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jcb 1CX Service Manual

Backhoe loader
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www.WorkshopManuals.co.uk
Service
Manual
1CX, 208S
Backhoe
Loader
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; ©
WATERLOO PARK, UTTOXETER,
STAFFORDSHIRE, ST14 5PA, ENGLAND
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9803/8550
Purchased from www.WorkshopManuals.co.uk
General Information
Care & Safety
Routine Maintenance
R
Attachments
Body & Framework
Electrics
Controls
Hydraulics
Transmission
Brakes
Engine
1
2
3
A
B
C
D
E
F
G
K

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  • Page 1 Electrics Controls 1CX, 208S Backhoe Hydraulics Loader Transmission PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT Brakes OF JCB SERVICE; © WATERLOO PARK, UTTOXETER, STAFFORDSHIRE, ST14 5PA, ENGLAND Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND Engine Publication No. 9803/8550 Purchased from www.WorkshopManuals.co.uk...
  • Page 2 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 3 JCB SERVICE CATALOGUE / MANUAL - REPLACEMENT PAGES 1CX, 208S Service Manual 11th set Publication No. 9803/8550 These pages should be inserted immediately in their correct positions and pages of a lower issue no. removed and destroyed. The total contents of this publication can be checked using the index below. Retain index at front of book. Replacement pages issued in this set are indicated by an asterisk (*).
  • Page 4 www.WorkshopManuals.co.uk Page No Issue Page No Issue Page No Issue Page No Issue 31 - 2 31 - 3 31 - 4 32 - 1 32 - 2 32 - 3 32 - 4 32 - 5 32 - 6 33 - 1 33 - 2 33 - 3...
  • Page 5 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 6 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...

  • Page 7: Table Of Contents

    www.WorkshopManuals.co.uk Section 1 General Information Section 1 Contents Page No. Identifying Your Machine 1 - 1 Torque Settings 2 - 1 Service Tools 3 - 1 - Numerical List 3 - 1 - Electrics 4 - 1 - Hydraulics 4 - 2 Sealing and Retaining Compounds 5 - 1 9803/8550...

  • Page 8: Identifying Your Machine

    1105 HF 58.1 2200 160 HF Manufacturer Location (E = England) 2800 1CX HF 2800 817/16599 Product Identification Number (PIN) Unit Identification The engine serial number on XUD engines is stamped on an aluminium plate B on the side of the cylinder block. On Perkins engines the number is stamped on a label F on the right side of the cylinder block.
  • Page 9 (10) (12) (16) (20) (24) (30) 1633 1205 (36) 2854 2105 Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. 9803/8550 Issue 2* Purchased from www.WorkshopManuals.co.uk...

  • Page 10: Torque Settings

    www.WorkshopManuals.co.uk Section 1 General Information Section 1 2 - 2 Torque Settings 2 - 2 BSP Adapters with Bonded Washers. Adapter Size Spanner size Torque Settings kgf m lbf ft 10.4 12.4 18.7 20.7 31.1 31.1 SAE Adapters with ‘O’ rings. Adapter Size Torque Settings kgf m...
  • Page 11 www.WorkshopManuals.co.uk Section 1 General Information Section 1 3 - 1 Service Tools 3 - 1 Numerical List Page No. Page No. 1406/0011 Bonded Washer 4 - 3 892/00268 Flow Monitoring Unit 4 - 2 1406/0018 Bonded Washer 4 - 3 892/00269 Sensor Head 4 - 2...
  • Page 12 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 1 Service Tools 4 - 1 Section C - Electrics AVO Test Kit 892/00283 Tool Kit Case 892/00281 AVO Meter 892/00286 Surface Temperature Probe 892/00284 Microtach Digital Tachometer 892/00282 Shunt - open type 892/00285 Hydraulic Oil Temperature Probe S188230...
  • Page 13 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 2 Service Tools 4 - 2 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 (0-400 lbf/in 892/00254...

  • Page 14: Service Tools

    www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 3 Service Tools 4 - 3 Section E - Hydraulics S220840 892/00252 Test Block for A. R. V. 193850 188140 Hand Pump Equipment 892/00223 Hand Pump Bonded Washers 892/00137 Micro-bore Hose 1/4 in BSP x 5 metres 892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1406/0011...

  • Page 15: Hydraulics

    www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 4 Service Tools 4 - 4 Section E - Hydraulics 193880 193870 Male Cone Blanking Plug Female Cone Blanking Plug 816/00294 1/4 in BSP 892/00055 1/4 in BSP 816/00189 3/8 in BSP 892/00056 3/8 in BSP 816/00190...
  • Page 16 www.WorkshopManuals.co.uk Section 1 General Information Section 1 4 - 5 Service Tools 4 - 5 Section E - Hydraulics 11 o 10mm 20mm S338410 Ram Seal Protection Sleeves 892/01017 For 30 mm Rod Diameter 892/01018 For 40 mm Rod Diameter 110mm 175mm 892/01027...

  • Page 17: Sealing And Retaining Compounds

    4104/1557 Aerosol The part numbers and descriptions of sealing and retaining compounds available from JCB Service have been revised with effect from January 1997 (see MI 563/H, 507/HA, 511/E). The list above has been changed accordingly. References to these products on subsequent pages in this service manual will be progressively updated but for convenience a cross reference table is shown below.
  • Page 18 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 19 www.WorkshopManuals.co.uk Section 2 Care and Safety Section 2 Contents Page No. Safety Notices 1 - 1 General Safety 2 - 1 Operating Safety 2 - 2 Maintenance Safety 2 - 2 Safety Decals 2 - 4 9803/8550 Issue 2* Purchased from www.WorkshopManuals.co.uk...

  • Page 20: Safety Notices

    www.WorkshopManuals.co.uk Section 2 Care and Safety Section 2 1 - 1 Safety Notices 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 21: General Safety

    All construction and agricultural equipment can be If you are unsure of anything, about the machine or the job, hazardous. When a JCB machine is correctly operated and ask someone who knows. Do not assume anything. properly maintained, it is a safe machine to work with. But...

  • Page 22: Operating Safety

    ! WARNING Passengers in or on the machine can cause accidents. The Petrol JCB 1CX is a one man machine. Do not carry passengers. Do not use petrol in this machine. Do not mix petrol with the INT-2-2-2 diesel fuel; in storage tanks the petrol will rise to the top and ! WARNING form flammable vapours.
  • Page 23 www.WorkshopManuals.co.uk Section 2 Care and Safety Section 2 2 - 3 2 - 3 Maintenance Safety (cont’d) ! CAUTION ! WARNING 'O' rings, Seals and Gaskets Battery Gases Badly fitted, damaged or rotted 'O' rings, seals and gaskets Batteries give off explosive gases. Keep flames and sparks can cause leakages and possible accidents.

  • Page 24: Safety Decals

    ! WARNING number printed on it, use this number to order a new decal Fluoroelastomeric Materials from your JCB distributor. Certain seals and gaskets (e.g. crankshaft oil seal) on JCB INT-3-3-3 machines contain fluoroelastomeric materials such as Viton, ! WARNING Fluorel and Technoflon.
  • Page 25 www.WorkshopManuals.co.uk Section 2 Care and Safety Section 2 2 - 5 2 - 5 Safety Decals (cont’d) 203470 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 26 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 27 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 Contents Page No. Fluids, Capacities and Lubricants 1 - 1 Lubricants Health and Safety 1 - 3 Fuel System 2 - 1 Service Schedules 3 - 1 Loader Arm Safety Strut 4 - 1 Greasing 5 - 1 Body and Framework...
  • Page 28 ASTM D975-66T Nos. 1D, 2D Grease Points JCB Special HP Grease Lithium complex NLGI No. 2 consistency including extreme pressure additives or JCB Special MPL-EP Grease Lithium based NLGI No. 2 consistency including extreme pressure additives Chain Case Fill to level plug Engine Oil Slew Oil up to m/c no.
  • Page 29 CAPACITY FLUID/LUBRICANT SPECIFICATION Engine Oil 1.32 US gal JCB Genuine Engine Oil 15W/40 CH-4/SJ, SAE 15W 40 100 series up to m/c no. 807552 2.17 US gal 400 series from m/c no. 807553 2.8 US gal Hydraulic System 11.89 US gal...
  • Page 30 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...

  • Page 31: Routine Maintenance Section

    Hygiene Note the following when removing engine oil from skin: Wash your skin thoroughly with soap and water. JCB lubricants are not a health risk when used properly for Using a nail brush will help. their intended purposes. Use special hand cleansers to help clean dirty hands.

  • Page 32: Fuel System

    Sulphur: 0.5% of mass (maximum) Distillation: 85% at 350 °C (662 °F) If you have to use non-standard fuels, contact your JCB distributor for advice on engine adjustments and oil change Cetane Number periods. Indicates ignition performance. Fuel with a low cetane...

  • Page 33: Service Schedules

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 3 - 1 3 - 1 Service Schedules EVERY 10 OPERATING HOURS OR DAILY EVERY 50 OPERATING HOURS OR WEEKLY whichever occurs first, for the first 50 Operating Hours whichever occurs first only Do the Daily jobs plus: Check (engine stopped) Check (Engine Stopped)
  • Page 34 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 3 - 2 3 - 2 EVERY 250 OPERATING HOURS OR MONTHLY EVERY 1000 OPERATING HOURS OR YEARLY whichever occurs first whichever occurs first Do the Daily to 100 hour jobs plus: Do the Daily to 500 hour jobs plus: Clean Check (Engine Stopped) Air cleaner dust valve...

  • Page 35: Loader Arm Safety Strut

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 4 - 1 4 - 1 Loader Arm Safety Strut Removing Installing ! WARNING ! WARNING Raised loader arms can drop suddenly and cause You could be killed or injured if the loader control is serious injury.

  • Page 36: Greasing

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 5 - 1 5 - 1 ! WARNING Greasing You will be working close into the machine for these The machine must be greased regularly to keep it working jobs. Lower the attachments if possible. Remove the efficiently.
  • Page 37 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 5 - 2 5 - 2 ! WARNING Greasing (cont'd) Raised loader arms can drop suddenly and cause Loader Arm Pivot Points - for interval see Service Schedule serious injury. Before working under raised loader arms, fit the loader arm safety strut.
  • Page 38 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 5 - 3 5 - 3 Greasing (cont'd) Note: Lubricate the kingpost mounting rails and stabiliser Backhoe Pivot Points - for interval see Service Schedule legs with diesel oil or Waxoyl. Switch off the engine and ensure it cannot be started while you are doing this job.

  • Page 39: Body And Framework

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 6 - 1 6 - 1 Body and Framework Oiling Control Levers - for interval see Service Schedule Oil the clevis A at the bottom of each backhoe control lever. Checking Slew Oil Level - for interval see Service Schedule Park the machine on level ground and stop the engine.

  • Page 40: Electrical System

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 7 - 1 7 - 1 ! WARNING Electrical system Battery Battery Safety A battery with frozen electrolyte can explode if it is used or charged. Do not use a machine with a frozen battery. ! WARNING To help prevent the battery from freezing, keep the Batteries give off an explosive gas.
  • Page 41 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 7 - 2 7 - 2 Electrical system (cont'd) Changing the Light Bulbs Worklight Bulb Support the light unit B remove screws A. Lift and turn light unit B to gain access to connectors C and D.
  • Page 42 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 7 - 3 7 - 3 Electrical system (cont'd) Changing the Light Bulbs Switches With a fine screwdriver ease the Switch A from its socket in the control panel. The bulb holder B can then be pulled from the back of the Switch and the bulb will come with it.

  • Page 43: Hydraulic System

    ! CAUTION If the fluid is cloudy, water or air has entered the system. This could damage the hydraulic pump. Contact your JCB distributor. 7-3-6-1 Changing the Filter - for interval see Service Schedule Stop the engine and wait for 5 minutes.
  • Page 44 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...

  • Page 45: Drive Chain Lubrication

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 9 - 1 9 - 1 Transmission Drive Chain Lubrication The final drive to the wheels is by chains. A chain casing on each side of the machine houses two chains, one to the front wheel and one to the rear wheel.
  • Page 46 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 9 - 2 9 - 2 Transmission (cont'd) Adjusting the Drive Chain Tension Note: The drive chains on machines after serial no. 751600 Remove the rear wheel. are pre-tensioned during manufacture and there is no provision for routine adjustment in service.

  • Page 47: Tyres And Wheels

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 9 - 3 9 - 3 Transmission (cont'd) Renewing Segments of Optional Non-Inflatable Tyres Tyres and Wheels Non-inflatable tyres are available as an option. These tyres consist of a number of individual segments bolted to the Inflating the Tyres wheel rim.

  • Page 48: Air Filter

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 10 - 1 10 - 1 Engine Air Filter Changing the Elements - for intervals, see Service If required, unscrew nut F and remove inner element E. Schedule Clean inside the canister C and dust valve D. ! CAUTION Test the seating of seals B and J: The outer element must be renewed immediately if the...

  • Page 49: Checking The Oil Level - Xud Engine

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 10 - 2 10 - 2 Engine (cont'd) Checking the Oil Level - XUD engine - for interval, see Service Schedule ! WARNING Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.

  • Page 50: Changing The Oil And Filter - Xud Engine

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 10 - 3 10 - 3 Engine (cont'd) Changing the Oil and Filter - XUD engine (continued) Drain the oil. This should be done using the drain plug kit. Place a container that can hold at least 12 litres (3.6 gal) beneath the drain hole at the right hand front corner of the engine compartment.

  • Page 51: Checking The Oil Level - 100 Series Engine Up To Machine No. 807552

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 10 - 4 10 - 4 Engine (cont'd) Checking the Oil Level - 100 series engine up to machine no. 807552 - for interval see Service Schedule ! WARNING Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.
  • Page 52 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 10 - 5 10 - 5 Engine (cont'd) Changing the Oil and Filter - 100 series engine up to machine no. 807552 (cont'd) Unscrew the filter canister E, using a chain wrench if necessary.
  • Page 53 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 10 - 5A 10 - 5A Engine (cont'd) Checking the Oil Level - 400 series engine from machine no. 807553 - for interval see Service Schedule ! WARNING Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.

  • Page 54: Renewing The Engine Breather From Machine No. 807553 10 - 5B

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 10 - 5B 10 - 5B Engine (cont'd) Changing the Oil and Filter - 400 series engine from machine no. 807553 (cont'd) Unscrew the filter canister E, using a chain wrench if necessary. Remember that it will contain some oil. Clean filter head F.

  • Page 55: Draining The Fuel Filter - Xud Engine

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 10 - 6 10 - 6 Engine (cont'd) Draining the Fuel Filter - XUD engine - for interval, see Service Schedule The fuel filter is located on the rear left hand side of the engine compartment.
  • Page 56 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 10 - 7 10 - 7 Engine (cont'd) Draining the Fuel Filter - 100 & 400 series engines - for interval see Service Schedule The fuel filter is located at the front left hand side of the engine compartment.
  • Page 57 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 10 - 7A 10 - 7A Engine (cont'd) Draining the Fuel Filter - 100 & 400 series engines (cont’d) 14 Prime the Filter. Early Machines Slacken bleed screw M and operate the lift pump priming lever N until fuel spurts from the loosened connection with no entrapped air.
  • Page 58 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...

  • Page 59: Cleaning The Coolant Radiator

    After allowing the engine to cool down use compressed - 37 °C (- 35 °F) air to remove debris from the radiator E. On 100 and 400 series engine machines use JCB Four Use a brush to remove any further debris. Seasons Antifreeze and Summer Coolant.

  • Page 60: Checking The Coolant Level - Xud Engine

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 10 - 9 10 - 9 Engine (cont'd) Checking the Coolant Level - XUD engine ! WARNING The cooling system is pressurised when the coolant is hot. Hot coolant will burn you. Make sure the engine is cool before checking the coolant level or draining the system.
  • Page 61 www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 10 - 10 10 - 10 Engine (cont'd) Checking the Coolant Level - 100 & 400 series engines Changing the Coolant - 100 & 400 series engines - for interval, see Service Schedule ! WARNING Park the machine on level ground.

  • Page 62: Adjusting The Alternator Belt

    www.WorkshopManuals.co.uk Section 3 Routine Maintenance Section 3 10 - 11 10 - 11 Engine (cont'd) Note: The top illustration shows the XUD engine, the middle illustration shows the 100 series engine up to machine number 807552, the bottom illustration shows the 400 series engine from machine number 807553.
  • Page 63 www.WorkshopManuals.co.uk Section A Optional Attachments Section A Contents Page No. Quick Release Couplings 1 - 1 Shovels General Purpose and Light Duty Shovels 3 - 1 6-in-1 Shovels 3 - 1 Pallet Forks 4 - 1 Manure/Silage Fork With Top Grab 5 - 1 Attachment Frame 6 - 1...

  • Page 64: Quick Release Couplings

    www.WorkshopManuals.co.uk Section A Optional Attachments Section A 1 - 1 Quick Release Couplings 1 - 1 ! WARNING Flat face quick release couplings allow the operator to remove and install attachments swiftly and efficiently. The Hydraulic Pressure attachment pipework has two male couplings fitted on the Hydraulic fluid at system pressure can injure you.
  • Page 65 www.WorkshopManuals.co.uk Section A Optional Attachments Section A 2 - 1 Connecting/Disconnecting Hydraulic Hoses 2 - 1 Some attachments are hydraulically powered. The following Disconnecting the Hoses paragraphs describe how to connect and disconnect the hydraulic hoses safely. Vent the hydraulic pressure as described on this page. ! WARNING Disconnect the hoses.

  • Page 66: General Purpose And Light Duty Shovels

    www.WorkshopManuals.co.uk Section A Optional Attachments Section A 3 - 1 Shovels 3 - 1 General Purpose and Light Duty Shovels Daily Maintenance Clean with the rest of the machine. Ensure that the Quickhitch framework is not damaged or badly worn. Repair if necessary. Check for damage.

  • Page 67: Pallet Forks

    www.WorkshopManuals.co.uk Section A Optional Attachments Section A 4 - 1 Pallet Forks 4 - 1 The pallet fork frame includes a Rating Plate which gives its weight and its Safe Working Load. The forks should always be used in pairs as supplied. Each fork is stamped with its Part Number and Safe Working Load.

  • Page 68: Manure/Silage Fork With Top Grab

    www.WorkshopManuals.co.uk Section A Optional Attachments Section A 5 - 1 Manure/Silage Fork with Top Grab 5 - 1 The Manure/Silage fork is fitted with a top grab as standard which gives extra security to the pay load when moving the machine.

  • Page 69: Attachment Frame

    www.WorkshopManuals.co.uk Section A Optional Attachments Section A 6 - 1 Attachment Frame 6 - 1 Some attachments utilise an attachment frame for installing on the machine. Daily Maintenance Clean with the rest of the machine. Check for damage. Repair or replace as necessary. 204170 9803/8550 Issue 2*...
  • Page 70 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 71 www.WorkshopManuals.co.uk Section B Body and Framework Section B Contents Page No. Floor Plates Removal and Replacement 1 - 1 Loader Arm Removal and Replacement 2 - 1 Dipper Removal and Replacement 3 - 1 Boom Removal and Replacement 4 - 1 Kingpost Assembly Removal and Replacement up to machine no.

  • Page 72: Body And Framework Section B

    www.WorkshopManuals.co.uk Section B Body and Framework Section B 1 - 1 1 - 1 To gain access to the pumps, motors, valves and pipework, it is necessary to remove some of the floor plates. Removal and Replacement At each side, remove the two bolts A and the metal strip B which hold the floor mat in position.

  • Page 73: Loader Arm

    ! WARNING Replacement is a reversal of the removal procedure. Grease Hydraulic Pressure all pins and securing bolts with JCB Special MPL grease. Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or Shims are available in two thicknesses (2 mm and 3 mm)
  • Page 74 Replacement is a reversal of the removal procedure. Grease Hydraulic fluid at system pressure can injure you. Before all pins and securing bolts with JCB Special MPL grease. disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in Reconnect all hoses and bleed the hydraulic system.
  • Page 75 It is assumed that the dipper has been removed as Replacement is a reversal of the removal procedure. Grease described on page B/3 - 1. all pins and securing bolts with JCB Special MPL grease. ! WARNING Reconnect all hoses and bleed the hydraulic system.
  • Page 76 www.WorkshopManuals.co.uk Section B Body and Framework Section B 5 - 1 Kingpost Assembly 5 - 1 S242442 347390 9803/8550 Issue 4 Purchased from www.WorkshopManuals.co.uk...

  • Page 77: Removal And Replacement Up To Machine No. 807225

    Remove rack seals 3 as each side of the rack 4 is exposed. Lubricate the pinion and rack with gear oil before assembly. Apply JCB Special MPL grease to pivot pin 10. Kingpost - Removal Check that shim 11 is the latest steel type; replace if not.
  • Page 78 www.WorkshopManuals.co.uk Section B Body and Framework Section B 5 - 3 Kingpost Assembly 5 - 3 S242442A 9803/8550 Issue 2 Purchased from www.WorkshopManuals.co.uk...

  • Page 79: Removal And Replacement From Machine No. 807226

    Repacement is a reversal of the removal procedure. Remove rack seals 3 as each side of the rack 4 is exposed. If bush 16 is to be renewed, coat outside diameter with JCB Multi-Gasket before pressing into position. Kingpost - Removal Lubricate the pinion and rack with gear oil before assembly.
  • Page 80 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 81 www.WorkshopManuals.co.uk Section C Electrics Section C Contents Page No. Technical Data 1 - 1 Light Bulbs 1 - 1 Relays up to machine no. 751599 1 - 1 from machine no. 751600 to 752370 1 - 3 from machine no. 752371 1 - 4 Circuit Protection up to machine no.

  • Page 82: Technical Data

    www.WorkshopManuals.co.uk Section C Electrics Section C 1 - 1 Technical Data 1 - 1 System Type 12 Volts, negative earth Battery Cold crank amps for 1 minute to 1.4 VPC at -18 °C (0 °F) 420 to 585 according to battery type Reserve capacity (minutes) for 25 Amp load 170 to 230 Alternator...

  • Page 83: Up To Machine No. 751599

    www.WorkshopManuals.co.uk Section C Electrics Section C 1 - 2 Technical Data 1 - 2 Circuit Protection up to machine no. 751599 Fuses The electrical circuits are protected by fuses. The fuses are located behind the panel A as shown in the illustration. Fuse Service Fuse Size...

  • Page 84: From Machine No. 751600 To 752370

    www.WorkshopManuals.co.uk Section C Electrics Section C 1 - 3 Technical Data 1 - 3 Circuit Protection from machine no. 751600 to 752370 Fuses The electrical circuits are protected by fuses. The fuses are located behind panel H. Parkbrake Auxiliary Hydraulics High-flow Hydraulics Instrumentation Front / Rear Horn...

  • Page 85: From Machine No. 752371

    www.WorkshopManuals.co.uk Section C Electrics Section C 1 - 4 Technical Data 1 - 4 Circuit Protection from machine no. 752371 Fuses The electrical circuits are protected by fuses. The fuses are located behind panel H. Park Brake Auxiliary Hydraulics High-flow Hydraulics Instrumentation Engine Shut-off Solenoid Float Hydraulics...
  • Page 86 www.WorkshopManuals.co.uk Section C Electrics Section C 1 - 5 Technical Data 1 - 5 Sensing Switches Transmission Charge Pressure Switch. Normally closed, opens at 2-3.4 bar (30-50 lbf/in ) falling. Transmission Oil Temperature Switch. Normally open, closes at 107-113 °C (225-235 °F) rising. Reverse Alarm Pressure Switches.

  • Page 87: Test Methods

    www.WorkshopManuals.co.uk Section C Electrics Section C 2 - 1 Test Methods 2 - 1 Use Of Multimeter In order to obtain maximum benefit from the fault finding information contained in Section C it is important that the technician fully understands the approach to fault finding and the use of the recommended test equipment, in this case an AVO 2003 digital multimeter, or a moving pointer (analogue) multimeter.

  • Page 88: Measuring Dc Voltage

    www.WorkshopManuals.co.uk Section C Electrics Section C 2 - 2 Test Methods *2 - 2 Measuring DC Voltage 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 89: Testing A Diode Or Diode Wire

    www.WorkshopManuals.co.uk Section C Electrics Section C 2 - 3 Test Methods *2 - 3 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 90: Safety

    www.WorkshopManuals.co.uk Section C Electrics Section C 3 - 1 Batteries 3 - 1 Safety Maintenance ! WARNING To ensure that the battery provides optimum performance the following steps should be observed: Batteries give off an explosive gas. Do not smoke when handling or working on the battery.

  • Page 91: Battery Testing

    www.WorkshopManuals.co.uk Section C Electrics Section C 3 - 2 Batteries 3 - 2 Specific Gravity (SG) Test The specific gravity of the electrolyte gives an idea of the If the electrolyte temperature is other than 15 °C (60 °F) state of charge of the battery. Readings should be taken a 'correction factor' must be applied to the reading using a hydrometer, when the electrolyte temperature is 15 obtained.

  • Page 92: Alternator

    www.WorkshopManuals.co.uk Section C Electrics Section C 4 - 1 Alternator 4 - 1 The alternator is a three phase generator having a rotating AVO 2003 Red lead to amps socket (marked A) on the field winding and static power windings. meter.

  • Page 93: Removal And Replacement

    www.WorkshopManuals.co.uk Section C Electrics Section C 4 - 2 Alternator 4 - 2 Removal and Replacement XUD Engines Removal Disconnect the battery negative lead. Disconnect the wiring from the rear of the alternator. Loosen the pivot bolt A and the adjustment lock nut B. Unscrew the adjustment bolt C to release the tension then slip the drive belt from the pulleys.
  • Page 94 www.WorkshopManuals.co.uk Section C Electrics Section C 4 - 3 Alternator 4 - 3 S213570 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...

  • Page 95: Dismantling And Assembly

    www.WorkshopManuals.co.uk Section C Electrics Section C 4 - 4 Alternator 4 - 4 Removal and Replacement Dismantling and Assembling Perkins Engines Dismantling Disconnect the battery negative lead. Remove suppressor 2 (if fitted) by removing nut 1 and disconnecting lead E from terminal F. Disconnect the wiring from the rear of the alternator.

  • Page 96: Starter Motor

    www.WorkshopManuals.co.uk Section C Electrics Section C 5 - 1 Starter Motor 5 - 1 Starting Circuit Test Before carrying out the voltmeter tests, check the battery If the reading is less than specified, connect the voltmeter condition (see Battery Testing) and ensure that all between the neutral start relay terminal D and earth.

  • Page 97: Removal And Replacement

    100 and 400 Series Engines Disconnect the battery negative lead. For Removal, Replacement and Servicing procedures refer to 100 Series Engine Workshop Manual (JCB part no. Disconnect the cables from main starter terminal A and 9806/2100) or 400 Series Engine Workshop Manual (JCB solenoid terminal B.

  • Page 98: Circuit Diagram

    www.WorkshopManuals.co.uk Section C Electrics Section C 6 - 1 Circuit Diagram 6 - 1 Up to machine no. 751599 61 Brake Light Switches 62 Brake Light Timer Main Components 63 Hydraulic Float Switch 64 Hydraulic Float Pressure Switch Battery 65 Hydraulic Float Relay Glow Plug 66 Hydraulic Float Solenoid Glow Plug...
  • Page 99 www.WorkshopManuals.co.uk Section C Electrics Section C 6 - 2 Circuit Diagram 6 - 2 34 35 50 51 52 101 102 60 59 A204781 Issue 2 9803/8550 Purchased from www.WorkshopManuals.co.uk...
  • Page 100 www.WorkshopManuals.co.uk Section C Electrics Section C 6 - 3 Circuit Diagram 6 - 3 852/95001/1 9803/8550 Issue 2 Purchased from www.WorkshopManuals.co.uk...

  • Page 101: From Machine No. 751600 To 752370

    www.WorkshopManuals.co.uk Section C Electrics Section C 6 - 4 Circuit Diagram 6 - 4 From machine no. 751600 to 752370 Main Components Battery 61 Hydraulic Float Pressure Switch Starter Switch 62 Latching Relay Neutral Start Relay 63 Hydraulic Float Solenoid Glow Plugs 64 Face Level Fan Starter Motor...

  • Page 102: From Machine No. 752371 To 752675

    www.WorkshopManuals.co.uk Section C Electrics Section C 6 - 5 Circuit Diagram 6 - 5 From machine no. 752371 to 752675 Main Components Lamps Battery 80 Alternator Warning Glow Plugs 81 Engine Coolant Temperature Warning Starter Motor 82 Hydraulic Oil Temperature Warning Starter Solenoid 83 Engine Oil Pressure Warning Neutral Start Relay...
  • Page 103 www.WorkshopManuals.co.uk Section C Electrics Section C 6 - 6 Circuit Diagram 6 - 6 30 31 32 33 12 13 415A 403C 414A 80 81 82 83 84 85 852/95001/2 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 104 www.WorkshopManuals.co.uk Section C Electrics Section C 6 - 7 Circuit Diagram 6 - 7 30 31 32 33 12 13 80 81 82 83 84 85 347381 9803/8550 Issue 2 Purchased from www.WorkshopManuals.co.uk...

  • Page 105: From Machine No. 752676

    www.WorkshopManuals.co.uk Section C Electrics Section C 6 - 8 Circuit Diagram 6 - 8 From machine no. 752676 Main Components Lamps Battery 80 Alternator Warning Glow Plugs 81 Engine Coolant Temperature Warning Starter Motor 82 Hydraulic Oil Temperature Warning Starter Solenoid 83 Engine Oil Pressure Warning Neutral Start Relay 84 Air Cleaner Warning...
  • Page 106 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 107 www.WorkshopManuals.co.uk Section D Controls Section D Contents Page No. Throttle Controls Hand and Foot Throttles Description 1 - 1 Removal and Replacement 1 - 1 Adjustment 1 - 1 Throttle Cable Removal and Replacement 1 - 2 Adjusting the Idle and Non-Stalling Settings 1 - 2 9803/8550 Issue 1...
  • Page 108 www.WorkshopManuals.co.uk Section D Controls Section D 1 - 1 Throttle Controls 1 - 1 Hand and Foot Throttles Description The combined foot and hand throttle controls are designed to operate in conjunction with each other. Once the engine has been started, the hand throttle can be set to give an engine speed suitable for the operations to be performed.
  • Page 109 www.WorkshopManuals.co.uk Section D Controls Section D 1 - 2 Throttle Controls 1 - 2 Throttle Cable Adjusting the Idle and Non-Stalling Settings Removal Note: These adjustments should be carried out with the Remove the inner cable from the slot in the accelerator lever. engine warm.
  • Page 110 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 111 www.WorkshopManuals.co.uk Section E Hydraulics Section E Contents Page No. Technical Data up to machine no. 752462 1 - 1 Technical Data from machine no. 752463 1 - 3 Connecting/Disconnecting Hydraulic Hoses 2 - 1 Hydraulic Contamination Hydraulic Fluid Quality 3 - 1 Effects of Contamination 3 - 1 Contaminant Standards...
  • Page 112 www.WorkshopManuals.co.uk Section E Hydraulics Section E Contents Page No. Pumps (cont’d) Hydrostatic Pump from machine no. 751012 Removal and Replacement - Shaft Seal 12 - 9 Dismantling and Assembly - Charge Check and High Pressure Relief Valves 12 - 10 - Charge/Anti-stall Valve 12 - 11 Charge Pressure Adjustment...
  • Page 113 www.WorkshopManuals.co.uk Section E Hydraulics Section E Contents Page No. Schematic Hydraulic Circuits Standard Machine - Single Lever Drive Control - up to machine number 751011 30 - 1 - from machine number 751012 to 752462 30 - 3 - from machine number 752463 30 - 5 Standard Machine - Dual Lever Drive Control - from machine number 751012 to 752462...
  • Page 114 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 115 www.WorkshopManuals.co.uk Section E Hydraulics Section E 1 - 1 Technical Data 1 - 1 Note: System Cleanliness is to be to ISO 16/13 - See page E/3 - 1 for guidance. Up to machine number 752462 Auxiliary Pump - Standard Type Gear Displacement...
  • Page 116 www.WorkshopManuals.co.uk Section E Hydraulics Section E 1 - 2 Technical Data 1 - 2 Up to machine number 752462 Relief Valve Operating Pressures kgf/cm lbf/in Main Relief Valve (M.R.V.) at 1500 rev/min 3006 Auxiliary Relief Valves (A.R.V.) Loader Shovel Crowd 3410 Shovel Dump 100-103...
  • Page 117 www.WorkshopManuals.co.uk Section E Hydraulics Section E 1 - 3 Technical Data 1 - 3 Note: System Cleanliness is to be to ISO 16/13 - See page E/3 - 1 for guidance. From machine number 752463 Auxiliary Pump - Standard Type Gear Displacement 48 l/min (10.5 UK gal/min, 12.7 US gal/min) at 3000 rev/min...
  • Page 118 www.WorkshopManuals.co.uk Section E Hydraulics Section E 1 - 4 Technical Data 1 - 4 From machine number 752463 Relief Valve Operating Pressures kgf/cm lbf/in Main Relief Valve (M.R.V.) at 1500 rev/min 3006 Auxiliary Relief Valves (A.R.V.) Loader Shovel Crowd 3410 Shovel Dump 100-103 102-105...

  • Page 119: Connecting/Disconnecting Hydraulic Hoses

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 2 - 1 Connecting/Disconnecting Hydraulic Hoses 2 - 1 The following paragraphs describe how to connect and Disconnecting the Hoses disconnect hydraulic hoses safely. Vent the hydraulic pressure as described on this page. ! WARNING Disconnect the hoses.

  • Page 120: Hydraulic Contamination

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 3 - 1 Hydraulic Contamination 3 - 1 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 hydraulic system for power transmission, equipment be seen with the eye.

  • Page 121: Cleaning Operation

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 3 - 2 Hydraulic Contamination 3 - 2 Cleaning Operation The purpose of cleaning the hydraulic oil is to remove Connect the hydraulic line to the head side of the rams contaminants of all types and sludge. (the retracting side), leave the rod side disconnected.
  • Page 122 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...

  • Page 123: General Description Up To Machine No. 752462

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 4 - 1 Descriptions 4 - 1 General Description up to machine no. 752462 The main components of the hydraulic circuit are the tank, pumps, drive motors, the servo operated loader and drive control circuits, the manually operated excavator valves, filters, cooler, rams and pressure reducing solenoid valve.

  • Page 124: General Description From Machine No. 752463

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 4 - 2 Descriptions 4 - 2 General Description from machine no. 752463 The main components of the hydraulic circuit are the tank, pumps, drive motors, the servo operated loader and drive control circuits, the manually operated excavator valves, filters, cooler, rams and solenoid brake valve. The pumps are driven by the engine and are mounted in tandem.
  • Page 125 www.WorkshopManuals.co.uk Section E Hydraulics Section E 8 - 8 Descriptions 8 - 8 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 126 www.WorkshopManuals.co.uk Section E Hydraulics Section E 9 - 1 Descriptions 9 - 1 PRESSURE IN JOYSTICK (LOADER) TANK SOL.19 SOL.18 BRAKE A204763 EXTRACTS FROM WIRING DIAGRAM SCHEMATICS 9803/8550 Issue 4 Purchased from www.WorkshopManuals.co.uk...

  • Page 127: Operation

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 9 - 2 Descriptions 9 - 2 Pressure Reducing Solenoid Valve Pressure Reducing Solenoid Valve (up to machine no. 751599) (from machine no. 751600) This valve supplies hydraulic oil at reduced pressure to This valve supplies hydraulic oil at reduced pressure to operate the loader joystick and the automatic parking brake.

  • Page 128: Drive Motor Operation

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 10 - 1 Descriptions 10 - 1 Drive Motor Operation Note: On the illustration below, the main parts of the motor Oil under pressure passes through the disc valve inlets to are shown slightly separated for purposes of explanation. the inter-tooth chambers on one side of the gearwheel set.
  • Page 129 www.WorkshopManuals.co.uk Section E Hydraulics Section E 10 - 2 Descriptions 10 - 2 Drive Motor Operation From machine no. 751818, a different type motor is fitted High pressure which has a flushing circuit. This is used to cool the motors during operation.
  • Page 130 www.WorkshopManuals.co.uk Section E Hydraulics Section E 10 - 3 Descriptions 10 - 3 9803/8550 Issue 4 Purchased from www.WorkshopManuals.co.uk...
  • Page 131 www.WorkshopManuals.co.uk Section E Hydraulics Section E 10 - 4 Descriptions 10 - 4 9803/8550 Issue 4 Purchased from www.WorkshopManuals.co.uk...
  • Page 132 www.WorkshopManuals.co.uk Section E Hydraulics Section E 11 - 0 Pumps 11 - 0 Hydrostatic Transmission Problem Solving The purpose of this page is to help you trace transmission problems to a faulty unit (pump, motor, joystick etc). Once you have traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the manual.
  • Page 133 www.WorkshopManuals.co.uk Section E Hydraulics Section E 11 - 0A Pumps 11 - 0A Hydrostatic Transmission Problem Solving (cont’d) KEY TO CAUSE REMEDY PAGE REF. No hydraulic feed from joystick to pump Check for feed from joystick to pump. E12-16 Motor seal leakage Check motor case drain for confirmation of seal leakage E12-15 (compare one motor with the other).

  • Page 134: Removal And Replacement

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 11 - 1 Pumps 11 - 1 Removal and Replacement Note: The illustration shows an early pump but although later Replacement pumps are visually different the same procedure applies. Using suitable lifting equipment, ease the pump unit into Removal position, making sure that the pump unit/engine couplings engage smoothly and completely.

  • Page 135: Pump/Engine Coupling

    E. The inner section A is tightened onto the pump shaft spline with cap screw D. Coat threads of capscrew D with JCB Threadlocker and Sealer and torque tighten to 47 Nm (35 lbf ft, 4.8 kgf m). Coat threads of capscrews E with JCB Threadlocker and Sealer and torque tighten to 28 Nm (21 lbf ft, 2.8 kgf m).
  • Page 136 www.WorkshopManuals.co.uk Section E Hydraulics Section E 11 - 3 Pumps 11 - 3 A168042 S246240 348890 9803/8550 Issue 3 Purchased from www.WorkshopManuals.co.uk...

  • Page 137: Start-Up Procedure

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 11 - 4 Pumps 11 - 4 Start-Up Procedure The following start-up procedure should always be followed Fill the hydraulic tank with the correct fluid (see page 3/1 - when starting up a new installation or when restarting an 1), via a 10 micron filter (no by-pass).
  • Page 138 www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 1 Pumps 12 - 1 168150 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...

  • Page 139: Hydrostatic Pump Up To Machine No. 751011

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 2 Pumps 12 - 2 Hydrostatic Pump up to machine no. 751011 Dismantling and Assembly Separating the Front and Rear Pumps The information on this page covers the dismantling and The front and rear pumps are secured together by four assembly of those 'auxiliary' components which are capscrews 18.
  • Page 140 www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 3 Pumps 12 - 3 168030 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...

  • Page 141: Dismantling And Assembly

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 4 Pumps 12 - 4 Hydrostatic Pump Endcaps up to machine no. 751011 Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. Each endcap 8, 9 is secured to its pump by four capscrews 2.
  • Page 142 www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 5 Pumps 12 - 5 168160 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 143 www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 6 Pumps 12 - 6 Hydrostatic Pump up to machine no. 751011 Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed.

  • Page 144: Fault Finding

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 7 Pumps 12 - 7 Fault Finding up to machine no. 751011 Machine veers to one side when travelling. This condition may be corrected by adjusting the pump servo units but before attempting this, carry out the following preliminary checks.
  • Page 145 www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 8 Pumps 12 - 8 Fault Finding up to machine no. 751011 Machine moves when drive control is in neutral. This may be caused by the neutral setting of the pump being Remove one locking plate screw and slacken the other incorrect but before assuming this check that the joystick screw then swing the locking plate F clear.

  • Page 146: Hydrostatic Pump From Machine No. 751012

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 9 Pumps 12 - 9 Hydrostatic Pump from machine no. 751012 Dismantling and Assembly Following a complete rebuild of this pump it is necessary for it to be set up on a dynamic test jig. Because of this it is recommended that no dismantling work is carried out beyond that covered in the following pages.

  • Page 147: Charge Check And High Pressure Relief Valves

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 10 Pumps 12 - 10 Hydrostatic Pump from machine no. 751012 Charge Check and High Pressure Relief Valves Dismantling and Assembly The charge check and high pressure relief valves are identical. The procedure for dismantling and assembly is, therefore, the same for both valves.

  • Page 148: Charge/Anti-Stall Valve

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 11 Pumps 12 - 11 Hydrostatic Pump from machine no. 751012 Charge/Anti-stall Valve Dismantling and Assembly Mark the plug 1, locknut 2 and the pump body so as to approximately maintain the original adjustment. Loosen locknut 2 and unscrew plug 1 from pump body Remove O-ring 3 from plug 1 and discard O-ring.

  • Page 149: Pump Neutral Adjustment

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 12 Pumps 12 - 12 Hydrostatic Pump from machine no. 751012 Pump Neutral Adjustment This procedure may be carried out if the machine creeps when the drive joystick is in the neutral position. This fault may be due to an incorrect neutral setting of the servo piston.

  • Page 150: Fault Finding

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 13 Pumps 12 - 13 Fault Finding from machine no. 751012 Machine veers to one side when travelling. Note: On standard machines the displacement limiter adjustment screws are set to allow a gap when the servo If the machine does not travel in a straight line, proceed as piston is at full travel.
  • Page 151 www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 14 Pumps 12 - 14 Checking for Faulty Pump or Motor If the transmission operates or is faulty on one side only then Restart the engine and re-check the operation of left swop the motor feed hoses to check if the fault is with the and right motors.
  • Page 152 www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 15 Pumps 12 - 15 Checking Motor Leakage Rate If the motor speed is low and the pump output is normal, the cause could be excessive internal wear in the motor which would result in high leakage of oil into the motor casing.
  • Page 153 www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 16 Pumps 12 - 16 Checking the Joystick Hydraulic Lines If the machine does not respond to joystick movements, If the supply pressure is correct, check the feed hose to check the hydraulic supply to and from the joystick as the joystick for blockage.
  • Page 154 www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 17 Pumps *12 - 17 S167751 139690 9803/8550 Issue 2* Purchased from www.WorkshopManuals.co.uk...

  • Page 155: Auxiliary Pump

    Fit the pressure loading ring/backing ring 10 and sealing unit. rings 11 to the flange 2 and cover 8. A little grease (JCB MPL Grease) in the grooves will help retain them. On replacement, torque tighten the bolts to 77 Nm (57 lbf ft, 7.9 kgf m).
  • Page 156 www.WorkshopManuals.co.uk Section E Hydraulics Section E 12 - 19 Pumps 12 - 19 291090 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...

  • Page 157: Dismantling And Assembly (High-Flow)

    If the outlet adapters are disturbed, clean the threads and Inspection apply JCB Threadlocker and Sealer to two of the threads. Tighten to 95 Nm (70 lbf ft, 9.7 kgf m). Do not overtighten. Wash all components then apply hydraulic oil immediately afterwards to prevent moisture from collecting.

  • Page 158: Drive Motors

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 13 - 1 Drive Motors 13 - 1 204320 S246250 205150 9803/8550 Issue 2 Purchased from www.WorkshopManuals.co.uk...
  • Page 159 Renew all seals and 'O' rings. Removal of the Drive Sprocket Apply JCB Threadlocker and Sealer to bolts 5 before fitting. On machines up to serial number 751817, remove the Apply JCB High Strength Retainer to capscrews B before roadwheels (see page F/1 - 1).
  • Page 160 www.WorkshopManuals.co.uk Section E Hydraulics Section E 13 - 3 Drive Motors 13 - 3 S167730A 167730 S167730B 9803/8550 Issue 2 Purchased from www.WorkshopManuals.co.uk...

  • Page 161: Dismantling And Assembly

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 13 - 4 Drive Motors 13 - 4 Dismantling and Assembly The numerical sequence shown is a guide to dismantling. For When fitting bolts 24, tighten them in sequence to avoid tilting assembly the sequence should be reversed. the bearing 28.
  • Page 162 www.WorkshopManuals.co.uk Section E Hydraulics Section E 13 - 5 Drive Motors 13 - 5 S243720 S243870 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 163 Remove O-ring 32 from rear case 21. Discard the O-ring. Thoroughly degrease capscrews 75 and 33 and mating parts, then assemble using JCB Threadlocker and Sealer. Make a note of the position of stop pin 23 in the slot in rear case 21 then remove the stop pin.
  • Page 164 Position drive shaft 1 vertically on a press. Warm bearing cone 8 and press into position on the shaft. Pack the front bearing cone with JCB HP Grease and assemble the front cover onto the shaft, taking care not to damage the lips of seal 11 on the splines of the shaft.
  • Page 165 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 166 www.WorkshopManuals.co.uk Section E Hydraulics Section E 13 - 8 Drive Motors 13 - 8 387340 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 167 www.WorkshopManuals.co.uk Section E Hydraulics Section E 13 - 9 Drive Motors 13 - 9 Dismantling and Assembly from machine number 807173 Dismantling Support the front case on blocks and press shaft 35 out of bearings 36 and 38. Drain the oil from the motor. Remove the cone from bearing 36.
  • Page 168 807173 Assembly (continued) Thoroughly degrease capscrews 15 and 11 and mating parts, then assemble using JCB Threadlocker and Sealer. Inspect the brake plates 8 for signs of wear or damage. Plates should not be renewed individually, the entire plate pack should be renewed.

  • Page 169: Loader/Excavator Circuit Problem Solving

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 14 - 0 Valves 14 - 0 Loader/Excavator Circuit Problem Solving The purpose of this page is to help you trace hydraulic problems to a faulty unit (valve, actuator, ram etc). Once you have traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the manual.
  • Page 170 www.WorkshopManuals.co.uk Section E Hydraulics Section E 14 - 0A Valves 14 - 0A KEY TO CAUSE REMEDY PAGE REF. 10 Neutral circuit or low pressure lines leaking, Check pipe lines and replace as required. damaged, trapped or kinked. 11 Restriction in neutral circuit lines. Check hoses and pipes, replace as necessary.

  • Page 171: Loader Valve

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 14 - 1 Valves 14 - 1 Loader Valve Removal Disconnect all hydraulic hoses from the valve ports (one check valve at inlet A, six work ports B, four servo Remove rear floor plates (see page B/1 - 1). connections C (two on the opposite side), one high pressure carry over D and one outlet E).
  • Page 172 www.WorkshopManuals.co.uk Section E Hydraulics Section E 14 - 2 Valves 14 - 2 205140 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 173 www.WorkshopManuals.co.uk Section E Hydraulics Section E 14 - 3 Valves 14 - 3 Loader Valve Dismantling Assembly Always work on a clean, dirt free surface. Assembly is a reversal of the dismantling procedure. Remove the plug from port B. Renew all seals and 'O' rings. Remove the cap screws 1 from the end caps 2.

  • Page 174: Dismantling And Assembly

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 14 - 4 Valves 14 - 4 Main Relief Valve and Auxiliary Relief Valves Note: The M.R.V. X and loader valve A.R.V.'s Y are identical Replacement in design. Replacement is a reversal of the removal procedure. Removal Torque Settings (Assumes rear floor plates removed.)

  • Page 175: Pressure Testing

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 15 - 1 Valves 15 - 1 Pressure Testing - Main Relief Valve (M.R.V.) - In Situ Connect a 0 - 400 bar (0 - 6000 lb/in , 0 - 422 kg/cm pressure gauge to test connector A located on the right- hand end of the loader valve block.
  • Page 176 www.WorkshopManuals.co.uk Section E Hydraulics Section E 15 - 2 Valves 15 - 2 Pressure Testing - Auxiliary Relief Valve (A.R.V.'s) - Using Hand Pump Insert the A.R.V. into the test block, part no. 892/00252. Connect hand pump 892/00223 and a 0 - 400 bar (0 - 6000 lb/in , 0 - 422 kg/cm ) pressure gauge.

  • Page 177: Check Valve

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 16 - 1 Valves 16 - 1 Check Valve The check valve consists of a plug A, plus a poppet and spring B in a body C. Opening pressure is 5 bar (75 lbf/in To check the opening pressure, compare the difference between the recorded pressures at the MRV test point and the brake pressure test point.
  • Page 178 www.WorkshopManuals.co.uk Section E Hydraulics Section E 17 - 1 Valves 17 - 1 205170 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...

  • Page 179: Excavator Valve

    13, hold a rod through the eye end of the spool. Lubricate new seals with Hydraulic Fluid and take care to prevent them from being damaged by the sharp edges of the spool. Apply JCB Lock and Seal to threads of screw 13. Torque Settings Item kgf m lbf ft 17.6 - 20.4...
  • Page 180 www.WorkshopManuals.co.uk Section E Hydraulics Section E 18 - 1 Valves 18 - 1 175600 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...

  • Page 181: Hydraclamp Valve

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 18 - 2 Valves 18 - 2 Hydraclamp Valve Dismantling and Assembly When Assembling The numerical sequence shown on the illustration is Note: View 'A' shows the clamp in the OFF position. intended as a guide to dismantling. Ensure that orifice X is clear.
  • Page 182 www.WorkshopManuals.co.uk Section E Hydraulics Section E 19 - 1 Valves 19 - 1 204990 204330 348890 9803/8550 Issue 3 Purchased from www.WorkshopManuals.co.uk...

  • Page 183: Pressure Reducing Solenoid Valve

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 19 - 2 Valves 19 - 2 Pressure Reducing Solenoid Valve up to serial no. 752462 Removal Adjusting the Pressure Reducing Valve Cartridge ! WARNING This cartridge should not be dismantled. If it malfunctions it Hydraulic Pressure should be replaced by a new one.
  • Page 184 www.WorkshopManuals.co.uk Section E Hydraulics Section E 19 - 3 Valves 19 - 3 Brake Valve from serial no. 752463 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’...

  • Page 185: Servo Joysticks

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 20 - 1 Servo Joysticks 20 - 1 Removal and Replacement Removal Note: Only the right-hand joystick is shown in the illustration. The other joystick is removed and replaced in the same way. Ensure that the engine is stopped and all hydraulic pressure is released from the system (see page E/2 - 1).
  • Page 186 www.WorkshopManuals.co.uk Section E Hydraulics Section E 20 - 2 Servo Joysticks 20 - 2 167950 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 187 www.WorkshopManuals.co.uk Section E Hydraulics Section E 20 - 3 Servo Joysticks 20 - 3 Joystick up to machine number 807146 Dismantling Assembly The numerical sequence is intended as a guide to Lubricate all parts with hydraulic fluid before assembly. 'O' dismantling, assembly is the reverse of this sequence.
  • Page 188 www.WorkshopManuals.co.uk Section E Hydraulics Section E 20 - 4 Servo Joysticks 20 - 4 388480 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 189 Select shims 7 so that there is a small clearance between cam plate 6 and the tops of plungers 11 when the lever is in the neutral position. Coat threads of item 5 with JCB Threadlocker and Sealer (High Strength) before assembly. Torque Settings...
  • Page 190 www.WorkshopManuals.co.uk Section E Hydraulics Section E 22 - 1 Rams 22 - 1 140731 343030 9803/8550 Issue 2 Purchased from www.WorkshopManuals.co.uk...

  • Page 191: Typical Ram

    Renew all seals and 'O' rings. Thoroughly clean the threads of the piston rod, piston head, end cap and cylinder using a wire brush. Use JCB Cleaner/Degreaser to ensure that all threads are free from grease, hydraulic oil and locking fluids. Allow 15 minutes for the solvent to dry before applying JCB Activator.
  • Page 192 DRILLING DETAILS FOR PISTON HEAD RETENTION Apply JCB Activator to the threads of the piston head 6. (all dimensions in mm) Allow to dry for 15 minutes before bringing into contact with JCB Threadlocker.
  • Page 193 Taking care to retain the end cap 1 at the further end of the piston rod from the cylinder, coat the thread of the cylinder with JCB Activator. Next apply JCB Threadlocker to the thread of the end cap. Wait 15 minutes before bringing the two together and then torque-tighten the end cap into the cylinder.
  • Page 194 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 195 www.WorkshopManuals.co.uk Section E Hydraulics Section E 23 - 1 Rams 23 - 1 Slew Cylinder Re-seal Filling Procedure Position machine on firm level ground. Slew the excavator Whenever the slew housing is re-filled with oil the following fully round so that the cylinder to be worked on is facing procedure must be carried out to ensure that all air is rearwards.
  • Page 196 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...

  • Page 197: Hydraulic Filter

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 25 - 1 Hydraulic Filter 25 - 1 Removal and Replacement See Section 3 Routine Maintenance for renewal of the filter element. ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this...

  • Page 198: Suction Strainer

    www.WorkshopManuals.co.uk Section E Hydraulics Section E 27 - 1 Suction Strainer 27 - 1 Removal and Replacement ! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses or couplings, vent the pressure trapped in the hoses in accordance with the instructions given in this publication.
  • Page 199 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 200 Main Pump Bi-restrictor Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Note: Excavator services shown here are to the JCB 'X' Suction Strainer control pattern. For ISO '+' control pattern, components 36 Tank and 37 are swapped over.
  • Page 201 www.WorkshopManuals.co.uk Section E Hydraulics Section E 30 - 2 Schematic Diagram 30 - 2 A204773A A204773A 9803/8550 Issue 4 Purchased from www.WorkshopManuals.co.uk...
  • Page 202 www.WorkshopManuals.co.uk Section E Hydraulics Section E Schematic Diagram 30 - 3 30 - 3 A243002A A243002A 9803/8550 Issue 4 Purchased from www.WorkshopManuals.co.uk...
  • Page 203 Loader Joystick One-way Restrictor Loader Valve Block Crowd Spool Lift Spool Note: Excavator services shown here are to the JCB 'X' Auxiliary Spool control pattern. For ISO '+' control pattern, components 36 Main Relief Valve (MRV) and 37 are swapped over.
  • Page 204 Return line fitted from machine no. 807226 Lift Spool Auxiliary Spool Main Relief Valve (MRV) Note 1: Excavator services shown here are to the JCB 'X' Crowd Ram Rod Side ARV control pattern. For ISO '+' control pattern, components 36 Crowd Ram Head Side ARV and 37 are swapped over.
  • Page 205 www.WorkshopManuals.co.uk Section E Hydraulics Section E 30 - 6 Schematic Diagram 30 - 6 316741 9803/8550 Issue 3 Purchased from www.WorkshopManuals.co.uk...
  • Page 206 www.WorkshopManuals.co.uk Section E Hydraulics Section E 31 - 1 Schematic Diagram 31 - 1 A243003A 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 207 One-way Restrictor Auxiliary Gear Pump Left Hand Drive Motor Right Hand Drive Motor Note: Excavator services shown here are to the JCB 'X' Suction Strainer control pattern. For ISO '+' control pattern, components 36 Tank and 37 are swapped over.
  • Page 208 Return line fitted from machine no. 807226 Suction Strainer Tank Left Hand Joystick Note 1: Excavator services shown here are to the JCB 'X' Loader Valve Block control pattern. For ISO '+' control pattern, components 36 Crowd Spool and 37 are swapped over.
  • Page 209 www.WorkshopManuals.co.uk Section E Hydraulics Section E 31 - 4 Schematic Diagram 31 - 4 316761 9803/8550 Issue 2 Purchased from www.WorkshopManuals.co.uk...
  • Page 210 www.WorkshopManuals.co.uk Section E Hydraulics Section E 32 - 1 Schematic Diagram 32 - 1 A204773B A204773B 9803/8550 Issue 2 Purchased from www.WorkshopManuals.co.uk...
  • Page 211 Main Relief Valve (MRV) Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Note: Excavator services shown here are to the JCB 'X' Lift Ram Head Side ARV control pattern. For ISO '+' control pattern, components 36 Auxiliary ARV and 37 are swapped over.
  • Page 212 One-way Restrictor Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Note: Excavator services shown here are to the JCB 'X' Auxiliary ARV control pattern. For ISO '+' control pattern, components 36 Auxiliary ARV and 37 are swapped over.
  • Page 213 www.WorkshopManuals.co.uk Section E Hydraulics Section E Schematic Diagram 32 - 4 32 - 4 A243000B A243000B 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 214 www.WorkshopManuals.co.uk Section E Hydraulics Section E Schematic Diagram 32 - 5 32 - 5 316751 9803/8550 Issue 2 Purchased from www.WorkshopManuals.co.uk...
  • Page 215 Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Note 1: Excavator services shown here are to the JCB 'X' Pressure Test Point (High-flow Relief Valve) control pattern. For ISO '+' control pattern, components 36 Pressure Test Point (Main Relief Valve) and 37 are swapped over.
  • Page 216 One-way Restrictor Crowd Ram Rod Side ARV Crowd Ram Head Side ARV Lift Ram Head Side ARV Note: Excavator services shown here are to the JCB 'X' Auxiliary ARV control pattern. For ISO '+' control pattern, components 36 Auxiliary ARV and 37 are swapped over.
  • Page 217 www.WorkshopManuals.co.uk Section E Hydraulics Section E Schematic Diagram 33 - 2 33 - 2 A243004 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 218 www.WorkshopManuals.co.uk Section E Hydraulics Section E Schematic Diagram 33 - 3 33 - 3 316771 9803/8550 Issue 2 Purchased from www.WorkshopManuals.co.uk...
  • Page 219 Lift Ram Head Side ARV Auxiliary ARV Auxiliary ARV Note 1: Excavator services shown here are to the JCB 'X' Pressure Test Point (High-flow Relief Valve) control pattern. For ISO '+' control pattern, components 36 Pressure Test Point (Main Relief Valve) and 37 are swapped over.
  • Page 220 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 221 www.WorkshopManuals.co.uk Section E Hydraulics Section E 35 - 1 Schematic Hydraulic Circuit 35 - 1 Optional Hand Tool Circuit Description The oil supply for the optional hand tool circuit is taken from the excavator valve auxiliary circuit feed lines. When the auxiliary circuit is selected by the foot pedal, oil is fed via the Manual Valve 2 to the Flow Regulator Valve 3.
  • Page 222 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 223 www.WorkshopManuals.co.uk Section F Transmission Section F Contents Page No. Tyres and Wheels Roadwheels - Removal and Replacement 1 - 1 Tyre Pressures see Section 3 Wheel Hub Assembly - Removal and Replacement up to machine no. 751599 1 - 2 - Dismantling and Assembly up to machine no.
  • Page 224 www.WorkshopManuals.co.uk Section F Transmission Section F 1 - 1 Tyres and Wheels 1 - 1 ! WARNING Roadwheels A raised and badly supported machine can fall on you. Removal Position the machine on a firm, level surface before raising one end. Ensure the other end is securely Procedure is the same for all four wheels.
  • Page 225 It is assumed that roadwheels are removed and the machine mounting lugs. is correctly supported. A new 'O' ring F must be fitted. (Grease with JCB MPL Place a suitable receptacle under the wheel hub to collect Grease.) the oil from the chain case.
  • Page 226 Assembly The numerical sequence shown in the dismantling procedure should be reversed. Lubricate all bearings and seals with JCB Special MPL Grease before assembly. Clean the mating faces of the sprocket and hub before assembly using JCB Cleaner/Degreaser. Apply JCB Retainer (High Strength) to the stub axle mounting face and place the sprocket onto the stub axle.
  • Page 227 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 228 www.WorkshopManuals.co.uk Section F Transmission Section F 1 - 4 Tyres and Wheels 1 - 4 S255770 S255790 S255780 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 229 Lubricate all bearings and seals with JCB Special HP Grease Remove the nut B and pull the hub assembly out; remove before assembly.
  • Page 230 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 231 www.WorkshopManuals.co.uk Section G Brakes Section G Contents Page No. Preparation for Towing/Winching up to machine number 751011 1 - 1 from machine number 751012 1 - 2 9803/8550 Issue 2 Purchased from www.WorkshopManuals.co.uk...
  • Page 232 www.WorkshopManuals.co.uk Section G Brakes Section G 1 - 1 1 - 1 Preparation for Towing/Winching up to machine no. 751011 The braking system components on this machine are Using an internal hexagonal wrench, loosen the four integral with the hydraulic drive motors and are covered in relief valves A (two on each side) on the hydraulic pump, Section E Hydraulics.
  • Page 233 www.WorkshopManuals.co.uk Section G Brakes Section G 1 - 2 1 - 2 Preparation for Towing/Winching from machine no. 751012 The braking system components on this machine are Remove the wheel blocks only when the machine is integral with the hydraulic drive motors and are covered in hitched up ready for towing/winching.
  • Page 234 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...
  • Page 235 www.WorkshopManuals.co.uk Section K Engine Section K Contents Page No. Specification Technical Data - XUD Engine 1 - 1 Technical Data - 100 Series Engine up to machine no. 807552 1 - 2 Technical Data - 400 Series Engine from machine no. 807553 1 - 3 Removal and Replacement 2 - 1...

  • Page 236: Specification

    www.WorkshopManuals.co.uk Section K Engine Section K 1 - 1 Specification 1 - 1 Technical Data - XUD engine Type 4 cylinder in-line, overhead camshaft, compression ignition, naturally aspirated. Bore (nominal) 83 mm (3.268 in) Stroke 88 mm (3.465 in) Swept Volume 1905 cm (116.24 in Compression Ratio...

  • Page 237: Technical Data - 100 Series Engine Up To Machine No. 807552

    www.WorkshopManuals.co.uk Section K Engine Section K 1 - 2 Specification 1 - 2 Technical Data - 100 Series engine up to machine no. 807552 Type 4 cylinder in-line, compression ignition, naturally aspirated. Bore (nominal) 84 mm (3.31 in) Stroke 100 mm (3.94 in) Swept Volume 2216 cm (135.2 in...

  • Page 238: Technical Data - 400 Series Engine From Machine No. 807553

    www.WorkshopManuals.co.uk Section K Engine Section K 1 - 3 Specification 1 - 3 Technical Data - 400 Series engine from machine no. 807553 Type 4 cylinder in-line, compression ignition, naturally aspirated. Bore (nominal) 84 mm (3.31 in) Stroke 100 mm (3.94 in) Swept Volume 2216 cm (135.2 in...
  • Page 239 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...

  • Page 240: Removal And Replacement

    www.WorkshopManuals.co.uk Section K Engine Section K 2 - 1 Removal and Replacement 2 - 1 204290 205180 9803/8550 Issue 1 Purchased from www.WorkshopManuals.co.uk...
  • Page 241 Note: If the mounting brackets are removed from the engine Disconnect and remove the battery. block it is necessary to use JCB Lock and Seal when re- installing the mounting bolts B before torque tightening. Remove the exhaust and air filter assembly.
  • Page 242 www.WorkshopManuals.co.uk Purchased from www.WorkshopManuals.co.uk...

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