page 438 www.WorkshopManuals.co.uk Section E Section E Hydraulics 27 - 2 Service Procedures 27 - 2 Hose Burst Protection Valves Pressure Testing - Loader Lift Ram The following text describes the pilot valve setting procedures and pressure testing sequences for ONE HBPV only, repeat the procedures for BOTH loader arm lift rams.
  • Page 439 www.WorkshopManuals.co.uk Section E Section E Hydraulics 27 - 3 Service Procedures 27 - 3 Hose Burst Protection Valves Pressure Testing - Loader Lift Ram (continued) Relief Valve Pressure Test If the hose burst protection valve has been stripped and cleaned, then pre-set the valve as detailed in step 1. The pressure test procedure is described in steps 2 to 6.
  • Page 440 Clean off all traces of gasket compound from the pump The following Procedure describes removal and replacement and gearbox mounting faces. Apply a thin bead of JCB of a double section pump, follow the same procedure for Multigasket to the gearbox mounting face.
  • Page 441 www.WorkshopManuals.co.uk Section E Hydraulics Section E 31 - 1 Main Pump 31 - 1 S401450 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 442 www.WorkshopManuals.co.uk Section E Hydraulics Section E 31 - 2 Main Pump 31 - 2 Fixed Flow Dismantling and Assembly Discard O-ring 31. Before removing and dismantling the pump, check flow and pressure. If either of these are low the pump must be Remove all sealant from the contact faces of the changed.
  • Page 443 www.WorkshopManuals.co.uk Section E Hydraulics Section E 31 - 3 Main Pump 31 - 3 S401450 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 444 Fit O-ring 18 into end cover 9. Fit shaft seals 22 into mounting flange 19, making sure Ap p ly a small amount of JCB M ult igasket t o t he the seal lips are the correct way round as noted in exposed face of rear body 6 (i.e.
  • Page 445 www.WorkshopManuals.co.uk Section E Hydraulics Section E 35 - 1 Main Pump 35 - 1 Variable Flow Dismantling and Assembly S272610 9 17 S213160 S272640 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 446 If a new All the ‘O’ rings, seals and bearings are available in a kit form bearing is installed a preload adjustment is required: from your JCB Distributor. Preload Adjustment: Dismantling Install a setting shim of known thickness (as shown at Refer also to Service Procedures, Variable Flow Pumps - A).
  • Page 447 Note: All hydraulic adapters that are installed together with the control cable D (if fitted). Undo the lock nut E. Undo a bonded sealing washer must also have JCB Threadseal the housing fixing screws and slide it down the cable.
  • Page 448 www.WorkshopManuals.co.uk Section E Hydraulics Section E 50 - 6 Loader Valve - Fixed Flow 50 - 6 S262710 S262720 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 449 Renew all 'O' rings and back-up rings. For assembly the sequence should be reversed. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. The following points MUST be avoided when dismantling...
  • Page 450 www.WorkshopManuals.co.uk Section E Hydraulics Section E 50 - 8 Loader Valve - Fixed Flow 50 - 8 S197420 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 451 Renew all 'O' rings and back-up rings. The numerical sequence shown on the illustration is intended as a guide to dismantling. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. For assembly the sequence should be reversed.
  • Page 452 www.WorkshopManuals.co.uk Section E Hydraulics Section E 50 - 10 Loader Valve - Fixed Flow 50 - 10 S197430 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 453 The numerical sequence shown on the illustration is intended Renew all 'O' rings and back-up rings. as a guide to dismantling. Lubricate parts with JCB Hydraulic Fluid before assembling. For assembly the sequence should be reversed. Make sure that all the parts move freely.
  • Page 454 www.WorkshopManuals.co.uk Section E Hydraulics Section E 50 - 12 Loader Valve - Fixed Flow 50 - 12 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 455 JCB Cleaner/Degreaser, leave it for 10 minutes then apply a small quantity of JCB Threadlocker and Sealer Care must b e t aken t o ensure t hat t he sp ool 8 is not to the threads of the spool.
  • Page 456 www.WorkshopManuals.co.uk Section E Hydraulics Section E 50 - 14 Loader Valve - Fixed Flow 50 - 14 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 457 JCB Cleaner/Degreaser, leave it for 10 minutes or seal grooves, for instance, item 4, which is a wiper seal then apply a small quantity of JCB Threadlocker and and is a press fit in the counterbore. Sealer to the threads of the spool.
  • Page 458 www.WorkshopManuals.co.uk Section E Hydraulics Section E 50 - 16 Loader Valve - Fixed Flow 50 - 16 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 459 JCB Cleaner/Degreaser, leave it for 10 minutes Use tool 992/10100 to hold the spool, remove circlip 13 and then apply a small quantity of JCB Threadlocker and 'clapper' 14. Unscrew spool end 15 and remove spring 17 Sealer to the threads of the spool.
  • Page 460 www.WorkshopManuals.co.uk Section E Hydraulics Section E 50 - 24 Loader Valve - Fixed Flow 50 - 24 A402610 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 461 www.WorkshopManuals.co.uk Section E Hydraulics Section E 50 - 25 Loader Valve - Fixed Flow 50 - 25 Dismantling and Assembly Bolt on Auxiliary Spool Section Body and Spool The numerical sequence shown on the illustration is intended Torque Settings as a guide to dismantling. Item kgf m lbf ft...
  • Page 462 www.WorkshopManuals.co.uk Section E Hydraulics Section E 50 - 26 Loader Valve - Fixed Flow 50 - 26 A402630 S402620 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 463 When Assembling Renew all 'O' rings and back-up rings. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. Make sure that the ‘O’ rings and back-up rings are fitted the correct way, items 13, 14 and 19, 20.
  • Page 464 www.WorkshopManuals.co.uk Section E Hydraulics Section E 51 - 1 Loader Valve - Fixed Flow 51 - 1 Dismantling and Assembly Precision Control (Servo) (Machines from January 2003) 8B 8C A403910 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 465 Excavator Valve, Dismantling damaged. and Assembly - Auxiliary Relief Valves (ARV’s). Lubricate parts with JCB Hydraulic Fluid before Pressure Compensator Valves assembling. Make sure that all the parts move freely. Each of the pressure compensator valves 11 can be removed as shown.
  • Page 466 www.WorkshopManuals.co.uk Section E Section E Hydraulics 51 - 3 Loader Valve - Fixed Flow 51 - 3 Dismantling and Assembly Precision Control (Servo) (Machines from January 2003) Standard Spool A403690 A403950 A403990 A404060 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 467 Clean the valve components in an appropriate solvent. Disconnect the control rod linkage from the spool Lubricate parts with JCB Hydraulic Fluid before tongue. assembling. Make sure that all the parts move freely. Remove the screws 1, boot 2 and plate 3.
  • Page 468 www.WorkshopManuals.co.uk Section E Section E Hydraulics 51 - 5 Loader Valve - Fixed Flow 51 - 5 Dismantling and Assembly Precision Control (Servo) (Machines from January 2003) Electric Detent Spool A403970 A404070 A404060 A404000 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 469 Clean the valve components in an appropriate solvent. Disconnect the control rod linkage from the spool Lubricate parts with JCB Hydraulic Fluid before tongue. assembling. Make sure that all the parts move freely. Remove the screws 1, boot 2 and plate 3.
  • Page 470 www.WorkshopManuals.co.uk Section E Section E Hydraulics 51 - 7 Loader Valve - Fixed Flow 51 - 7 Dismantling and Assembly Precision Control (Servo) (Machines from January 2003) Mechanical Detent Spool A403980 A404080 A404060 A404010 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 471 Clean the valve components in an appropriate solvent. Disconnect the control rod linkage from the spool Lubricate parts with JCB Hydraulic Fluid before tongue. assembling. Make sure that all the parts move freely. Remove the screws 1, boot 2 and plate 3.
  • Page 472 Note: All hydraulic adapters that are installed together with a INT-3-1-11/1 bonded sealing washer must also have sealant (JCB Threadseal) applied to the threads of the adapter. Removal Operate the valve block levers back and forth to vent residual pressure.
  • Page 473 www.WorkshopManuals.co.uk Section E Hydraulics Section E 55 - 2 Loader Valve - Variable Flow 55 - 2 Dismantling and Assembly Priority Inlet Section S276050 A276060 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 474 Renew all 'O' rings and back-up rings. The numerical sequence shown on the illustration is intended as a guide to dismantling. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. For assembly the sequence should be reversed.
  • Page 475 www.WorkshopManuals.co.uk Section E Hydraulics Section E 55 - 4 Loader Valve - Variable Flow 55 - 4 Dismantling and Assembly Auxiliary Spool S276070 A276080 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 476 The numerical sequence shown on the illustration is intended as a guide to dismantling. When fitting bolt 14, clean the threads then apply a small quantity of JCB Threadlocker & Sealer to the threads of the For assembly the sequence should be reversed. spool.
  • Page 477 www.WorkshopManuals.co.uk Section E Hydraulics Section E 55 - 6 Loader Valve - Variable Flow 55 - 6 Dismantling and Assembly Loader Shovel Spool S276140 A276150 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 478 Inspect gasket 14, replace with a new one if required. O-ring O-ring When fitting coupling 22, clean the threads then apply a O-ring small quantity of JCB Threadlocker & Sealer to the threads Primary shuttle housing of the spool. Shuttle plug assembly Ball bearing Check the operation of the solenoid 12 after assembly by connecting a 12V supply .
  • Page 479 www.WorkshopManuals.co.uk Section E Hydraulics Section E 55 - 8 Loader Valve - Variable Flow 55 - 8 Dismantling and Assembly Loader Lift Spool A276120 S276110 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 480 The numerical sequence shown on the illustration is intended as a guide to dismantling. When fitting coupling 20, clean the threads then apply a small quantity of JCB Threadlocker & Sealer to the threads For assembly the sequence should be reversed. of the spool.
  • Page 481 Fitting Spool Seal Use the procedure described below to correctly install the valve spool seals: Lubricate the spool, bore and O-ring groove with JCB Hydraulic Fluid. Move the spool to the position shown and then install the O-ring A in its groove.
  • Page 482 Note: All hydraulic adapters that are installed together with position when refitting. a bonded sealing washer must also have JCB Threadseal applied to the threads of the adapter. Loosen nuts B - do not completely remove the retaining nuts.
  • Page 483 www.WorkshopManuals.co.uk Section E Hydraulics Section E 60 - 4 Excavator Valve 60 - 4 Removal and Replacement Variable Flow S278930 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 484 Operate the valve block levers back and forth to vent Note: All hydraulic adapters that are installed together with a residual pressure. bonded sealing washer must also have JCB Threadseal applied to the threads of the adapter. Remove the hose guide A (this makes access to the valve block easier).
  • Page 485 www.WorkshopManuals.co.uk Section E Section E Hydraulics 60 - 6 Excavator Valve 60 - 6 A402450 A402460 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 486 www.WorkshopManuals.co.uk Section E Section E Hydraulics 60 - 7 Excavator Valve 60 - 7 Removal and Replacement Precision Control (Servo) Disconnect the stabiliser spool control cables 3 as follows: DANGER Undo the lock nut 4. Hydraulic fluid at system pressure can injure you. Before Undo the housing retaining screws 5 and slide the disconnecting or connecting hydraulic hoses, stop the housing down the cable.
  • Page 487 www.WorkshopManuals.co.uk Section E Section E Hydraulics 60 - 8 Excavator Valve 60 - 8 A402450 A402460 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 488 www.WorkshopManuals.co.uk Section E Section E Hydraulics 60 - 9 Excavator Valve 60 - 9 Removal and Replacement (Cont’d) Precision Control (Servo) Replacement Replacement is a reversal of the removal sequence. Hoses and pipes (when applicable) must be re-connected and phased in same position as removal. ! WARNING Fine jets of hydraulic fluid at high pressure can penetrate the skin.
  • Page 489 www.WorkshopManuals.co.uk Section E Section E Hydraulics 61 - 1 Excavator Valve 61 - 1 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 490 Renew 'O' ring 21 and seal 20. Make sure the 'O' ring and wiper seal are not trapped or damaged. Lubricate new seals with JCB Hydraulic Fluid and take care to prevent them from being damaged by the sharp edges of 10 Fit seal 20 and seal plate 19 to the valve block section.
  • Page 491 www.WorkshopManuals.co.uk Section E Section E Hydraulics 61 - 3 Excavator Valve 61 - 3 Auxiliary Relief Valves 4L 4J 4K 4H A401470 A401470 S161700 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 492 Discard old and worn O-rings and back-up rings. Assembly Renew all O-rings and back-up rings. Lubricate O-rings and back-up rings with JCB Hydraulic Fluid. Fit back-up ring 13 on the upper side of 'O' ring 12 as shown in the inset.
  • Page 493 2, 2A, 4, 6, 10 and 14. Fit seal 2A with the recess towards ‘O’ ring 2, as shown at A. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.
  • Page 494 SLEW SLEW CROWD S270740 DIPPER SLEW BOOM STABILISER ISO EXCAVATOR VALVE CROWD DIPPER STABILISER BOOM SLEW CLAMP BOOM BOOM DIPPER DIPPER CROWD CROWD SLEW SLEW S270750 CROWD BOOM SLEW DIPPER STABILISER JCB EXCAVATOR VALVE 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 495 (when applicable) must be re-connected and phased in same position as removal. STABILISER DIPPER CROWD BOOM SLEW STABILISER S273370 CROWD BOOM DIPPER SLEW ISO EXCAVATOR VALVE DIPPER BOOM CROWD STABILISER SLEW STABILISER CROWD S273380 DIPPER SLEW BOOM JCB EXCAVATOR VALVE 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 496 www.WorkshopManuals.co.uk Section E Hydraulics Section E 62 - 1 Excavator Valve 62 - 1 (B) (B) (G) (G) A402500 A402510 A402600 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 497 0.8 - 1.1 6 - 8 58 - 72 6 - 7.3 43 - 53 Lubricate new seals with JCB Hydraulic Fluid and take care 58 - 72 6 - 7.3 43 - 53 to prevent them from being damaged by the sharp edges of 58 - 72 6 - 7.3...
  • Page 498 www.WorkshopManuals.co.uk Section E Section E Hydraulics 62 - 3 Excavator Valve 62 - 3 A402640 9803/3280 Issue 3* Purchased from www.WorkshopManuals.co.uk...
  • Page 499 When Assembling Renew all 'O' rings and back-up rings. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. Make sure that the ‘O’ rings and back-up rings are fitted the correct way, items 7 and 8.
  • Page 500 Renew components as required. Assembly Renew all 'O' rings. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. Ensure that the small drilling C in the piston 3 is clear. Do not over-tighten the solenoid assembly, it may affect the...
  • Page 501 www.WorkshopManuals.co.uk Section E Hydraulics Section E 62 - 20 Excavator Valve 62 - 20 Dismantling and Assembly Precision Control (Servo) (Machines from January 2003) A403840 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 502 Make sure the ‘O’ ring seals are not trapped or damaged. Anti-cavitation Valve The dismantling and assembly procedures for the Lubricate parts with JCB Hydraulic Fluid before anticavitation valve 11 are detailed separately, refer to Anti- assembling. Make sure that all the parts move freely. cavitation Valve.
  • Page 503 Clean the valve components in an appropriate solvent. Renew all 'O' rings and back-up rings. Flow Regulator Valve Lubricate parts with JCB Hydraulic Fluid before Removal assembling. Make sure that all the parts move freely. It is possible to remove a valve without removing the Be sure to fit filter gauze 5 the correct way round.
  • Page 504 Clean the valve components in an appropriate solvent. Renew all 'O' rings and back-up rings. Load Sense Relief Valve Lubricate parts with JCB Hydraulic Fluid before Removal assembling. Make sure that all the parts move freely. It is possible to remove a valve without removing the Adjust the pressure setting as required.
  • Page 505 Clean the valve components in an appropriate solvent. Renew all 'O' rings and back-up rings. Auxiliary Relief Valves (ARV’s) Lubricate parts with JCB Hydraulic Fluid before Removal assembling. Make sure that all the parts move freely. It is possible to remove a valve without removing the Adjust the pressure setting as required.
  • Page 506 Clean the valve components in an appropriate solvent. Renew all 'O' rings and back-up rings. Anti-cavitation Valve Lubricate parts with JCB Hydraulic Fluid before Removal assembling. Make sure that all the parts move freely. It is possible to remove a valve without removing the excavator valve block from the machine.
  • Page 507 www.WorkshopManuals.co.uk Section E Hydraulics Section E 70 - 1 Hose Burst Protection Valves 70 - 1 Removal and Replacement ! WARNING Disconnect all hydraulic hoses from the HBPV and plug all orifices to prevent ingress of dirt. Label each hose Make the machine safe before working underneath it.
  • Page 508 This procedure applies to Hose Burst Protection Valves Assembly fitted to the loader arm rams ONLY. DO NOT apply JCB Threadlocker and Sealer or any other The numerical sequence shown on the illustration is type of locking fluid to the threads of item 17. The threads intended as a guide to dismantling.
  • Page 509 www.WorkshopManuals.co.uk Section E Hydraulics Section E 70 - 3 Hose Burst Protection Valves 70 - 3 Dismantling and Assembly (Cont’d) - Boom and Dipper Rams This procedure applies to Hose Burst Protection Valves fitted to the boom/dipper rams ONLY. There is no servicing permitted on this valve apart from the removing and fitting a new check valve assembly A when the seal B has been broken.
  • Page 510 www.WorkshopManuals.co.uk Section E Section E Hydraulics 75 - 1 Hydraulic Rams 75 - 1 Removal and Replacement - Loader Lift Ram S266330 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 511 www.WorkshopManuals.co.uk Section E Section E Hydraulics 75 - 2 Hydraulic Rams 75 - 2 Removal and Replacement - Loader Lift Ram Removal Replacement ! WARNING Replacement is a reversal of the removal sequence. The loader arm interlevers are potentially dangerous, when pivoting about their centre they form a 'scissor' ! WARNING point with the loader arm.
  • Page 512 www.WorkshopManuals.co.uk Section E Section E Hydraulics 76 - 1 Hydraulic Rams 76 - 1 Removal and Replacement - Loader Shovel Ram S266340 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 513 www.WorkshopManuals.co.uk Section E Section E Hydraulics 76 - 2 Hydraulic Rams 76 - 2 Removal and Replacement - Loader Shovel Ram Removal Replacement ! WARNING Replacement is a reversal of the removal sequence. The loader arm interlevers are potentially dangerous, when pivoting about their centre they form a 'scissor' ! WARNING point with the loader arm.
  • Page 514 www.WorkshopManuals.co.uk Section E Section E Hydraulics 77 - 1 Hydraulic Rams 77 - 1 Removal and Replacement - Slew Ram S254901 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 515 www.WorkshopManuals.co.uk Section E Section E Hydraulics 77 - 2 Hydraulic Rams 77 - 2 Removal and Replacement - Slew Ram Removal Inspection Slew the backhoe to the left to remove the right hand Inspect the liner bearings 7 (located in the trunnion retaining slew ram and visa versa.
  • Page 516 www.WorkshopManuals.co.uk Section E Section E Hydraulics 78 - 1 Hydraulic Rams 78 - 1 S271860 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 517 www.WorkshopManuals.co.uk Section E Section E Hydraulics 78 - 2 Hydraulic Rams 78 - 2 Removal and Replacement - Stabiliser Ram (Sideshift) Removal Replacement Park the machine on firm level ground, engage the Replacement is a reversal of the removal sequence. parking brake and set the transmission to neutral.
  • Page 518 www.WorkshopManuals.co.uk Section E Section E Hydraulics 78 - 3 Hydraulic Rams 78 - 3 Removal and Replacement - Stabiliser Ram (Centremount) Removal Replacement Park the machine on firm level ground, engage the Replacement is a reversal of the removal sequence. parking brake and set the transmission to neutral.
  • Page 519 www.WorkshopManuals.co.uk Section E Section E Hydraulics 79 - 1 Hydraulic Rams 79 - 1 Removal and Replacement - Dipper Ram S266350 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 520 www.WorkshopManuals.co.uk Section E Section E Hydraulics 79 - 2 Hydraulic Rams 79 - 2 Removal and Replacement - Dipper Ram Removal Replacement Park the machine on firm level ground, engage the Replacement is a reversal of the removal sequence. parking brake and set the transmission to neutral. ! WARNING Lower the backhoe and loader end to the ground and stop the engine.
  • Page 521 www.WorkshopManuals.co.uk Section E Section E Hydraulics 80 - 1 Hydraulic Rams 80 - 1 Removal and Replacement - Bucket Crowd Ram S266360 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 522 www.WorkshopManuals.co.uk Section E Section E Hydraulics 80 - 2 Hydraulic Rams 80 - 2 Removal and Replacement - Bucket Crowd Ram Removal Replacement Park the machine on firm level ground, engage the Replacement is a reversal of the removal sequence. parking brake and set the transmission to neutral.
  • Page 523 www.WorkshopManuals.co.uk Section E Section E Hydraulics 81 - 1 Hydraulic Rams 81 - 1 Removal and Replacement - Boom Ram S266370 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 524 www.WorkshopManuals.co.uk Section E Section E Hydraulics 81 - 2 Hydraulic Rams 81 - 2 Removal and Replacement - Boom Ram Removal Replacement Park the machine on firm level ground, engage the Replacement is a reversal of the removal sequence. parking brake and set the transmission to neutral. ! WARNING Lower the backhoe and loader end to the ground and stop the engine.
  • Page 525 www.WorkshopManuals.co.uk Section E Section E Hydraulics 85 - 1 Hydraulic Rams 85 - 1 s263650 TYPICAL RAM ASSEMBLY Note that on boom and bucket rams, pivot pin grease seals are fitted. A263680 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 526 Apply JCB Activator to threads of end cap and cylinder. bench as shown. Allow Activator to dry for 15 minutes before bringing into c ont ac t w it h t he JCB Thread loc ker and Sealer (High Strength). Note: Neither the JCB Threadlocker and Sealer (High Strength) nor Activator must be allowed to contact seals, bearing rings, or 'O' rings.
  • Page 527 Position cylinder on bench and install rod assembly into cylinder. A263750 Apply JCB Threadlocker and Sealer (High Strength) to first (all dimensions in mm) three threads of cylinder, torque tighten the end cap to 678 Nm (500 lbf ft).
  • Page 528 www.WorkshopManuals.co.uk Section E Section E Hydraulics 86 - 1 Hydraulic Rams 86 - 1 S263740 S263730 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 529 Apply JCB Activator to threads of end cap and cylinder. Allow Activator to dry for 15 minutes before bringing into c ont ac t w it h t he JCB Thread loc ker and Sealer (High Strength). Note: Neither the JCB Threadlocker and Sealer (High...
  • Page 530 Position cylinder on bench and install rod assembly into (all dimensions in mm) cylinder. Dowel Guide Guide Dowel Dowel Apply JCB Threadlocker and Sealer (High Strength) to first Size Size Drill Ø Drill Drill Ø X Drill three threads of cylinder, torque tighten the end cap to 678...
  • Page 531 www.WorkshopManuals.co.uk Section E Section E Hydraulics 87 - 1 Hydraulic Rams 87 - 1 S263690 S263710 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 532 (e.g. nylon). Allow Activator to dry for 15 minutes before bringing into c ont ac t w it h t he JCB Thread loc ker and Sealer (High Position the piston rod assembly in a vice, use soft jaws and Strength).
  • Page 533 Firmly push the cylinder over the piston head seals. A263750 Apply JCB Threadlocker and Sealer (High Strength) to first three threads of cylinder, torque tighten the cylinder to 678 (all dimensions in mm) Nm (500 lbf ft).
  • Page 534 www.WorkshopManuals.co.uk Section E Hydraulics Section E 88 - 1 Hydraulic Rams 88 - 1 A258580 A258590 322580 A326710 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 535 Apply JCB Activator to threads of the end caps and Carefully inspect the bore of the cylinder and the piston cylinder. Allow Activator to dry for 15 minutes before rod outer diameter for scoring, nicks and burrs.
  • Page 536 Section E 89 - 1 Hydraulic Rams 89 - 1 JCB Ram Sealing Procedure To fit new rod seal: Use seal fitting tool (892/00334) to fit rod seals, the size (diameter) and position of pins A is determined by the diameter and radial width of the rod seal being fitted.
  • Page 537 Section E 89 - 2 Hydraulic Rams 89 - 2 JCB Ram Sealing Procedure (continued) Fit new piston head seals: Use a blunt instrument (892/01027) shown at F, lever the inner seal G into the piston head seal groove, do not let the seal twist.
  • Page 538 www.WorkshopManuals.co.uk Section E Hydraulics Section E 95 - 1 Hydraulic Oil Cooler 95 - 1 Removal and Replacement ! WARNING Replacement Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the Replacement is a reversal of the removal sequence. loader arm safety strut.
  • Page 539 www.WorkshopManuals.co.uk Section E Hydraulics Section E 96 - 1 Smooth Ride System 96 - 1 Accumulator Removal and Replacement Replacement Removal Replacement is a reverse of removal. Park the machine on level ground, lower the loader arms, switch off the engine and chock all four wheels. Charge the accumulator, refer to Service Procedures, Release all hydraulic pressure in the accumulator by Smooth Ride System - Charging/ Discharging the...
  • Page 540 www.WorkshopManuals.co.uk Section E Hydraulics Section E 96 - 2 Smooth Ride System 96 - 2 S308280 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 541 www.WorkshopManuals.co.uk Section E Hydraulics Section E 96 - 3 Smooth Ride System 96 - 3 Accumulator Dismantling and Assembly Assembly Dismantling Coat all internal components with clean hydraulic oil. ! DANGER Before disconnecting or dismantling the accumulator Fit piston seal 9, teflon back up rings 10 and seals 11. discharge all gas pressure.
  • Page 542 www.WorkshopManuals.co.uk Section F Transmission Section F Contents Page No. Service Tools 1 - 1 Technical Data Wheels and Tyres 2 - 1 Axles 3 - 1 Synchro Shuttle Gearbox 4 - 1 Powershift Gearbox - 6 Speed 5 - 1 Powershift Gearbox - 4 Speed 6 - 1 Engine Stall Speed Combinations...
  • Page 543 www.WorkshopManuals.co.uk Section F Transmission Section F Contents Page No. Service Procedures Front Axle - SD55, SD70 Renewing the Pinion Oil Seal 50 - 1 Rear Axle - SD80, PD70 Renewing the Pinion Oil Seal 51 - 1 Brakes - Testing for Piston Seal Leakage 52 - 1 Synchro Shuttle Gearbox Stall Test...
  • Page 544 www.WorkshopManuals.co.uk Section F Transmission Section F Contents Page No. Rear Axle – PD70, SD80 Removal and Replacement 90 - 1 Brakes Dismantling and Assembly 91 - 1 Hub and Driveshaft - SD80 Dismantling and Assembly 92 - 1 Hub and Driveshaft - PD70 Dismantling and Assembly 93 - 1 Drivehead...
  • Page 545 www.WorkshopManuals.co.uk Section F Transmission Section F 1 - 1 Service Tools 1 - 1 892/01077 Synchro Shuttle Gearbox - Selector 892/01078 Synchro Shuttle Gearbox - Mainshaft Shaft Lock Screw Adjuster A395350 A396510 Synchro Shuttle Gearbox - Setting ring socket spanners 892/01079 (Mainshaft setting ring) A396590...
  • Page 546 www.WorkshopManuals.co.uk Section 1 Transmission Section 1 1 - 2 Service Tools 1 - 2 Service Tools (cont'd) 892/00179 Bearing Press (use with appropriate adapters) 892/00812 Drive Coupling Spanner S107750 S188200 992/07608 Bearing Adapter 992/07609 Bearing Adapter 992/07610 Bearing Adapter 992/07611 Bearing Adapter 992/07612 Bearing Adapter...
  • Page 547 www.WorkshopManuals.co.uk Section F Transmission Section F 1 - 3 Service Tools 1 - 3 892/00224 Impulse Extractor Set for Hub Bearing Seals S197070 S261230 Torque Measuring Tool for Wheel Hub Seals Manufacture locally, procedures in this manual show checking the wheel hub seal using a rolling force. However, the torque can be measured using above locally manufactured tool.
  • Page 548 www.WorkshopManuals.co.uk Section F Transmission Section F 1 - 4 Service Tools 1 - 4 992/04000 Torque Multiplier (use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts) S197030 892/00174 Measuring Cup - Pinion Head Bearing 992/04800 Flange Spanner - for locking brake disc flange while pinion nut is slackened or...
  • Page 549 www.WorkshopManuals.co.uk Section F Transmission Section F 1 - 5 Service Tools 1 - 5 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/in :892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in :892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in :892/00254...
  • Page 550 www.WorkshopManuals.co.uk Section F Transmission Section F 1 - 6 Service Tools 1 - 6 A396960 A396930 A396950 A396940 8, 9 A396580 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 551 www.WorkshopManuals.co.uk Section F Transmission Section F 1 - 7 Service Tools 1 - 7 Service Tools (cont'd) Solid Spacer Setting Kit 921/53400 Spacer Kit - Sychro Shuttle Gearbox, Synchro Shuttle Gearbox, SD70, SD80 SD70, SD80 Axles Axles Comprises of: 892/00918 Setting Tool Kit Spacer thickness mm 921/52627...
  • Page 552 www.WorkshopManuals.co.uk Section F Section F Transmission 1 - 8 Service Tools 1 - 8 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.
  • Page 553 www.WorkshopManuals.co.uk Section F Section F Transmission 1 - 9 Service Tools 1 - 9 Service Tools (cont'd) 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.
  • Page 554 www.WorkshopManuals.co.uk Section F Section F Transmission 1 - 10 Service Tools 1 - 10 Service Tools (cont'd) 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.
  • Page 555 www.WorkshopManuals.co.uk Section F Section F Transmission 1 - 11 Service Tools 1 - 11 Service Tools (cont'd) Powershift Gearbox - hydraulic pump removal tools The tools detailed below enable the pump to be removed with the torque converter housing in place. Reaction bar.
  • Page 556 Section F 2 - 1 Technical Data 2 - 1 Tyre Pressures Note: If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures. Front Wheels AWS/4WD MACHINES Item Size x Ply...
  • Page 557 Section F 2 - 2 Technical Data 2 - 2 Tyre Pressures Note: If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures. Rear Wheels AWS MACHINES Item Size x Ply...
  • Page 558 Note: It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle with a different ratio to the axle being replaced. ALL WHEEL STEER MACHINES Type JCB spiral bevel input with epicyclic hub reduction Designation SD70 Installation...
  • Page 559 Note: It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle with a different ratio to the axle being replaced. ALL WHEEL STEER MACHINES Type 3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard braking. Pinion mounted park brake disc. Designation SD80...
  • Page 560 www.WorkshopManuals.co.uk Section F Transmission Section F 4 - 1 Technical Data 4 - 1 Synchro Shuttle Gearbox Description Combined torque converter, reverser, and gearbox unit. Synchromesh manual gear selection. Electro hydraulic selection of forward and reverse. Designation SS700 (4 wheel drive) Weight (dry) * 170 kg (375 lb) * 200 kg (441 lb)
  • Page 561 www.WorkshopManuals.co.uk Section F Transmission Section F 5 - 1 Technical Data 5 - 1 Powershift Gearbox - 6 Speed Description Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft, 6 speed and 4 wheel drive clutch packs giving 6 forward and 4 reverse speeds. Electronically controlled gear selection.
  • Page 562 www.WorkshopManuals.co.uk Section F Transmission Section F 6 - 1 Technical Data 6 - 1 Powershift Gearbox - 4 Speed Description Full electro-hydraulic transmission unit with input, reverse, layshaft, mainshaft and 4 wheel drive clutch packs giving 4 forward and 4 reverse speeds. Designation PS764 (4 wheel drive) Weight (dry)
  • Page 563 www.WorkshopManuals.co.uk Section F Transmission Section F 7 - 1 Technical Data 7 - 1 Engine Stall Speed Combinations The stall speed figures on the following pages are intended as a guide to assist with machine fault diagnosis. The figures relate to tests conducted at an ambient of 25 deg.
  • Page 564 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 565 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 566 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 567 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 568 www.WorkshopManuals.co.uk Front Axle - Steer Drive Type SD55, SD70 Component Identification The illustration shows a typical steer drive front axle. A Yoke connection to propshaft B Pinion C Crownwheel D Differential unit Drive shaft Universal coupling G Reduction gear hub H Steer swivel trunnion bearings Axle pivot K Oil fill and drain plugs...
  • Page 569 www.WorkshopManuals.co.uk Rear Axle - Steer Drive Type SD80 Component Identification The illustration shows a typical steer drive rear axle. 2WS A Park brake disc. The disc is fitted to the pinion instead of a yoke. The propshaft is bolted to the machines are fitted with non steer axles (PD70).
  • Page 570 www.WorkshopManuals.co.uk Synchro Shuttle Gearbox A388431 A396620 Purchased from www.WorkshopManuals.co.uk...
  • Page 571 Synchro Shuttle Gearbox Principle of Operation Component Identification This Illustration shows a typical JCB Syncro Shuttle A Forward/reverse clutch unit which consists of a torque converter, hydraulic B Transmission oil pump reverser unit, and integral manual 4-speed gearbox. C Torque converter pressure regulating valve...
  • Page 572 www.WorkshopManuals.co.uk A A1 Key to Oil Flow & Pressure Full Pressure Pressure Lubrication Exhaust A396520 Purchased from www.WorkshopManuals.co.uk...
  • Page 573 www.WorkshopManuals.co.uk Synchro Shuttle Gearbox Hydraulic and Electrical Operation Solenoid Valve (E) Operation Oil from the pump B is fed through an internal Pressurised oil at the solenoid valve E is used to passage via the filter to the pressure maintenance Forward/reverse clutch unit control the forward/reverse clutches A1 and A2.
  • Page 574 www.WorkshopManuals.co.uk A401080 A401070 Purchased from www.WorkshopManuals.co.uk...
  • Page 575 www.WorkshopManuals.co.uk Powershift Gearbox Component Identification Principle of Operation The J CB Po w ershif t is an elec t ro - hyd raulic Torque converter t ransmission unit . Gear shift ing and d irec t ion Forward/input clutch assembly selection are controlled using multi-disc clutch Reverse clutch assembly packs.
  • Page 576 www.WorkshopManuals.co.uk Section F Transmission Section F 17 - 3 Basic Operation 17 - 3 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 577 www.WorkshopManuals.co.uk Section F Section F Transmission 17 - 4 Basic Operation 17 - 4 Powershift Gearbox 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 4 Speed Powershift converter.
  • Page 578 www.WorkshopManuals.co.uk Section F Transmission Section F 17- 5 Basic Operation 17 - 5 Powershift Gearbox - 6 Speed ShiftMaster Operation Characteristics Central to the system is the ShiftMaster ECU (Electronic Transmission dump Control Unit) A. The unit receives ‘inputs’ from electrical When the operator presses the dump switch the ECU selects devices such as the gear select switch B.
  • Page 579 www.WorkshopManuals.co.uk Section F Transmission Section F 18 - 1 Basic Operation 18 - 1 Powershift Gearbox Drivepaths - 4 Speed 1st GEAR FORWARD (4 wheel drive) Clutches Engaged Solenoids Energised Forward Low Layshaft 2/4 Wheel Drive 2nd GEAR FORWARD (4 wheel drive) Clutches Engaged Solenoids Energised Forward High...
  • Page 580 www.WorkshopManuals.co.uk Section F Transmission Section F 18 - 2 Basic Operation 18 - 2 Powershift Gearbox A396660 A396670 A396690 A396680 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 581 www.WorkshopManuals.co.uk Section F Transmission Section F 18 - 3 Basic Operation 18 - 3 Powershift Gearbox A396710 A396700 A396720 A396730 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 582 www.WorkshopManuals.co.uk Section F Transmission Section F 18 - 4 Basic Operation 18 - 4 Powershift Gearbox Drivepaths - 4 Speed 1st GEAR REVERSE (4 wheel drive) Clutches Engaged Solenoids Energised Reverse Low Layshaft 2/4 Wheel Drive 2nd GEAR REVERSE (4 wheel drive) Clutches Engaged Solenoids Energised Reverse High...
  • Page 583 www.WorkshopManuals.co.uk Section F Transmission Section F 18 - 5 Basic Operation 18 - 5 Powershift Gearbox Drivepaths - 6 Speed 1st GEAR FORWARD (4 wheel drive) Clutches Engaged Solenoids Energised ‘6 Speed’ Layshaft 2/4 Wheel Drive 2nd GEAR FORWARD (4 wheel drive) Clutches Engaged Solenoids Energised Forward Low...
  • Page 584 www.WorkshopManuals.co.uk Section F Transmission Section F 18 - 6 Basic Operation 18 - 6 A387860 A387850 A387870 A387880 A387890 A387900 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 585 www.WorkshopManuals.co.uk Section F Transmission Section F 18 - 7 Basic Operation 18 - 7 A387910 A387920 A387940 A387930 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 586 www.WorkshopManuals.co.uk Section F Transmission Section F 18 - 8 Basic Operation 18 - 8 Powershift Gearbox Drivepaths - 6 Speed 1st GEAR REVERSE (4 wheel drive) Clutches Engaged Solenoids Energised Reverse Low Layshaft 2/4 Wheel Drive 2nd GEAR REVERSE (4 wheel drive) Clutches Engaged Solenoids Energised Reverse High...
  • Page 587 www.WorkshopManuals.co.uk Section F Transmission Section F 20 - 1 Basic Operation 20 - 1 Torque Converter Component Identification Impeller Turbine Reaction member Drive plate Engine flywheel Drive to gearbox input shaft Spline location for reaction member Direct drive from the engine to the gearbox oil pump Direction of oil flow Principle of Operation The torque converter is similar to a fluid coupling, which...
  • Page 588 www.WorkshopManuals.co.uk Section F Transmission Section F 25 - 1 Systems Description 25 - 1 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 589 www.WorkshopManuals.co.uk Section F Transmission Section F 25 - 2 Systems Description 25 - 2 Syncro Shuttle Gearbox Synchromesh (Blocking Pin Type) The gearbox is fitted with ' Blocking Pin' synchromesh, As the speeds are synchronised the radial load on the comprising the following parts.
  • Page 590 www.WorkshopManuals.co.uk Syncro Shuttle Gearbox Forward/Reverse Clutch Operation The forward/reverse clutch unit 1 transfers drive from the input shaft A3 to either gear G1 or gear G2 depending on which of the two clutches (A1 or A2) is engaged, giving forward or reverse drive. When neither clutch is engaged, neutral is selected.
  • Page 591 www.WorkshopManuals.co.uk Syncro Shuttle Gearbox Forward/Reverse Clutch Operation 10 A2 A1 6 A390970 Purchased from www.WorkshopManuals.co.uk...
  • Page 592 www.WorkshopManuals.co.uk Synchro Shuttle Gearbox 2/4 Wheel Drive Clutch Operation - Pressure ON/Spring OFF Type 4 Wheel Drive Operation 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.
  • Page 593 www.WorkshopManuals.co.uk Synchro Shuttle Gearbox 2/4 Wheel Drive Clutch Operation - Pressure ON/Spring OFF Type (cont’d) 2 Wheel Drive Operation Because there is no pressure behind piston C, the When the switch is in the 2 wheel drive position, friction/counter plates of clutch pack B now freely solenoid valve A is de-energised.
  • Page 594 www.WorkshopManuals.co.uk Synchro Shuttle Gearbox 2/4 Wheel Drive Clutch Operation - Spring ON/Pressure OFF Type 4 Wheel Drive Operation Because there is no pressure behind piston C, the This clutch is of the ‘Spring-ON (4WD)/Pressure- clutch friction/counter plates of clutch pack B are OFF (2WD)’...
  • Page 595 www.WorkshopManuals.co.uk Synchro Shuttle Gearbox 2/4 Wheel Drive Clutch Operation - Spring ON/Pressure OFF Type (cont’d) 2 Wheel Drive Operation When the switch is in the 2 wheel drive position, Because there spring force, solenoid valve A is energised. The energised friction/counter plates of clutch pack B now freely solenoid A1 causes the valve spool to move and rotate on the output shaft, thus disengaging drive...
  • Page 596 www.WorkshopManuals.co.uk Powershift Gearbox Clutch Operation - Forward, Reverse The forward and reverse clutch units are very similar in † The valve E is shown using symbols. For an explanation of d esign and op erat e in t he sam e w ay. The follow ing how the symbols work, see Section E, Introduction to description refers to one unit and can be applied to either Hydraulic Schematic Symbols.
  • Page 597 www.WorkshopManuals.co.uk Powershift Gearbox Clutch Operation - Forward, Reverse 10 A2 A1 6 A396830 Purchased from www.WorkshopManuals.co.uk...
  • Page 598 www.WorkshopManuals.co.uk Section F Transmission Section F 32 - 1 Electrical Connections 32 - 1 Powershift Gearbox - 4 Speed Introduction This section explains how the electrical system works when the following gearbox functions are operated: 1st, 2nd, 3rd and 4th gears forward Neutral 1st, 2nd, 3rd and 4th gears reverse Transmission dump...
  • Page 599 www.WorkshopManuals.co.uk Section F Transmission Section F 32 - 2 Electrical Connections 32 - 2 Powershift Gearbox - 4 Speed (cont’d) Electrical Connections - Quick Reference The tables show switch positions together with energised Reverse alarm relay and gearbox solenoids for each gearbox function Park brake switch (reverse gears are shown on the next page).
  • Page 600 www.WorkshopManuals.co.uk Section F Transmission Section F 32 - 3 Electrical Connections 32 - 3 Powershift Gearbox - 4 Speed Column Switch FL Relay FG Relay FD2 Relay FE2 Relay FF1 Diode Gate FK Relay FD1 Relay FE1 Relay FF2 Gearbox Gearbox Solenoid function Dump...
  • Page 601 www.WorkshopManuals.co.uk Section F Transmission Section F Electrical Connections 32 - 4 32 - 4 Powershift Gearbox -4 Speed Gearbox Column Switch FL Relay FG Relay FD2 Relay FE2 Relay FF1 Diode Gate FK Relay FD1 Relay FE1 Relay FF2 Gearbox Solenoid function Dump Forward...
  • Page 602 www.WorkshopManuals.co.uk Section F Transmission Section F 32 - 5 Electrical Connections 32 - 5 Powershift Gearbox - 4 Speed (cont’d) Electrical Connections - Quick Reference (cont’d) The tables show switch positions together with energised Reverse alarm relay and gearbox solenoids for each gearbox function. The Park brake switch numbers show which contacts are ‘live’...
  • Page 603 www.WorkshopManuals.co.uk Section F Transmission Section F 32 - 6 Electrical Connections 32 - 6 Powershift Gearbox - 4 Speed (Machines up to 933756) Connectors (h3) î Electrical Connections - Wires and Connectors î Although the system is straight forward in design it is never CCA Fuses the less fairly complex in practice.
  • Page 604 www.WorkshopManuals.co.uk Section F Transmission Section F 32 - 7 Electrical Connections 32 - 7 Powershift Gearbox - 4 Speed Relay Actuation (Machines up to 933756) FD1, FE1 FD1, FE1 934C 884A 600AC 883B 600AD 107AL 858A 600AG 934D 856A 1858A 856B 11 10 11 10...
  • Page 605 www.WorkshopManuals.co.uk Section F Transmission Section F 32 - 8 Electrical Connections 32 - 8 Powershift Gearbox - 4 Speed Gearbox Solenoid Actuation (Machines up to 933756) FF2 FG 852N 852P 852P 107AD 846B 1858 852N 1858D 1858B 812/848 9 10 811/849 9 10 846B...
  • Page 606 www.WorkshopManuals.co.uk Section F Transmission Section F 32 - 9 Electrical Connections 32 - 9 Powershift Gearbox - 4 Speed (cont’d) (Machines up to 933756) Electrical Connections - Wires and Connectors Gearbox Solenoid Actuation For relay activation see previous page. Component Key (solenoid activation): The following key identifies the component connectors on the diagrams opposite.
  • Page 607 www.WorkshopManuals.co.uk Section F Transmission Section F 33 - 1 Electrical Connections 33 - 1 Powershift Gearbox - 6 Speed Introduction This section explains how the Powershift 6 speed The ECU can be connected to diagnostics software loaded (ShiftMaster) electrical system works . on a laptop PC.
  • Page 608 www.WorkshopManuals.co.uk Section F Transmission Section F 33 - 2 Electrical Connections 33 - 2 Powershift Gearbox - 6 Speed ECU Electrical Connections GB1 Feed from GC10 GC3 Speed sensor - GB2 12v Feed input GB4 12v Feed GC4 Output - ‘Z’ solenoid Electrical connections at the ECU are shown in the diagram GB6 Diagnostics connector GC6 Output - ‘U’...
  • Page 609 www.WorkshopManuals.co.uk Section F Transmission Section F 33 - 3 Electrical Connections 33 - 3 Powershift Gearbox - 6 Speed Electrical Connections - Quick Reference Diagram X The tables show live connector pins and also relevant earth The diagram X (opposite) shows the electrical circuit for the destinations for given gearbox functions/systems as follows: gearbox control.
  • Page 610 www.WorkshopManuals.co.uk Section F Transmission Section F 33 - 4 Electrical Connections 33 - 4 Powershift Gearbox - 6 Speed Gearbox FROM PARKBRAKE Relay FG1 Dump Switch NG E.C.U. GB function WARNING LIGHT A - B (MB1) 3 - 5, 1 - 2 TRANSMISSION DUMP TO NEUTRAL FROM IGNITION...
  • Page 611 www.WorkshopManuals.co.uk Section F Transmission Section F 33 - 5 Electrical Connections 33 - 5 Powershift Gearbox - 6 Speed Electrical Connections - Quick Reference Diagram X FROM PARKBRAKE WARNING LIGHT The tables show live connector pins and also relevant earth The diagram X (opposite) shows the electrical circuit for the destinations for given gearbox functions/systems as follows: gearbox control.
  • Page 612 www.WorkshopManuals.co.uk Section F Transmission Section F 33 - 6 Electrical Connections 33 - 6 Gearbox Column Switch FL E.C.U. GB E.C.U. GC Solenoid Connector Gearbox Solenoid Gearbox Column Switch FL E.C.U. GB function (Inputs) (Outputs) function Labelled NEUTRAL 7 - 6 1st GEAR 14 - 12 4 (Z)
  • Page 613 www.WorkshopManuals.co.uk Section F Transmission Section F 33 - 7 Electrical Connections 33 - 7 Powershift Gearbox - 6 Speed Connectors (h3) î Electrical Connections - Wires and Connectors î Schematics are divided into 2 parts: Input Controls and Park brake warning light relay Gearbox Solenoid Actuation.
  • Page 614 www.WorkshopManuals.co.uk Section F Transmission Section F 33 - 8 Electrical Connections 33 - 8 Powershift Gearbox - 6 Speed Input Controls 815C 1876 808G 810D 858A F G 1 9 10 11 11 10 12 13 14 14 13 12 600MJ 600MK 135B...
  • Page 615 www.WorkshopManuals.co.uk Section F Transmission Section F 33 - 9 Electrical Connections 33 - 9 Powershift Gearbox - 6 Speed Gearbox Solenoid Actuation 1864 1861 1860 1862 1863 1866 1865 600MH 600Z 1865 1866 1863 1862 1860 1861 1864 1860 1865 11 10 600BX 600BZ...
  • Page 616 www.WorkshopManuals.co.uk Section F Transmission Section F 33 - 10 Electrical Connections 33 - 10 Powershift Gearbox - 6 Speed (cont’d) Electrical Connections - Wires and Connectors Gearbox Solenoid Actuation For input controls see previous page. Component Key (solenoid activation): The following key identifies the component connectors on the diagrams opposite.
  • Page 617 www.WorkshopManuals.co.uk Section F Transmission Section F 35 - 1 Fault Finding 35 - 1 Synchro Shuttle Gearbox Before carrying out the checks listed the machine should, if possible, be operated to determine the fault area(s), and bring the systems to their normal working temperatures. Ensure that the correct quantity and grade of oil is used and that there are no obvious leaks.
  • Page 618 www.WorkshopManuals.co.uk Section F Transmission Section F 35 - 2 Fault Finding 35 - 2 Synchro Shuttle Gearbox (cont'd) CHECK ACTION Is 'converter in' pressure as specified? YES: Check 15 NO: Inspect converter relief valve for damage. Check cooler bypass valve pressure setting. Is pump being driven by converter? YES: Check pump pressure.
  • Page 619 www.WorkshopManuals.co.uk Section F Transmission Section F 35 - 3 Fault Finding 35 - 3 Synchro Shuttle Gearbox (cont'd) CHECK ACTION Are the selector rods worn or damaged? YES: Renew. NO: Check 34 Are the selector fork pads out of position? YES: Reposition or renew (check interlock).
  • Page 620 www.WorkshopManuals.co.uk Section F Transmission Section F 36 - 1 Fault Finding 36 - 1 Synchro Shuttle Gearbox - 2/4 Wheel Drive Clutch 4WD CANNOT BE ENGAGED In normal operation the 2/4 wheel drive clutch is spring loaded off and therefore disengaged to give 2 wheel drive. The clutch must be pressurised to give 4 wheel drive.
  • Page 621 www.WorkshopManuals.co.uk Section F Transmission Section F 36 - 2 Fault Finding 36 - 2 Synchro Shuttle Gearbox - 2/4 Wheel Drive Clutch (cont'd) 2WD CANNOT BE ENGAGED No pressure is required to engage 2WD(spring loaded). Check that the solenoid spool is not sticking (in the 4WD position), then see below.
  • Page 622 www.WorkshopManuals.co.uk Section F Transmission Section F 40 - 1 Fault Finding 40 - 1 Powershift Gearbox Introduction 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.
  • Page 623 www.WorkshopManuals.co.uk Powershift Gearbox Chart A - Machine drives but lacks power in all gears. Gearbox oil may also be overheating. Top up oil level START Is gearbox oil level low? Check reason for contamination. Rectify as applicable Drain and flush oil, see Flushing the Gearbox Oil.
  • Page 624 www.WorkshopManuals.co.uk Powershift Gearbox Chart B - Machine does not drive in any gear. START Is gearbox oil level low? Top up oil level. Are the park brake and transmission Renew switch or repair wiring as dump switches working correctly? applicable. Is the gear selection column switch Renew switch or repair wiring as working correctly.
  • Page 625 www.WorkshopManuals.co.uk Powershift Gearbox Chart C - Some gears fail to engage or lack power. 4WD fails to engage. START Are the gear selection column/4WD Renew applicable switch or repair switches working correctly. See wiring as applicable. Powershift Electrical System Tests. Are the solenoids or associated Renew applicable solenoid or repair Are the relevant the clutch solenoids...
  • Page 626 www.WorkshopManuals.co.uk Powershift Gearbox 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.
  • Page 627 www.WorkshopManuals.co.uk Powershift Gearbox Chart E - Gearbox oil overheats START Clean the matrix. Is the gearbox oil cooler heat exchanger matrix clogged with dirt/chaff? Adjust oil to correct level. Is gearbox oil level incorrect (too low or too high)? Check reason for contamination. Rectify as applicable.
  • Page 628 www.WorkshopManuals.co.uk Powershift Gearbox Chart F - External oil leakage START Is the oil leaking from the gearbox or from another source? Remember that the main machine hydraulic pump is Rectify as applicable. mounted on the gearbox. Oil leakage from inside the torque converter housing may be engine oil.
  • Page 629 www.WorkshopManuals.co.uk Powershift Gearbox Chart G - Noisy operation START Is gearbox oil level low? Top up oil level. Check reason for contamination. Is gearbox oil the correct type and Rectify as applicable Drain and flush free from contamination? oil, see Flushing the Gearbox Oil. Carry out a Lubrication Pressure Carry out Torque Converter Out Test.
  • Page 630 www.WorkshopManuals.co.uk Section F Section F Transmission 40 - 9 Fault Finding 40 - 9 Powershift Gearbox 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.
  • Page 631 www.WorkshopManuals.co.uk Section F Transmission Section F 50 - 1 50 - 1 Service Procedures Front Axle - SD55, SD70 Renewing the Pinion Oil Seal The pinion oil seal 3 may be renewed without removing the Check the sealing surface on the yoke for wear or axle from the machine.
  • Page 632 www.WorkshopManuals.co.uk Section F Transmission Section F 51 - 1 51 - 1 Service Procedures Rear Axle - SD80, PD70 Renewing the Pinion Oil Seal The rear axle pinion oil seal is renewed using the same procedure as Front Axle SD55, SD70 but note the following: The rear axles are fitted with a brake disc/drive flange in place of the yoke on front axles.
  • Page 633 www.WorkshopManuals.co.uk Section F Transmission Section F 52 - 1 52 - 1 Service Procedures Rear Axle - SD80, PD70 Brakes - Testing for Piston Seal Leakage See Section G, Brakes, Service Procedures. 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 634 www.WorkshopManuals.co.uk Section F Transmission Section F 55 - 1 Service Procedures 55 - 1 A396910 S266880 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 635 www.WorkshopManuals.co.uk Section F Transmission Section F 55 - 2 Service Procedures 55 - 2 Synchro Shuttle Gearbox Torque Converter Stall Test Ensure that the engine and transmission are at normal Start engine and run at 1000 rev/min. The flowmeter will working temperature.
  • Page 636 www.WorkshopManuals.co.uk Section F Transmission Section F 57 - 1 Service Procedures 57 - 1 Synchro Shuttle Gearbox Forward/Reverse Solenoid Control Valve Dismantling Unscrew the knurled nut 2 and remove 'O' ring 3, withdraw the solenoid 4 and 'O' ring 5. Hold the solenoid valve body 6 in a vice, using the spanner flats A, remove spindle 7 and 'O' ring 8.
  • Page 637 www.WorkshopManuals.co.uk Section F Section F Transmission 63 - 1 Service Procedures 63 - 1 A405990 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 638 Gearbox Removal and Replacement. Fit a new sealing ring 4. Locate the pump over the input shaft aligning the bolt holes. Apply JCB Threadlocker IMPORTANT NOTE: After removing the gearbox DO NOT and Sealer to bolts 2. Fit the bolts together with new REMOVE THE TORQUE CONVERTER HOUSING 1 from the sealing washers 3.
  • Page 639 www.WorkshopManuals.co.uk Section F Section F Transmission 64 - 1 Service Procedures 64 - 1 Powershift Gearbox Suction Strainer - Removal and Replacement Removal Replacement The suction strainer is located inside the gearbox front case. Replacement is the reverse of the removal sequence but Access is gained by removing the 4WD clutch assembly.
  • Page 640 www.WorkshopManuals.co.uk Section F Transmission Section F 65 - 1 Service Procedures 65 - 1 Powershift Gearbox 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’...
  • Page 641 www.WorkshopManuals.co.uk Section F Section F Transmission 65 - 2 Service Procedures 65 - 2 Powershift Gearbox Torque Converter Stall Test, cont’d Interpreting the Test Results If all the engine speeds are below the stated figures either engine losing power should serviced/overhauled or the torque converter reaction member clutch is slipping.
  • Page 642 www.WorkshopManuals.co.uk Section F Transmission Section F 66 - 1 Service Procedures 66 - 1 Powershift Gearbox Pressure and Flow Testing A396470 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 643 www.WorkshopManuals.co.uk Section F Transmission Section F 66 - 2 Service Procedures 66 - 2 Powershift Gearbox Pressure and Flow Testing 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/converter relief valve pressure operating temperature (not less than 50°...
  • Page 644 www.WorkshopManuals.co.uk Section F Section F Transmission 66 - 3 Service Procedures 66 - 3 Powershift Gearbox Pressure and Flow Testing A396990 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 645 www.WorkshopManuals.co.uk Section F Section F Transmission 66 - 4 Service Procedures 66 - 4 Powershift Gearbox Pressure and Flow Testing, cont’d Pump Flow Mainline Pressure Stop engine, remove the gearbox oil filter and fit Stop engine, connect a 0-20 bar (0-300 lbf/in ) pressure adapter X (460/15708) into the gearbox casing.
  • Page 646 www.WorkshopManuals.co.uk Section F Section F Transmission 66 - 5 Service Procedures 66 - 5 Powershift Gearbox Pressure and Flow Testing A397000 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 647 www.WorkshopManuals.co.uk Section F Section F Transmission 66 - 6 Service Procedures 66 - 6 Powershift Gearbox Pressure and Flow Testing, cont’d Converter Relief (Safety) Valve Pressure Converter Out Pressure/Oil Cooler Flow Rate The purpose of the torque converter relief valve is to protect the torque converter from excessive oil pressure.
  • Page 648 www.WorkshopManuals.co.uk Section F Section F Transmission 66 - 7 Service Procedures 66 - 7 Powershift Gearbox Pressure and Flow Testing A396470 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 649 www.WorkshopManuals.co.uk Section F Transmission Section F 66 - 8 Service Procedures 66 - 8 Powershift Gearbox Pressure Testing - Clutches Isolating a Suspect Clutch Start engine and run at 1000 rev/min, engage 1st gear By performing the tests in the first 3 gears in forward and forward.
  • Page 650 www.WorkshopManuals.co.uk Section F Transmission Section F 66 - 9 Service Procedures 66 - 9 Powershift Gearbox Pressure and Flow Testing A396470 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 651 www.WorkshopManuals.co.uk Section F Section F Transmission 66 - 10 Service Procedures 66 - 10 Powershift Gearbox Pressure Testing - Clutches Individual Clutch Leakage Test In the following procedures the forward low clutch (T) is When testing individual clutch pressures it is necessary to tested, therefore in step 2 a pressure gauge is connected to isolate the clutch being tested.
  • Page 652 www.WorkshopManuals.co.uk Section F Transmission Section F 67 - 1 Service Procedures 67 - 1 Powershift Gearbox Speed Sensor Powershift machines fitted with an electronic control unit (ShiftMaster ECU) or a speedometer have a speed sensor D fitted. The speed sensor detects the speed of rotation of the gearbox output shaft and relays this information to the ECU or speedometer as applicable.
  • Page 653 Flash Programmer application. This application is part of caused by faulty or damaged wiring, electrical components the JCB Service Master package found on the JCB Service or hydraulic faults than by failure of the ShiftMaster ECU. Technical Information CD’s. The Flash Programmer application includes comprehensive help files.
  • Page 654 Powershift Controllers used on the PS750 series gearboxes. To utilise any supporting ShiftMaster Service Tools requires the use of the JCB Data Link Adaptor [or DLA] (717/ 20138) which is part of the standard JCB Electronic Service Tool Kit, part number 892/01033.
  • Page 655 Powershift Gearbox - 6 speed ShiftMaster Diagnostics - User Guide 4. Starting ShiftMaster Diagnostics This document assumes that JCB Service Master has Step 2: Connect the 'Machine Cable' between the DLA and already been installed. the machines' Diagnostic Connector. The 'Machine Cable'...
  • Page 656 69 - 3 Powershift Gearbox - 6 speed ShiftMaster Diagnostics - User Guide Connection Problems: Step 4: Start JCB Service Master. And go to the BHL section. ShiftMaster Diagnostics will start and can be partly used even if there are connection problems.
  • Page 657 www.WorkshopManuals.co.uk Section F Transmission Section F 69 - 4 Service Procedures 69 - 4 Powershift Gearbox - 6 speed ShiftMaster Diagnostics - User Guide 5. ShiftMaster Diagnostics: Overview There are several key elements to the ShiftMaster Diagnostics tool. These can be seen labelled below. Each element is explained in detail in later sections.
  • Page 658 www.WorkshopManuals.co.uk Section F Transmission Section F 69 - 5 Service Procedures 69 - 5 Powershift Gearbox - 6 speed ShiftMaster Diagnostics - User Guide 6. Menu Bar File Menu · English (British) The File Menu contains and Exit option to close down the ·...
  • Page 659 Selecting the About… option will bring up a window Help Menu showing the JCB part number and the version number of the installed copy of ShiftMaster Diagnostics. To assist the Service Engineer, ShiftMaster Diagnostics is supplied with a set of documentary Guides. These Guides can be accessed directly from within the ShiftMaster Diagnostics tool itself, via the Help menu.
  • Page 660 www.WorkshopManuals.co.uk Section F Transmission Section F 69 - 7 Service Procedures 69 - 7 Powershift Gearbox - 6 speed ShiftMaster Diagnostics - User Guide 8. Page List 10. ECU Setup Page In the top left corner of the main window is displayed a list of This page displays crucial information about the ECU pages which can be displayed.
  • Page 661 www.WorkshopManuals.co.uk Section F Transmission Section F 69 - 8 Service Procedures 69 - 8 Powershift Gearbox - 6 speed ShiftMaster Diagnostics - User Guide 11. Dashboard Information in this display is constantly updated in real-time. This offers a simple uncluttered display showing; (Some older PCs may experience a slight delay in updating this page, but usually only less than one second.) The left hand side shows the inputs to the ECU, their status...
  • Page 662 For all enquiries about the ShiftMaster Diagnostics tool interact as follows; please follow your normal channels of enquiry. This ensures that useful information can filter through to JCB Service Firstly there is a Direct 4WD input which is, in general, personnel at all levels.
  • Page 663 DLA there will be an error message displayed. To utilise any supporting ShiftMaster Service Tools requires the use of the JCB Data Link Adaptor (DLA) which is part of the standard JCB Electronic Service Tool Kit, part number 892/01033.
  • Page 664 PC. but never used, then try disabling the driver; The update of both these sets of drivers is handled by JCB System Properties > Device Manager > Ports > ..(infrared) Service Master.
  • Page 665 REAR previously made or, in the case of a shaft being renewed, use the manufacturer's alignment markings. Apply JCB Threadlocker and Sealer to threads of all flange bolts. Retaining straps C stretch with use, therefore these straps must always be replaced with new ones.
  • Page 666 www.WorkshopManuals.co.uk Section F Transmission Section F 80 - 1 Front Axle - SD55, SD70 80 - 1 Removal and Replacement -238.14 A401290 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 667 www.WorkshopManuals.co.uk Section F Transmission Section F 80 - 2 Front Axle - SD55, SD70 80 - 2 Removal and Replacement (cont’d) Note: The following procedure can be applied to both AWS and 2WS machines. Dis-regard information not applicable to your machine type, for instance, 2 wheel steer machines will not have steering proximity switches fitted.
  • Page 668 Whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct. Apply JCB Lock & Seal to the threads of bolts A. The front axle must be shimmed to give a maximum fore and aft movement of 0.5 mm (0.020 in).
  • Page 669 www.WorkshopManuals.co.uk Section F Transmission Section F 81 - 1 Front Axle - SD55, SD70 81 - 1 Hub and Driveshaft - Dismantling The following illustrations show the axle removed from the machine but the hubs may be dismantled without removing the axle.
  • Page 670 www.WorkshopManuals.co.uk Section F Transmission Section F 81 - 2 Front Axle - SD55, SD70 81 - 2 Hub and Driveshaft - Dismantling (cont'd) Remove circlip D to allow the sun gear to be slid off the drive shaft. 256010 To remove the ‘Verbus Ripp’ bolts E, it is necessary to remove the spacer F.
  • Page 671 www.WorkshopManuals.co.uk Section F Transmission Section F 81 - 3 Front Axle - SD55, SD70 81 - 3 Hub and Driveshaft - Dismantling (cont'd) Remove circlip G to separate the annulus ring from the annulus carrier. S248910 Pull off the bearing carrier together with the outer bearing cone and its bearing cup.
  • Page 672 www.WorkshopManuals.co.uk Section F Transmission Section F 81 - 4 Front Axle - SD55, SD70 81 - 4 Hub and Driveshaft - Dismantling (cont'd) Pull off the inner bearing - see Note at step 13. Remove and discard the seal. Note: The inner bearing and oil seal may withdraw with the bearing carrier.
  • Page 673 www.WorkshopManuals.co.uk Section F Transmission Section F 81 - 5 Front Axle - SD55, SD70 81 - 5 Hub and Driveshaft - Dismantling (cont'd) Use a puller to remove the trunnion seal and bearing. S258270 Withdraw drive shaft. Prise out drive shaft inner oil seal J. Remove circlip K Remove bearing using tool 892/00225.
  • Page 674 www.WorkshopManuals.co.uk Section F Transmission Section F 81 - 6 Front Axle - SD55, SD70 81 - 6 Hub and Driveshaft - Assembly Tap drive shaft inner bearing into position and secure with circlip K. Fit new oil seal J. Pack grease between lips of seal. Fit drive shaft, taking care to locate inner end into splines of differential gears.
  • Page 675 Front Axle - SD55, SD70 81 - 7 Hub and Driveshaft - Assembly (cont'd) Locate hub carrier and fit bottom trunnion. Apply JCB Lock and Seal (part no. 4101/ 0202) to the bottom trunnion bolt threads, fit and tighten to 98Nm (72 lbf ft).
  • Page 676 www.WorkshopManuals.co.uk Section F Transmission Section F 81 - 8 Front Axle - SD55, SD70 81 - 8 Hub and Driveshaft - Assembly (cont'd) Assemble the annulus ring to the annulus carrier. Secure with the circlip G. S248910 Fit annulus assembly in the same angular position as removal (see Note, Dismantling, step 11) using new 'Verbus Ripp' bolts.
  • Page 677 www.WorkshopManuals.co.uk Section F Transmission Section F 81 - 9 Front Axle - SD55, SD70 81 - 9 Hub and Driveshaft - Assembly (cont'd) To measure rolling force: Refit the planet gear carrier - DO NOT FIT THE SUN GEAR. Use a spring balance and cord wrapped around the planet gear carrier flange as shown.
  • Page 678 Fit and torque tighten screws A to 56Nm (41Ibf ft; 5.7kgf m) after applying JCB Lock and Seal to the threads. Note: Do not strike the centre of the planet gear carrier when fitting as this may dislodge the driveshaft thrust pad fitted at step 17.
  • Page 679 www.WorkshopManuals.co.uk Section F Transmission Section F 82 - 1 Front Axle - SD55 82 - 1 Drive Head - Dismantling ITL00670 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 680 www.WorkshopManuals.co.uk Section F Transmission Section F 82 - 2 Front Axle - SD55 82 - 2 Drive Head - Dismantling (cont’d) Drain the oil from the drive head. Remove the propshaft. To remove the drive head it is necessary to withdraw both drive shafts from the axle.
  • Page 681 www.WorkshopManuals.co.uk Section F Transmission Section F 82 - 3 Front Axle - SD55 82 - 3 Drive Head - Assembly (cont’d) ITL00670 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 682 www.WorkshopManuals.co.uk Section F Transmission Section F 82 - 4 Front Axle - SD55 82 - 4 Drive Head - Assembly The outline procedure below refers also to the following Fit special bracket D to the drive-head housing using aspects of the drivehead assembly, which are covered two M10 x 30 nuts and bolts.
  • Page 683 www.WorkshopManuals.co.uk Section F Transmission Section F 82 - 5 Front Axle - SD55 82 - 5 Drive Head - Assembly (cont’d) 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 684 Note: If the pinion is not free to rotate check the correct size Meshing. spacer has been fitted. Apply JCB Multigasket to the mating faces of drive head carrier 2 and the axle casing. Fit the drive head If rolling torque measured at step 10 is too high, fit the carrier to the axle casing with the crownwheel towards next larger size spacer.
  • Page 685 www.WorkshopManuals.co.uk Section F Transmission Section F 82 - 7 Front Axle - SD55 82 - 7 Pinion Depth Setting Place new pinion head inner 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.
  • Page 686 www.WorkshopManuals.co.uk Section F Transmission Section F 82 - 8 Front Axle - SD55 82 - 8 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.
  • Page 687 www.WorkshopManuals.co.uk Section F Transmission Section F 83 - 1 Front Axle - SD70 83 - 1 S161871 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 688 www.WorkshopManuals.co.uk Section F Transmission Section F 83 - 2 Front Axle - SD70 83 - 2 Drivehead, SD70 - Dismantling The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. Drain the oil from the axle centre casing.
  • Page 689 www.WorkshopManuals.co.uk Section F Transmission Section F 83 - 3 Front Axle - SD70 83 - 3 S161871 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 690 www.WorkshopManuals.co.uk Section F Transmission Section F 83 - 4 Front Axle - SD70 83 - 4 Drive Head - Assembly The outline procedure below refers also to the following Fit special bracket D to the drive-head housing using aspects of the drivehead assembly, which are covered two M10 x 30 nuts and bolts.
  • Page 691 www.WorkshopManuals.co.uk Section F Transmission Section F 83 - 5 Front Axle - SD70 83 - 5 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 692 If rolling torque measured at step 10 is too high, fit the next larger size spacer. If rolling torque is too low, fit Apply JCB Multigasket to the mating faces of drive the next smallest size spacer. If a correct spacer is not head carrier 2 and the axle casing.
  • Page 693 www.WorkshopManuals.co.uk Section F Transmission Section F 83 - 7 Front Axle - SD70 83 - 7 Pinion Depth Setting Place new pinion head inner 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.
  • Page 694 www.WorkshopManuals.co.uk Section F Transmission Section F 83 - 8 Front Axle - SD70 83 - 8 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.
  • Page 695 www.WorkshopManuals.co.uk Section F Transmission Section F 85 - 1 Front Axle 85 - 1 Removal and Replacement (2 Wheel Drive Machines) The removal and replacement procedures for the 2 wheel drive axle (beam type) is the same as described on pages F/80-1 and F/80-2.
  • Page 696 Add shims 16 as required to give zero to 0.1mm (0.004in) clearance between axle beam and bearing 15. Apply JCB Lock and Seal to threads of bolt 9. Pack JCB Special MPL Grease into hubs 5 and between lips of seals 7. S258280...
  • Page 697 www.WorkshopManuals.co.uk Section F Transmission Section F 90 - 1 Rear Axle - PD70, SD80 90 - 1 Removal and Replacement -238.14 A401300 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 698 L. Disconnect the cable from the calliper M . Tie the cable up, out of Apply JCB Threadlocker and Sealer to the threads of bolts harms way. Remove bolts A to disconnect the drive shaft from the SD 80 Steer axles only;...
  • Page 699 www.WorkshopManuals.co.uk Section F Transmission Section F 91 - 1 91 - 1 Rear Axle - PD70, SD80 378120 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 700 www.WorkshopManuals.co.uk Section F Transmission Section F 91 - 2 91 - 2 Rear Axle - PD70, SD80 Brakes (with controlled back off) Axles are fitted with brake controlled back off to maintain a Match mark the brake piston housing 7 and the drive constant clearance of 0.6mm (0.02in) within the brake pack.
  • Page 701 www.WorkshopManuals.co.uk Section F Section F Transmission 91 - 3 91 - 3 Rear Axle - PD70, SD80 378120 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 702 Apply JCB High Strength Gasketing to the mating face in their grooves. of the drive head, and JCB Threadlocker and Sealer to the threads of bolts 1. Locate the axle arm onto the Carefully press the piston 15 all the way into its housing drivehead, with the embossed word 'TOP' on the axle 7.
  • Page 703 www.WorkshopManuals.co.uk Section F Transmission Section F 92 - 1 Rear Axle - SD80 92 - 1 A313631 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 704 www.WorkshopManuals.co.uk Section F Transmission Section F 92 - 2 Rear Axle - SD80 92 - 2 Hub - Dismantling ! WARNING A raised and badly supported machine can fall on you. Remove and discard combination oil seal 18. Position the machine on a firm, level surface before raising one end.
  • Page 705 www.WorkshopManuals.co.uk Section F Transmission Section F 92 - 3 Rear Axle - SD80 92 - 3 A313631 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 706 www.WorkshopManuals.co.uk Section F Transmission Section F 92 - 4 Rear Axle - SD80 92 - 4 Hub-Assembly Measure seal drag rolling force as follows: Refit the planet gear carrier 2 - DO NOT FIT THE Fit drive shaft 26 inner end into splines of differential SUN GEAR 8.
  • Page 707 www.WorkshopManuals.co.uk Section F Transmission Section F 93 - 1 Rear Axle - PD70 93 - 1 Hub-Dismantling & Assembly The procedures for dismantling and assembling the hub on a PD70 axle are virtually the same as for a SD80 axle - described on the previous pages (F/92-1 to F/92-4).
  • Page 708 www.WorkshopManuals.co.uk Section F Transmission Section F 94 - 1 Rear Axle - SD80, PD70 94 - 1 Drive Head-Dismantling As the drivehead cannot be dismantled whilst fitted on the machine, we recommend that the complete axle is removed. See Brakes and Hub and Driveshaft for axle arm removal procedure.
  • Page 709 www.WorkshopManuals.co.uk Section F Transmission Section F 94 - 2 Rear Axle - SD80, PD70 94 - 2 Drive Head-Dismantling (cont'd) Remove the pinion spacer. Pull off the bearing cone. S256080 10 To dismantle the differential assembly, first remove bolts. Lift off the top half housing. 12 Remove the differential gears and spherical washers.
  • Page 710 www.WorkshopManuals.co.uk Section F Transmission Section F 94 - 3 Rear Axle - SD80, PD70 94 - 3 Drive Head-Assembly Pinion Depth Determine the pinion depth setting as follows: Note: See p age Crow nw heel and Pinion for general guidance on crownwheel and pinion adjustment. 1 Assemble the pinion inner bearing and its cup on a flat surface.
  • Page 711 (see Note above). Apply S256100 JCB Threadlocker & Sealer 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.
  • Page 712 www.WorkshopManuals.co.uk Section F Transmission Section F 94 - 5 Rear Axle - SD80, PD70 94 - 5 Drive Head-Assembly (cont'd) Fit special tool sleeve B and special pinion shaft adapter C. Tighten adapter C to approximately 50 Nm, making sure the pinion is free to rotate and there is end float, this will prevent any damage to the bearing.
  • Page 713 Step 24. Then install the crownwheel /differential assembly into the drive head. S256070 Apply JCB Multi-Gasket to the drive head mating face, then fit the brake piston housing. Ensure that the match & - marks mad e d uring d ismant ling are aligned . Fit capscrews.
  • Page 714 www.WorkshopManuals.co.uk Section F Transmission Section F 94 - 7 Rear Axle - SD80, PD70 94 - 7 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 25.
  • Page 715 www.WorkshopManuals.co.uk Section F Transmission Section F 94 - 8 Rear Axle - SD80, PD70 94 - 8 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.
  • Page 716 22 shown. Smear output shaft inner bearing 27 with JCB HP Grease before refitting. Fit bearing cup 28 over pinion shaft 23 and assemble into drive head casing.
  • Page 717 www.WorkshopManuals.co.uk Section F Transmission Section F 100 - 1 100 - 1 Limited Slip Differential S212800 S171530 S212790 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 718 www.WorkshopManuals.co.uk Section F Transmission Section F 100 - 2 100 - 2 Limited Slip Differential Friction Plate Wear Limits Dismantling and Assembly Measure and note the thickness of the friction plate, the The numeric al seq uenc e show n on t he illust rat ion is result must not be less than 1.25 mm (0.049 in).
  • Page 719 www.WorkshopManuals.co.uk Section F Transmission Section F 105 - 1 Synchro Shuttle Gearbox 105 - 1 Removal and Replacement A401310 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 720 www.WorkshopManuals.co.uk Section F Transmission Section F 105 - 2 Synchro Shuttle Gearbox 105 - 2 Removal and Replacement (cont’d) IMPORTANT: The gearbox is heavy. Unless it is safely At a later stage the gearbox and engine assembly is supported during removal and replacement it could fall and tilted to allow access to fixing bolts.
  • Page 721 www.WorkshopManuals.co.uk Section F Transmission Section F 105 - 3 Synchro Shuttle Gearbox 105 - 3 Removal and Replacement (cont’d) A401310 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 722 www.WorkshopManuals.co.uk Section F Transmission Section F 105 - 4 Synchro Shuttle Gearbox 105 - 4 Removal and Replacement (cont’d) Replacement Replacement is a reversal of the removal procedure but note the following: Before replacing the gearbox remove circlip 5 and withdraw the pump driveshaft 6 together with its bearing 7 approximately 50 mm (2.0 in).
  • Page 723 www.WorkshopManuals.co.uk Section F Transmission Section F 110 - 1 Synchro Shuttle Gearbox 110 - 1 Dismantling 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;...
  • Page 724 www.WorkshopManuals.co.uk Section F Transmission Section F 110 - 2 Synchro Shuttle Gearbox 110 - 2 Dismantling (cont'd) Drain the oil from the casing by removing the suction strainer 3a. Remove and discard the oil filter 3b. If the gearbox is fitted with a 2/4 wheel drive unit B, remove it.
  • Page 725 www.WorkshopManuals.co.uk Section F Transmission Section F 110 - 3 Synchro Shuttle Gearbox 110 - 3 Dismantling (cont'd) Position transmission vertically, standing on the face of the torque converter housing. Unscrew capscrews and remove solenoid control valve. Note ‘O’ rings fitted around ports on mating face of solenoid valve body.
  • Page 726 www.WorkshopManuals.co.uk Section F Transmission Section F 110 - 4 Synchro Shuttle Gearbox 110 - 4 Dismantling (cont'd) Unscrew plug and withdraw pressure maintenance valve spool and spring. Unscrew four bolts and remove pressure maintenance valve body. Remove and discard gasket. A387960 Remove the torque converter pressure relief valve ball and spring assembly 14a.
  • Page 727 www.WorkshopManuals.co.uk Section F Transmission Section F 110 - 5 Synchro Shuttle Gearbox 110 - 5 Dismantling (cont'd) Unscrew selector detent plugs. Remove selector detent balls and springs. Unscrew selector fork retaining screws and lift out selector rods. Note that the selector forks are not interchangeable. Mark the forks to ensure they are replaced correctly.
  • Page 728 www.WorkshopManuals.co.uk Section F Transmission Section F 110 - 6 Synchro Shuttle Gearbox 110 - 6 Dismantling (cont'd) Remove idler gear upper thrust washers and bearing. Keep the thrust washers and bearing together. Tilt mainshaft L to one side and lift off idler gear together with its needle roller bearing 24a.
  • Page 729 www.WorkshopManuals.co.uk Section F Transmission Section F 110 - 7 Synchro Shuttle Gearbox 110 - 7 Dismantling (cont'd) Mainshaft 34c 34b 34a 34d Using service tool 892/00179 and adapter 992/06300 pull off 3rd gear together with synchro cup 34a, gear 34b, spacer washer 34c, oil retention washer 34d and bearing 34e.
  • Page 730 www.WorkshopManuals.co.uk Section F Transmission Section F 110 - 8 Synchro Shuttle Gearbox 110 - 8 Dismantling (cont'd) Setting Ring Removal The mainshaft and layshaft end float is controlled by a threaded ‘setting ring’ screwed into the casing. To enable access to the mainshaft setting ring the torque converter housing must be removed.
  • Page 731 www.WorkshopManuals.co.uk Section F Transmission Section F 111 - 1 Synchro Shuttle Gearbox 111 - 1 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 732 www.WorkshopManuals.co.uk Section F Transmission Section F 111 - 2 Synchro Shuttle Gearbox 111 - 2 Inspection Before assembling the gearbox make sure that a thorough inspection of all components is carried out. Remember that although a failed component may be easy to identify, the cause of that failure may be less easy to trace.
  • Page 733 Transfer the plugs and adapters to the new casings. Apply JCB Threadlocker and Sealer to the threads. Note that new plugs may be supplied with a sealant ‘patch’, in which case sealant need not be applied. Torque tighten plugs to 25 - 28 Nm (18.4 - 20 lbf ft).
  • Page 734 Fit spacer washer 7a and oil retention washer 7b. Note the correct way round of components 7a and 7b. Press bearing 7c onto shaft and smear with JCB HP Grease. Press bearing onto assembled mainshaft and smear bearing with JCB HP Grease.
  • Page 735 Note: Make sure that the layshaft bearing outer cup is fitted to the rear casing before fitting the transfer gear/output shaft. a Liberally coat output shaft inner bearing with JCB HP Grease before fitting inner bearing P. b Fit the service solid spacer N (13.70 mm) over output shaft and assemble into casing.
  • Page 736 www.WorkshopManuals.co.uk Section F Transmission Section F 112 - 4 Synchro Shuttle Gearbox 112 - 4 Assembly (cont'd) a Fit dial test indicator E (DTI) . b Set torque wrench F to 35 Nm and measure the end float while rotating the output shaft. c To select the right size spacer, subtract the end float obtained at step 11b from the solid spacer (13.70 mm).
  • Page 737 www.WorkshopManuals.co.uk Section F Transmission Section F 112 - 5 Synchro Shuttle Gearbox 112 - 5 Assembly (cont'd) a Remove nut B and sleeve A. Fit new oil seal S, grease between seal lips before fitting. Note that the seal does not fix to the back of the housing - use servicel tool to locate the seal.
  • Page 738 18a to the spindle whilst tilting mainshaft L to one side. Fit thrust washers and bearing assembly. S407370 Smear front end bearing of layshaft with JCB HP Grease, and carefully lower layshaft into position. If re-using synchro assembly fit the parts in their original positions.
  • Page 739 M8 bolt approximately 100 mm long can be used. Apply a bead of JCB Multigasket to mating face of casing. Insert 'O' rings Z. Smear grease onto reverser shaft ring seals, and apply JCB HP Grease to bearings prior to fitting output end casing.
  • Page 740 Do not use excessive force when fitting the casing. Apply JCB Threadocker and Sealer to bolts and torque to 56 Nm (42 lbf ft). Remove service tool at position B. Fit the detent ball and spring.
  • Page 741 www.WorkshopManuals.co.uk Section F Transmission Section F 112 - 9 Synchro Shuttle Transmission 112 - 9 Assembly (cont'd) End Float Checking - Forward/Reverse Unit Measure end float of forward/reverse unit shaft which should be 0.01 to 0.16 mm (0.0004 to 0.006 in). Note: Rotate shaft whilst measuring to seat bearings fully.
  • Page 742 This is important as the ring will otherwise restrict the flow of lubrication oil. e Using a new gasket, refit the layshaft bearing cover. Apply JCB Threadlocker and Sealer to the fixing bolts and tighten to 56 Nm (42 lbf ft). A396630...
  • Page 743 JCB Threadlocker and Sealer to bolts and, using new sealing washers, tighten to 28 Nm (21 lbf ft). A388140 Apply a bead of JCB Multigasket to the mating face of the gearbox cover as shown at A. Refit the torque converter housing. Apply JCB Threadlocker and Sealer to the 12 bolts and tighten to 56 Nm (42 lbf ft).
  • Page 744 Fit the valve ball and spring. Ensure that larger diameter of spring is located securely over the spigot on the plug. Use a new sealing washer, apply JCB Threadlocker and Sealer to the plug, then tighten. Fit the torque converter pressure regulating valve assembly 39b;...
  • Page 745 Make sure the plate is the correct way round. A388270 Locate a second gasket and then fit the turret assembly. Apply JCB Threadlocker and Sealer to mounting bolts and tighten to 56 Nm (42 lbf ft). Check for gear selection. 9803/3280 Issue 2*...
  • Page 746 Remove the service strainer and fit a production strainer after the first 100 hours operation. Renew the oil. Using a new gasket, install suction strainer. Apply JCB Threadlocker and Sealer to bolts and tighten to 10 Nm (7 lbf ft).
  • Page 747 www.WorkshopManuals.co.uk Section F Transmission Section F 113 - 1 Synchro Shuttle Gearbox 113 - 1 Reverser Unit - Dismantling Carefully remove piston ring seals. Note: If the piston ring seals are excessively worn then check for burrs or damage on the shaft grooves. If necessary remove burrs with a fine grade abrasion paper and oil.
  • Page 748 www.WorkshopManuals.co.uk Section F Transmission Section F 113 - 2 Synchro Shuttle Gearbox 113 - 2 Reverser Unit - Dismantling (cont'd) Remove the clutch friction/counter plates. Keep them together in sets, DO NOT mix the plates with those from other clutches. Remove last counter plate.
  • Page 749 www.WorkshopManuals.co.uk Section F Transmission Section F 113 - 3 Synchro Shuttle Gearbox 113 - 3 Reverser Unit - Assembly Fit new 'O' rings onto the piston and shaft, lubricate with oil then press piston fully into bore of clutch housing. S407200 Install the oil baffle and piston spring, make sure the spring seats in the piston.
  • Page 750 Note: Ensure that the spacer is fitted first. Fit the thrust bearing and thrust washers. S407220 Smear the clutch end bearing with JCB HP Grease and press the bearing onto shaft. Fit piston ring seals, refer to Piston Ring Seals - Fitting Procedure.
  • Page 751 www.WorkshopManuals.co.uk Section F Transmission Section F 114 - 1 114 - 1 Synchro Shuttle Gearbox Hydraulic 2/4 Wheel Drive Unit (4WD Pressure ON) 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 752 Fit the 2/4WD unit to the gearbox. 17 and 18. Apply a thin bead of JCB Multigasket to the 4WD Note: The piston housing cannot be separated from the mating face of the gearbox front case. Fit the case P, shaft, as on the other types of 2/4WD units.
  • Page 753 www.WorkshopManuals.co.uk Section F Transmission Section F 115 - 1 115 - 1 Synchro Shuttle Gearbox Hydraulic 2/4 Wheel Drive Unit (4WD Spring ON) 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 754 www.WorkshopManuals.co.uk Section F Transmission Section F 115 - 2 115 - 2 Synchro Shuttle Gearbox Hydraulic 2/4 Wheel Drive Unit (4WD Spring ON) Dismantling and Assembly Inspection Note: Before dismantling the unit drain the gearbox oil. Carry out a visual inspection of the friction and counter plates.
  • Page 755 www.WorkshopManuals.co.uk Section F Transmission Section F 115 - 3 115 - 3 Synchro Shuttle Gearbox 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 756 Fit sealing ring 2 and bearing 1. Fit the 2/4WD unit to the gearbox. Apply a thin bead of JCB Multigasket to the 4WD mating face of the gearbox front case. Fit the case P, apply JCB Threadlocker and Sealer to bolts D and progressively torque tighten to 56 Nm, 46 lbf ft.
  • Page 757 www.WorkshopManuals.co.uk Section F Transmission Section F 116 - 1 116 - 1 Synchro Shuttle Gearbox Pressure Testing the 2/4WD Clutch Assemble the 2/4 wheel drive clutch, as described in ‘Assembly’. Check the clutch pack end float and adjust as required (see Assembly).
  • Page 758 www.WorkshopManuals.co.uk Section F Transmission Section F 117 - 1 Synchro Shuttle Transmission 117 - 1 Polytetrafluoroethylene (PTFE) Piston Ring Seals - Fitting Procedure Wind the PTFE piston ring seal around your finger as shown, so that the seal forms a 'coil'. 157250 Smear the seal with grease and then fit the seal to the shaft.
  • Page 759 www.WorkshopManuals.co.uk Section F Transmission Section F 120 - 1 Powershift Gearbox 120 - 1 Removal and Replacement A401320 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 760 www.WorkshopManuals.co.uk Section F Transmission Section F 120 - 2 Powershift Gearbox 120 - 2 Removal and Replacement (cont’d) IMPORTANT: The gearbox is heavy. Unless it is safely At a later stage the gearbox and engine assembly is supported during removal and replacement it could fall and tilted to allow access to fixing bolts.
  • Page 761 www.WorkshopManuals.co.uk Section F Transmission Section F 120 - 3 Powershift Gearbox 120 - 3 Removal and Replacement (cont’d) A401320 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 762 www.WorkshopManuals.co.uk Section F Transmission Section F 120 - 4 Powershift Gearbox 120 - 4 Removal and Replacement (cont’d) Replacement Replacement is a reversal of the removal procedure but note the following: Before replacing the gearbox remove circlip 5 and withdraw the pump driveshaft 6 together with its bearing 7 approximately 50 mm (2.0 in).
  • Page 763 www.WorkshopManuals.co.uk Section F Transmission Section F 125 - 1 Powershift Gearbox 125 - 1 A395250 A395260 A395540 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 764 www.WorkshopManuals.co.uk Section F Transmission Section F 125 - 2 Powershift Gearbox 125 - 2 Dismantling N ot e : The Dism ant ling , Insp ec t io n and Assem b ly procedures in this manual illustrate and describe the 6x4 gearbox.
  • Page 765 www.WorkshopManuals.co.uk Section F Transmission Section F 125 - 3 Powershift Gearbox 125 - 3 A396090 A395230 A395240 A395330 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 766 www.WorkshopManuals.co.uk Section F Transmission Section F 125 - 4 Powershift Gearbox 125 - 4 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.
  • Page 767 www.WorkshopManuals.co.uk Section F Transmission Section F 125 - 5 Powershift Gearbox 125 - 5 A395210 A396120 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 768 www.WorkshopManuals.co.uk Section F Transmission Section F 125 - 6 Powershift Gearbox 125 - 6 Dismantling (cont’d) Remove the Torque Converter Relief Valve Undo the plug 7a and remove the sealing washer 7b, spring 7c and poppet 7d. Note that some gearboxes are fitted with a ball instead of a poppet.
  • Page 769 www.WorkshopManuals.co.uk Section F Transmission Section F 125 - 7 Powershift Gearbox 125 - 7 A395280 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 770 www.WorkshopManuals.co.uk Section F Transmission Section F 125 - 8 Powershift Gearbox 125 - 8 Dismantling (cont’d) Remove the Transfer Gear Using service tool 892/00812 hold the output yoke 11b and at the same time undo the bolt 11c. The bolt is very tight, the help of an assistant will be required.
  • Page 771 www.WorkshopManuals.co.uk Section F Transmission Section F 126 - 1 Powershift Gearbox 126 - 1 Inspection A395290 A395210 A395110 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 772 Transfer the plugs and adapters to the new casings. Apply JCB Threadlocker and Sealer to the threads. Gearbox Hydraulic Pump Note that new plugs may be supplied with a sealant ‘patch’, If tests have shown the pump performance to be in which case sealant need not be applied.
  • Page 773 www.WorkshopManuals.co.uk Section F Transmission Section F 127 - 1 Powershift Gearbox 127 - 1 A396070 A395280 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 774 www.WorkshopManuals.co.uk Section F Transmission Section F 127 - 2 Powershift Gearbox 127 - 2 Assembly Using suitable lifting equipment locate the gearbox rear Checking Transfer Gear/Output Shaft casing in a work cradle. Clamp the casing in position at the 3 Assembly End Float clamping points as shown at A.
  • Page 775 www.WorkshopManuals.co.uk Section F Transmission Section F 127 - 3 Powershift Gearbox 127 - 3 A396050 A395060 A395620 A335160 A395210 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 776 Make sure that the 3 off ‘O’ rings 4a are correctly fitted to the rear case. Apply a thin bead of JCB Multigasket to the rear casing mating face as shown at B. Make sure that the shaft bearing outer cups are correctly...
  • Page 777 www.WorkshopManuals.co.uk Section F Transmission Section F 127 - 5 Powershift Gearbox 127 - 5 A335160 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 778 Fit a bolt to the threaded hole in the end of the shafts. Pull up on the bolt to detect excessive end float. Remove the bolt. Apply JCB Threadlocker and Sealer to the plugs X and Y as applicable. Torque tighten the plugs to 102 Nm (75 lbf ft).
  • Page 779 www.WorkshopManuals.co.uk Section F Transmission Section F 127 - 7 Powershift Gearbox 127 - 7 A395240 A395570 A405220 A395230 9803/3280 Issue 3* Purchased from www.WorkshopManuals.co.uk...
  • Page 780 7b. Using a new sealing washer fit plug 7c. Fit the Pressure Maintenance Valve Oil the spool 8a and fit to the casing. Fit spring 8b. Apply JCB Threadlocker and Sealer to the plug 8c. Using a new sealing washer fit plug. Fit the Gearbox Hydraulic Pump Make sure that the pump is fitted with a new oil seal 9a, see Powershift Gearbox, Inspection, step 4.
  • Page 781 www.WorkshopManuals.co.uk Section F Transmission Section F 127 - 9 Powershift Gearbox 127 - 9 A396130 A402660 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 782 www.WorkshopManuals.co.uk Section F Transmission Section F 127 - 10 Powershift Gearbox 127 - 10 Assembly (cont’d) Fit the Torque Converter Housing - Gearboxes with 18 bolt fix only Important Note: Only the specified sealant can be used. The machine MUST NOT be operated for at least 6 hours after sealant has been applied and the converter housing assembled.
  • Page 783 www.WorkshopManuals.co.uk Section F Transmission Section F 127 - 11 Powershift Gearbox 127 - 11 A404970 M8 x 45 mm M8 x 25 mm A404980 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 784 www.WorkshopManuals.co.uk Section F Transmission Section F 127 - 12 Powershift Gearbox 127 - 12 Assembly (cont’d) Fit the Torque Converter Housing - Gearboxes with 23 bolt fix only Important Note: Only the specified sealant can be used. The machine MUST NOT be operated for at least 6 hours after sealant has been applied and the converter housing assembled.
  • Page 785 www.WorkshopManuals.co.uk Section F Transmission Section F 127 - 13 Powershift Gearbox 127 - 13 A390510 A395260 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 786 If applicable fit the layshaft cover 13a. Make sure the casing mating faces are clean and undamaged. Apply a thin bead of JCB Multigasket to the rear casing and fit the cover. Fit bolts 13b and progressively torque tighten to 56Nm (41 lbf ft).
  • Page 787 www.WorkshopManuals.co.uk Section F Transmission Section F 130 - 1 Powershift Gearbox 130 - 1 PS 760 - Forward/Input & Reverser Clutch - Dismantling A396140 A396270 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 788 www.WorkshopManuals.co.uk Section F Transmission Section F 130 - 2 Powershift Gearbox 130 - 2 PS 760 - Forward/Input & Reverser Clutch - Dismantling Note: The illustration shows a reverser shaft assembly for Lift off spring retaining plate 18. the 6 - speed transmission. The input shaft assembly has some small differences.
  • Page 789 www.WorkshopManuals.co.uk Section F Transmission Section F 130 - 3 Powershift Gearbox 130 - 3 PS 760 - Forward/Input & Reverser Clutch - Assembly A396140 A402700 A396270 9803/3280 Issue 3* Purchased from www.WorkshopManuals.co.uk...
  • Page 790 www.WorkshopManuals.co.uk Section F Transmission Section F 130 - 4 Powershift Gearbox 130 - 4 PS 760 - Forward/Input & Reverser Clutch - Assembly Visually inspect the friction and counter plates: Using a dial test indicator as shown, measure the end Counter plates - light scoring/polishing is permissible, float of the pressure end plate 13, which should be 1.90 plates that are not flat, worn or heavily marked or scored...
  • Page 791 www.WorkshopManuals.co.uk Section F Transmission Section F 131 - 1 Powershift Gearbox 131 - 1 PS760 - Layshaft Clutch - Dismantling A396160 A396230 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 792 www.WorkshopManuals.co.uk Section F Transmission Section F 131 - 2 Powershift Gearbox 131 - 2 PS760 - Layshaft Clutch - Dismantling Note: The illustration shows a layshaft assembly for a 6 - Lift off spring retaining plate 19. speed transmission. The layshaft assembly for a 4 - speed transmission has some small differences.
  • Page 793 www.WorkshopManuals.co.uk Section F Transmission Section F 131 - 3 Powershift Gearbox 131 - 3 PS760 - Layshaft Clutch - Assembly 11/11A A405340 9803/3280 Issue 3* Purchased from www.WorkshopManuals.co.uk...
  • Page 794 www.WorkshopManuals.co.uk Section F Transmission Section F 131 - 4 Powershift Gearbox 131 - 4 PS760 - Layshaft Clutch - Assembly End Float Setting - Plate Carrier and Gear (Only clutch assemblies fitted with thrust washer 9A) Later clutch assemblies feature an additional thrust washer 9A.
  • Page 795 www.WorkshopManuals.co.uk Section F Transmission Section F 131 - 5 Powershift Gearbox 131 - 5 PS760 - Layshaft Clutch - Assembly A396160 A396230 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 796 www.WorkshopManuals.co.uk Section F Transmission Section F 131 - 6 Powershift Gearbox 131 - 6 PS760 - Layshaft Clutch - Assembly Visually inspect the friction and counter plates: † Fit the thick thrust washer 11, thin thrust washer 9A Counter plates - light scoring/polishing is permissible, thrust bearing 10 and thin thrust washer 9.
  • Page 797 www.WorkshopManuals.co.uk Section F Transmission Section F 132 - 1 132 - 1 Powershift Gearbox PS760 - Mainshaft Clutch - Dismantling (4-speed type) A396150 A396250 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 798 www.WorkshopManuals.co.uk Section F Transmission Section F 132 - 2 132 - 2 Powershift Gearbox PS760 - Mainshaft Clutch - Dismantling Note: The illustration shows a mainshaft assembly for a 6 - Lif t o f f sp ring ret aining p lat e 12. The 4 - sp eed speed transmission.
  • Page 799 www.WorkshopManuals.co.uk Section F Transmission Section F 132 - 3 132 - 3 Powershift Gearbox PS760 - Mainshaft Clutch - Assembly (4-speed type) A396150 A402700 A396250 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 800 www.WorkshopManuals.co.uk Section F Transmission Section F 132 - 4 132 - 4 Powershift Gearbox PS760 - Mainshaft Clutch - Assembly Visually inspect the friction and counter plates: Use an airline to check the operation of the clutch. Smear the taper roller bearing 5 with gearbox oil and Counter plates - light scoring/polishing is permissible, press the bearing onto the shaft.
  • Page 801 www.WorkshopManuals.co.uk Section F Transmission Section F 133- 1 Powershift Gearbox 133 - 1 PS760 - 6 Speed Clutch - Dismantling A396170 A396240 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 802 www.WorkshopManuals.co.uk Section F Transmission Section F 133- 2 Powershift Gearbox 133 - 2 PS760 - 6 Speed Clutch - Dismantling Carefully remove piston ring seals 1 at each end of the shaft. Lift off spring retaining plate 20. Note: If the piston ring seals are excessively worn then Remove the spring 21 and oil baffle 22.
  • Page 803 www.WorkshopManuals.co.uk Section F Transmission Section F 133- 3 Powershift Gearbox 133 - 3 PS760 - 6 Speed Clutch - Assembly A396170 A402700 A396240 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 804 www.WorkshopManuals.co.uk Section F Transmission Section F 133- 4 Powershift Gearbox 133 - 4 PS760 - 6 Speed Clutch - Assembly Visually inspect the friction and counter plates: 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).
  • Page 805 www.WorkshopManuals.co.uk Section F Transmission Section F 134 - 1 134 - 1 Powershift Gearbox PS 760 - 2/4WD Clutch (Pressure ON) - Dismantling A396260 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 806 www.WorkshopManuals.co.uk Section F Transmission Section F 134 - 2 134 - 2 Powershift Gearbox PS 760 - 2/4WD Clutch (Pressure ON) Dismantling Remove bearing 1, only if to be renewed. 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.
  • Page 807 www.WorkshopManuals.co.uk Section F Transmission Section F 134 - 3 134 - 3 Powershift Gearbox PS 760 - 2/4WD Clutch (Pressure ON) - Assembly A396260 9803/3280 Issue 2* Purchased from www.WorkshopManuals.co.uk...
  • Page 808 www.WorkshopManuals.co.uk Section F Transmission Section F 134 - 4 134 - 4 Powershift Gearbox PS 760 - 2/4WD Clutch (Pressure ON) - Assembly Visually inspect the friction and counter plates: Fit thrust washer 7. Counter plates - light scoring/polishing is permissible, 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...
  • Page 809 www.WorkshopManuals.co.uk Section F Transmission Section F 140 - 1 Powershift Gearbox 140 - 1 Polytetrafluoroethylene (PTFE) Piston Ring Seals - Fitting Procedure See Synchro Shuttle Gearbox, Piston Ring Seals - Fitting Procedure. 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 810 www.WorkshopManuals.co.uk Section F Transmission Section F 150 - 1 Torque Converter 150 - 1 Torque Converter Removal Rotate the flywheel until the next bolt hole is See the relevant gearbox removal procedure for torque accessible, fit and hand tighten the next bolt 3. Repeat converter removal.
  • Page 811 www.WorkshopManuals.co.uk Section F Transmission Section F 150 - 2 Torque Converter 150 - 2 A265990 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 812 www.WorkshopManuals.co.uk Section G Brakes Section G Contents Page No. Technical Data System type 2 - 1 Basic System Operation Compensating Master Cylinder - Description 3 - 1 Pedals Locked - Normal Operation 3 - 1 Pedals Locked - Compensating Operation 3 - 1 Pedals Unlocked - Normal Operation 3 - 1...
  • Page 813 Hydraulic servo assisted service brakes in rear axle only, operated from * separate pedals. Independant cable operated parking brake in the drive to the rear wheels. Service Brake Type JCB Oil-immersed multi-plate disc Actuation Hydraulic - vacuum servo assisted Location Rear axle centre casing (2 brake packs)
  • Page 814 www.WorkshopManuals.co.uk Section G Brakes Section G 3 - 1 Basic System Operation 3 - 1 Compensating Master Cylinder Pedals Locked - Compensating Operation When the brake pedals are pushed down (the brake pedals are mechanically locked together), actuation of the brake Description packs H and H1 is as described in Pedals Locked - Normal Compensating master cylinders overcome the problem of...
  • Page 815 www.WorkshopManuals.co.uk Section G Brakes Section G 10 - 1 Fault Finding 10 - 1 Brake System Note: The brakes generate a high temperature when operating, this means that the casing will be hot to touch, this condition is normal. Note aslo that 4WS machines do not have dual pedal braking. FAULT POSSIBLE CAUSE ACTION...
  • Page 816 www.WorkshopManuals.co.uk Section G Brakes Section G 10 - 2 Fault Finding 10 - 2 FAULT POSSIBLE CAUSE ACTION Pulling to one side when pedals Braking system inoperative on Unlatch pedals to test circuits locked together (cont'd). one side. individually. Friction plates worn beyond limits Renew friction/counter plates - or distorted on one side.
  • Page 817 www.WorkshopManuals.co.uk Section G Brakes Section G 10 - 3 Fault Finding 10 - 3 FAULT POSSIBLE CAUSE ACTION Poor braking when hot. Moisture in system vapourizing Strip axle and clean annular piston to when axle is hot. remove moisture. Remove master cylinders and check for corrosion, service as required.
  • Page 818 www.WorkshopManuals.co.uk Section G Brakes Section G 20 - 1 Service Procedures 20 - 1 Service Brakes Brake Light Switch - Adjustment Select the starter key switch to the ON position, do not start the engine. With the brake pedal in the return position, adjust locknuts B and use feeler gauges to set the proximity switch A so that there is clearance of 2mm MIN - 3mm MAX between the end of the switch and the brake...
  • Page 819 BRAK 2-1 1 Remove and cap brake piston feed pipe A. 2 Fill the brake piston housing with JCB Light Hydraulic Fluid. 3 Check for severe piston seal damage: Install a hand pump fitted with a 0 - 40 bar (0 - 600 lbf/in ) pressure gauge to port B, as shown at X.
  • Page 820 Parking Brake - Testing If you have any queries concerning this test procedure or SAFETY NOTICE: Ensure all routine health and safety parking brake adjustment, consult your local JCB distributor. precautions are observed before operating machines. ! WARNING ! WARNING Do not use a machine with a faulty parking brake.
  • Page 821 www.WorkshopManuals.co.uk Section G Brakes Section G 20 - 4 Service Procedures 20 - 4 Parking Brake - Adjustment Cable Adjustment ! CAUTION Adjust the cable at the calliper if there is insufficient The parking brake must not be used to slow the machine adjustment at the parking brake lever.
  • Page 822 www.WorkshopManuals.co.uk Section G Brakes Section G 20 - 5 Service Procedures 20 - 5 Parking Brake - Switch Adjustment Select the starter key switch to the ON position, do not start the engine. Select either forward or reverse. Raise the handbrake to the ON position. Adjust locknuts B and use feeler gauges to set the proximity switch A so that there is clearance of 2mm MIN - 3mm MAX between the end of the switch and the...
  • Page 823 www.WorkshopManuals.co.uk Section G Brakes Section G 20 - 6 Service Procedures 20 - 6 Parking Brake - Renewing the Brake Pads Pad Replacement ! WARNING Fit the pad 2 to the lever side of the calliper. Position the pad inside housing 15. Locate the plastic clip in the This is a safety critical installation.
  • Page 824 www.WorkshopManuals.co.uk Section G Brakes Section G 30 - 1 30 - 1 A396450 327340 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 825 BRAK 1-1 Fill the brake system with JCB Light Hydraulic Fluid and bleed the system. Refer to Service Brakes - Bleeding. Note: 4WS machines do not have dual pedal braking.
  • Page 826 Clean and lubricate all components, including new Examine the working surfaces of piston and cylinder. If seals, with JCB Special Hydraulic Fluid. DO NOT USE these are not in perfect condition the master cylinder CONVENTIONAL...
  • Page 827 www.WorkshopManuals.co.uk Section G Brakes Section G 40 - 1 Service Brakes 40 - 1 Dismantling and Assembly 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 F - Rear Axle Brakes. A264180 9803/3280 Issue 1...
  • Page 828 www.WorkshopManuals.co.uk Section G Brakes Section G 40 - 2 Service Brakes 40 - 2 Bleeding ! 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...
  • Page 829 www.WorkshopManuals.co.uk Section G Brakes Section G 50 - 1 Parking Brake 50 - 1 Torque Figures The illustration shows a typical installation. Where appropriate, the grade of bolt is indicated in parenthesis eg. (10.9). Refer also to relevant dismantling and assembly procedures.
  • Page 830 www.WorkshopManuals.co.uk Section G Brakes Section G 50 - 2 Parking Brake 50 - 2 Calliper Removal and Replacement ! WARNING Replacement This is a safety critical installation. Do not attempt to do Replacement is the reverse of the removal sequence. this procedure unless you are skilled and competent to do so.
  • Page 831 www.WorkshopManuals.co.uk Section G Brakes Section G 50 - 3 Parking Brake 50 - 3 Component Listing: Carrier Side Pad Lever Side Pad Bolt Anti-rotation Clip Washer Washer Lever Spring Rotor Ball Spacer Ball Bearings Mounting Bush O-ring Shaft Seal Housing 228362 9803/3280 Issue 1...
  • Page 832 www.WorkshopManuals.co.uk Section G Brakes Section G 50 - 4 Parking Brake 50 - 4 Calliper Dismantling and Assembly Dismantling Inspection The numerical sequence shown on the illustration on the Clean and dry all parts. Check all parts are free from adjacent page is intended as a guide to dismantling.
  • Page 833 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 834 www.WorkshopManuals.co.uk Section G Brakes Section G 50 - 6 Parking Brake 50 - 6 Dismantling and Assembly (cont’d) Assembly Before assembly make sure all parts are clean and serviceable. Fit a new shaft seal 14 if removed. Install the seal as shown.
  • Page 835 www.WorkshopManuals.co.uk Section G Brakes Section G 50 - 7 Parking Brake 50 - 7 Brake Disc - Removal and Replacement ! WARNING This is a safety critical installation. Do not attempt to do this procedure unless you are skilled and competent to do so.
  • Page 836 www.WorkshopManuals.co.uk Section H Steering Section H Contents Page No. 1 - 1 Service Tools Technical Data System Type 2 - 1 Basic System Operation 2 Wheel Steer Machines - Steer System Schematics 3 - 1 - Hydraulic Operation 3 - 2 4 Wheel Steer Machines - Steer System Schematics 3 - 3...
  • Page 837 www.WorkshopManuals.co.uk Section H Steering Section H 1 - 1 Service Tools 1 - 1 Hexagon Spanners for Ram Pistons and End Caps 992/09300 55mm A/F 992/09400 65mm A/F 992/09500 75mm A/F 992/09600 85mm A/F 992/09700 95mm A/F 992/09900 115mm A/F 992/10000 125mm A/F S191750...
  • Page 838 www.WorkshopManuals.co.uk Section H Steering Section H 2 - 1 Technical Data 2 - 1 System Type Full power hydrostatic with selectable 2-wheel, 4- wheel and crab steer modes on 4 wheel steer machines. Oil supply from Main Hydraulic Pump via Priority Valve to Steer Unit Valve complete with Load Sensing and Integral Relief Valve.
  • Page 839 www.WorkshopManuals.co.uk Section H Steering Section H 3 - 1 Basic System Operation 3 - 1 2 Wheel Steer Machines Steer System Schematics Component Key: Pump, Main Section Pump, Secondary Section Pressure Test Point Suction Line Tank In-tank Filter Priority Valve Front Power Track Rod Ram Steer Unit Shock Valve...
  • Page 840 www.WorkshopManuals.co.uk Section H Steering Section H 3 - 2 Basic System Operation 3 - 2 2 Wheel Steer Machines Hydraulic Operation The main components of the steering system are the priority valve 7, load sensing steer unit 42, hydraulic tank T and the front power track rod ram 10.
  • Page 841 www.WorkshopManuals.co.uk Section H Steering Section H 3 - 3 Basic System Operation 3 - 3 4 Wheel Steer Machines Steer System Schematics Component Key: Pump, Main Section Pump, Secondary Section Pressure Test Point Suction Line Tank In-tank Filter Priority Valve Steer Mode Control Valve Front Power Track Rod Ram Rear Power Track Rod Ram...
  • Page 842 www.WorkshopManuals.co.uk Section H Steering Section H 3 - 4 Basic System Operation 3 - 4 4 Wheel Steer Machines Hydraulic Operation The main components of the steering system are the priority valve 7, load sensing steer unit 42, hydraulic tank T, front power track rod ram 10 and rear power track rod ram 11.
  • Page 843 www.WorkshopManuals.co.uk Section H Steering Section H 3 - 5 Basic System Operation 3 - 5 4 Wheel Steer Machines Electrical Operation Three steering modes are available: - 2 Wheel Steer (front axle) - 4 Wheel Steer - Crab Steer The three modes are selected in the cab from a three position switch A which operates relays in the steer mode control unit B.
  • Page 844 www.WorkshopManuals.co.uk Steer Unit Operation - 2 Wheel Steer Machines On 2 wheel steer machines the hydraulic steer unit operation is identical to that described for the 4 wheel steer machines, except the unit pumps oil out directly to a power track rod ram fitted on the front axle only.
  • Page 845 www.WorkshopManuals.co.uk Steer Unit Operation - 4 Wheel Steer Machines 4 Wheel Steer Mode - Neutral Flow from the priority valve enters the steering unit through the bottom right hand port past the non- ret urn valve 43C. When t he st eering w heel is stationary the inner spool A and sleeve B are held in the neutral position by the centring springs K.
  • Page 846 www.WorkshopManuals.co.uk Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A395640 Purchased from www.WorkshopManuals.co.uk...
  • Page 847 www.WorkshopManuals.co.uk Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A395650 Purchased from www.WorkshopManuals.co.uk...
  • Page 848 www.WorkshopManuals.co.uk Steer Unit Operation - 4 Wheel Steer Machines 4 Wheel Steer Mode - Left Turn The illustration shows the flow through the steering unit in a left hand turn condition. Turning the steering wheel rotates the inner spool A a few degrees relative to the outer spool B, and sends a pressure signal to the relief valve 43B and through the LS port back to the priority valve.
  • Page 849 www.WorkshopManuals.co.uk Steer Unit Operation - 4 Wheel Steer Machines 4 Wheel Steer Mode - Right Turn The illustration shows the flow through the steering unit in a right hand turn condition. The operation is identical to that described for a left hand turn, except that the oil is diverted by spool A to the other side of stator D and power track rod rams 40 and 41.
  • Page 850 www.WorkshopManuals.co.uk Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A395660 Purchased from www.WorkshopManuals.co.uk...
  • Page 851 www.WorkshopManuals.co.uk Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A395670 Purchased from www.WorkshopManuals.co.uk...
  • Page 852 www.WorkshopManuals.co.uk Steer Unit Operation - 4 Wheel Steer Machines 4 Wheel Steer Mode - Right Turn, Unassisted The illustration shows the circuit operation with the engine stopped. Turning the steering wheel rotates the inner spool A until the cross pin engages with and rotates outer sleeve B, metering oil to the stator D, and pumping it out to power track rod rams 40 and 41 under manual pressure only.
  • Page 853 www.WorkshopManuals.co.uk Steer Unit Operation - 4 Wheel Steer Machines 4 Wheel Steer Mode - Shock Valve In normal operation oil flow from the pump enters the steering unit via the right hand port, opening a spring-loaded non-return valve 43C. The flow is directed by the steering unit to achieve the desired turn (right hand shown).
  • Page 854 www.WorkshopManuals.co.uk Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A395680 Purchased from www.WorkshopManuals.co.uk...
  • Page 855 www.WorkshopManuals.co.uk Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A395700 Purchased from www.WorkshopManuals.co.uk...
  • Page 856 www.WorkshopManuals.co.uk Steer Unit Operation - 4 Wheel Steer Machines 2 Wheel Steer Mode - Right Turn The illustration shows the flow through the steering unit in a right hand turn condition. The operation is identical to that described for the 4 wheel steer mode, except the steer mode control valve X iscolates the oil flow to the rear power track rod ram 41, consiquently the rotor lobes pump oil out...
  • Page 857 www.WorkshopManuals.co.uk Steer Unit Operation - 4 Wheel Steer Machines Crab Steer Mode - Right Turn The illustration shows the flow through the steering unit in a right hand turn condition. The operation is identical to that described for the 4 wheel steer mode, except the steer mode control valve X directs the pressurised oil from the front power track rod ram 40 to the other side of the rear power...
  • Page 858 www.WorkshopManuals.co.uk Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A395690 Purchased from www.WorkshopManuals.co.uk...
  • Page 859 www.WorkshopManuals.co.uk Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 R-CF A395710 Purchased from www.WorkshopManuals.co.uk...
  • Page 860 www.WorkshopManuals.co.uk Priority Valve Operation 1 - Neutral When the steering is not being operated, flow to the steering circuit is dead ended by the closed centre steering unit 43 and no load is sensed in line LS. Pressure from the main pump to the priority valve is fed via a drilling 2C to the rear of spool 2B.
  • Page 861 www.WorkshopManuals.co.uk Priority Valve Operation 2 - Turning As the steering unit 43 is operated, pressure is applied to the spring end of the priority valve spool 2B via sensing line LS from the steering unit. This reduces the pressure differential across the spool, causing it to move to the right under spring force.
  • Page 862 www.WorkshopManuals.co.uk Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 R-CF A395720 Purchased from www.WorkshopManuals.co.uk...
  • Page 863 www.WorkshopManuals.co.uk Section H Steering Section H 10 - 1 Fault Finding 10 - 1 Fault Finding Contents Introduction Page No. The purpose of this section is to help you trace hydraulic faults to a faulty unit (valve, actuator, ram etc). Once you have traced the faulty unit, refer to the appropriate Introduction 10 - 1...
  • Page 864 www.WorkshopManuals.co.uk Section H Steering Section H 10 - 2 Fault Finding 10 - 2 Fault Probable Cause Action Steering wheel difficult to turn. Priority valve not operating Check if the priority valve (continued) correctly is st ic k ing , rec t if y as required.
  • Page 865 www.WorkshopManuals.co.uk Section H Steering Section H 10 - 3 Fault Finding 10 - 3 Fault Probable Cause Action Machine will not turn when the Priority valve not operating Check if the priority valve steering wheel turned (continued). correctly is st ic k ing , rec t if y as required.
  • Page 866 www.WorkshopManuals.co.uk Section H Steering Section H 20 - 1 Service Procedures 20 - 1 Steering System - Bleeding Whenever hydraulic steering component disconnected or removed the system must be bled as follows. With the engine running, the following procedure must be carried out in the correct order that is laid down.
  • Page 867 www.WorkshopManuals.co.uk Section H Steering Section H 20 - 2 Service Procedures 20 - 2 Steering System - Pressure Testing Park the machine on level ground, engage the parking brake and set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.
  • Page 868 www.WorkshopManuals.co.uk Section H Steering Section H 20 - 3 Service Procedures 20 - 3 Proximity Switch - Setting ! WARNING Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut. GEN 3-2 Note: The proximity switch setting procedure is the same for both the front and rear axles.
  • Page 869 www.WorkshopManuals.co.uk Section H Steering Section H 20 - 4 Service Procedures 20 - 4 Steer Mode Valve - Checking Solenoid Operation The solenoids operate according to the steer mode that is selected. Mode: Solenoid(s) Energised: 2 Wheel Steer 4 Wheel Steer X, Z Crab Steer X, Y...
  • Page 870 www.WorkshopManuals.co.uk Section H Steering Section H 20 - 5 Service Procedures 20 - 5 Priority Valve - Cleaning The priority valve spool and spring may be removed for cleaning. Remove the priority valve from the machine. Refer to Priority Valve - Removal and Replacement. Unscrew adaptor 9 and extract the priority valve spring Remove the blanking plug 7.
  • Page 871 www.WorkshopManuals.co.uk Section H Steering Section H 20 - 6 Service Procedures 20 - 6 Priority Valve - Standby Pressure Testing Disconnect hose A and install a 0 - 40 bar (0 - 580 lbf/in ) pressure test gauge into the valve port. Position the open end of hose A into a clean container in order to collect any oil drainage.
  • Page 872 www.WorkshopManuals.co.uk Section H Steering Section H 30 - 1 Power Track Rod 30 - 1 Removal and Replacement This procedure is for a typical power steering track rod removal and replacement. ! WARNING Make the machine safe before working underneath it. Park the machine on level ground, lower the arms.
  • Page 873 www.WorkshopManuals.co.uk Section H Steering Section H 31 - 1 Power Track Rod 31 - 1 Link Arms - Removal and Replacement A258480 A258470 S300370 S258450 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 874 Remember to fit the target disc G (where applicable). Using two suitable open ended spanners at L and M react against each other until one ball joint unscrews. Use JCB Threadlocker & Sealer on the trackrod link arms. Unscrew the ball joint L until an open ended spanner can be fitted on the rod N.
  • Page 875 www.WorkshopManuals.co.uk Section H Steering Section H 32 - 1 Power Track Rod 32 - 1 Rams Dismantling and Assembly A258580 S258430 A258590 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 876 Note 2: The piston head cannot be removed from the rod. If Apply JCB Activator to threads of the end caps and there is damage to the rod or piston head, replace the cylinder. Allow Activator to dry for 15 minutes before complete assembly.
  • Page 877 Lubricate all parts with hydraulic fluid. Renew aluminium washers 8 and 10. Note 2: All hydraulic adapters that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adapter. Torque Settings...
  • Page 878 www.WorkshopManuals.co.uk Section H Steering Section H 45 - 1 Steer Mode Valve 45 - 1 Removal and Replacement ! WARNING Replacement ! WARNING Make the machine safe before working underneath it. Park the machine on level ground, lower the arms. Apply Fine jets of hydraulic fluid at high pressure can penetrate the parking brake, put the transmission in neutral and the skin.
  • Page 879 Assembly intended as a guide to dismantling. Renew all 'O' rings. For assembly the sequence should be reversed. Lubricate parts with JCB Special Hydraulic fluid before Dismantling assembling. Before dismantling scratch an alignment mark X along Use the alignment marks X (see dismantling) to ensure the faces of the solenoid valves and the manifold block.
  • Page 880 Note: All hydraulic adapters that are installed together with a Get an assistant to hold the steering unit, and, working bonded sealing washer must also have JCB Threadseal inside the cab, loosen and remove 4 bolts B. Lift the applied to the threads of the adapter.
  • Page 881 www.WorkshopManuals.co.uk Section H Steering Section H 50 - 2 Hydraulic Steer Unit 50 - 2 S10221A 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 882 www.WorkshopManuals.co.uk Section H Steering Section H 50 - 3 Hydraulic Steer Unit 50 - 3 Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. Note: 1 During manufacture, a small mark X will have been made on sleeve 12 and spool 15, close to one of the slots for the centring springs 13.
  • Page 883 If the shock valves have been dismantled, clean the threads of adjusting screw 31 and the threads in the bore of the steering unit body using JCB Cleaner/Degreaser, allow to dry. Assemble seat 35, ball 34, cap 33 and spring 32 then coat threads of screw 31 with JCB Threadlocker and Sealer.
  • Page 884 www.WorkshopManuals.co.uk Section K Engine Section K Contents Page No. Service Tools 1 - 1 Technical Data 2 - 1 Service Procedures Fuel Lift Pump - Cleaning the Strainer 20 - 1 Engine - Removal & Replacement 30 - 1 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 885 www.WorkshopManuals.co.uk Section K Engine Section K 1 - 1 Service Tools 1 - 1 892/00836 Lifting Wire Assembly (for engine removal) S192390 892/00041 De-glazing Tool for Cylinder Bores (to assist bedding-in of new piston rings) A314530 S219080 892/00936 Timing pin for fuel injection pump (AK, AM, AR) 892/0104 Adaptor for compression testing...
  • Page 886 www.WorkshopManuals.co.uk Section K Engine Section K 2 - 1 Technical Data 2 - 1 Type 1000 Series 4 cylinder Engines AB - Turbocharged AA - Naturally Aspirated AK - Turbocharged AM - Turbocharged and Intercooled AR - Naturally Aspirated Engine Build List Number AA50608 - AR50656, AR50654, AR50678 - 56kw (75bhp), AK50745 60kw (80bhp) AA50606 - 56kw (75bhp) AB50607 - 67.5 kw (90.5bhp), AK50628 - 68.5 kw (92bhp)
  • Page 887 www.WorkshopManuals.co.uk Section K Engine Section K 20 - 1 Service Procedures 20 - 1 Fuel Lift Pump - Cleaning the Strainer To remove and fit pump, see Engine Service Manual. Remove and c lean fuel inlet st rainer 2 if b loc kage is suspected ie.
  • Page 888 www.WorkshopManuals.co.uk Section K Engine Section K 30 - 1 Engine 30 - 1 A401530 9803/3280 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 889 www.WorkshopManuals.co.uk Section K Engine Section K 30 - 2 Engine 30 - 2 Removal and Replacement Loosen and remove the exhaust silencer retaining Removal bolts, remove the silencer. Park the machine on firm level ground, engage the Loosen and remove the retaining clamp for the heater parking brake and set the transmission to neutral.
  • Page 890 www.WorkshopManuals.co.uk Section K Engine Section K 30 - 3 Engine 30 - 3 Removal and Replacement Replacement Removal (continued) Replacement is a reversal of the removal procedure. If fitted, loosen and disconnect the ether cold start fuel line from the engine. Plug and cap open orifices to When mating the gearbox/torque converter to engine, prevent ingress of dirt and loss of fluid.

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