Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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Page 1 9803/9340-8 Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 2: Section 0 - Service Manual
Section 0 - Service manual Notes: 9803/9340-8...
Page 3 9803/9340-8 Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 4: Section 1 - General Information
Section 1 - general Information Notes: 9803/9340-8...
Page 5: Table Of Contents
Section 1 - General Information Contents Page No. Introduction About this Manual ..................1-1 Identifying your Machine ................1-3 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ........1-7 Hydraulic Connections ................1-11 Service Tools Numerical List ..................1-15 Tool Detail Reference Section B - Body and Framework ......1-16 Numerical List Section C - Electrics ............
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Page 7: Introduction
– JCB Mini CX from serial number M1042000 The manual is compiled in sections, the first three are numbered and contain information as follows: – JCB Mini CX 4x4 from serial number M1042000 – Micro Tier 3 from serial number General Information - includes torque settings and service tools.
Page 8: Units Of Measurement
( ) eg 28 litres (6 gal). Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. Fig 2. Mini CX 4x4 707430-B2 Fig 1. Cross References...
Page 9: Identifying Your Machine
Typical Vehicle Identification Number (VIN) The machine identification plate is located as shown at A (Mini CX) or B (Mini CX 4x4). The plate is stamped with the Fig 5. ( 1-3) machine serial number and the serial numbers of the major individual units.
Page 10: Unit Identification
Section 1 - General Information Introduction Identifying your Machine Unit Identification The chassis serial number B is stamped on the mainframe. C036120 Fig 8. 760130-1 Fig 6. The engine serial number is stamped on a label C on the right side of the cylinder block. 707660-1 Fig 9.
Page 11: Section 1 - General Information Introduction
Section 1 - General Information Introduction Identifying your Machine Tier 3 Typical Engine Identification ROPS and FOPS Number WARNING The engine data label is located on the cylinder block at You could be killed or seriously injured if you operate position A.
Page 12 Section 1 - General Information Introduction Identifying your Machine Page left intentionally blank 9803/9340-8...
Page 13: Torque Settings
For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
Page 14 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 kgf m lbf ft kgf m lbf ft 7/16 11.2 10.0 5/16 22.3...
Page 15 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric Thread kgf m lbf ft kgf m lbf ft 13.9 10.2 12.5 34.0 25.0...
Page 16 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread kgf m lbf ft 10.0 24.0 18.0 48.0 35.5 82.0 60.5 Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size ISO Metric Thread...
Page 17: Hydraulic Connections
Section 1 - General Information Torque Settings Hydraulic Connections Hydraulic Connections T11-003 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.
Page 18 Section 1 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 2. Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring Note: Dimension 2-D will vary depending upon the torque 2-C which is compressed into a 45° seat machined into the applied.
Page 19 Section 1 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size kgf m lbf ft 20.0 15.0 34.0 25.0 75.0 55.0 102.0 10.3 75.0 122.0 12.4...
Page 20 Section 1 - General Information Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 3. `Torque Stop' Hoses 3-B screwed into adaptors 3-A seal Stop' Hoses have an additional shoulder 3-D, which acts onto an 'O' ring 3-C which is compressed into a 45° seat as a physical stop.
Page 21: Service Tools
Tool Detail Reference, Section 1. These tools are available from JCB Service. Note: Tools other than those listed will be required. It is Some tools are available as kits or sets, the part numbers expected that such general tools will be available in any for parts within such kits or sets are not listed here.
Page 22: Tool Detail Reference Section B - Body And Framework
Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework Tool Detail Reference Section B - Body and Framework Fig 1. Rivet Nuts 826/01099 M6 x 16mm Rivet Nut 826/01101 M6 x 19mm Rivet Nut 826/01103 M8 x 18mm Rivet Nut 826/01102 M8 x 21mm Rivet Nut 826/01104 M10 x 23mm Rivet Nut...
Page 23: Numerical List Section C - Electrics
The tools listed in the table are special tools required for Note: Tools other than those listed will be required. It is testing electrics. These tools are available from JCB expected that such general tools will be available in any Service.
Page 24: Tool Detail Reference Section C - Electrics
Section 1 - General Information Service Tools Tool Detail Reference Section C - Electrics Tool Detail Reference Section C - Electrics Fig 2. 892/00283 Tool Kit Case 892/00281 AVO Meter 892/00286 Surface Temperature 892/00284 Microtach Digital Tachometer 892/00282 Shunt - open type 892/00285 Hydraulic Oil Temperature Probe 1-18 9803-9340-8...
Page 25: Numerical List Section E- Hydraulics
Note: Tools other than those listed will be required. It is testing, removing and replacing hydraulics. These tools expected that such general tools will be available in any are available from JCB Service. well equipped workshop or be available locally from any good tool supplier.
Page 26 Section 1 - General Information Service Tools Numerical List Section E- Hydraulics Part Description Tool Detail Reference Number 892/00074 Female Connector Fig 14. ( 1-24) 892/00075 Female Connector Fig 14. ( 1-24) 892/00077 Female Connector Fig 14. ( 1-24) 892/00137 Hose Fig 8.
Page 27 Section 1 - General Information Service Tools Numerical List Section E- Hydraulics The following parts are replacement items for kits and would normally be included in the kit numbers quoted above. Table 1. Replacement items for kit no. 892/00253 Part Description Tool Detail Reference Number...
Page 28: Tool Detail Reference Section E- Hydraulics
Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics Tool Detail Reference Section E- Hydraulics 892/00263 5/8 in BSP x 5/8 in F BSP x Test Point 892/00264 3/4 in BSP x 3/4 in F BSP x Test Point 892/00265 1 in M BSP x 1 in F BSP x Test Point Fig 5.
Page 29 Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics 1604/0006 Adapter 3/4 in M x 3/4 in M BSP 1612/0006 Adapter 3/4 in F x 3/4 in M BSP 892/00271 Adapter 3/4 in F x 5/8 in M BSP 892/00272 Adapter 5/8 in F x 3/4 in M BSP 816/20008 Adapter 3/4 in F x 1/2 in M BSP 892/00275 Adapter 1/2 in F x 3/4 in M BSP...
Page 30 Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics 892/00059 3/4 in BSP 892/00060 1 in BSP'T' Fig 14. Female Connectors Fig 12. Male Cone Blanking Plug 892/00074 3/8 in BSP x 3/8 in BSP 892/00075 1/2 in BSP x 1/2 in BSP 816/00294 1/4 in BSP 816/00189 3/8 in BSP 892/00077 3/4 in BSP x 3/4 in BSP...
Page 31 Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics 10mm 20mm 110mm 175mm Fig 16. Piston Seal Assembly Tool 892/01027 Fig 17. Ram Seal Protection Sleeves 892/01017 For 30 mm Rod Diameter 892/01018 For 40 mm Rod Diameter 1-25 9803-9340-8 1-25...
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Page 33: Numerical List Section F - Transmission
The tools listed in the table are special tools required for Note: Tools other than those listed will be required. It is testing electrics. These tools are available from JCB expected that such general tools will be available in any Service.
Page 34: Tool Detail Reference Section F - Transmission
Section 1 - General Information Service Tools Tool Detail Reference Section F - Transmission Tool Detail Reference Section F - Transmission 732930 Fig 18. Axle Case Spreader 892/01161 732920 Fig 19. Pinion Setting Tool 892/01162 1-28 9803-9340-8 1-28...
Page 35: Consumables
A medium strength sealant suitable for all sizes of 4102/1212 50 ml gasket flanges, and for hydraulic fittings of 25-65 mm diameter. JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml components. Gasketing for all sizes of flange where the strength of the joint is important.
Page 36 Section 1 - General Information Consumables Sealing and Retaining Compounds Page left intentionally blank 1-30 9803/9340-8 1-30...
Page 37 9803/9340-8 Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 38: Section 2 - Care & Safety
Section 2 - Care & Safety Notes: 9803/9340-8...
Page 39 Section 2 - Care & Safety Contents Page No. Safety Notices Important Information ................2-1 Safety Checklist ..................2-2 Safety Decals ..................2-12...
Page 40 Section 2 - Care & Safety Page left intentionally blank 2-ii 2-ii...
Page 41: Safety Notices
If you are other operators. unsure about anything, ask your JCB dealer or employer. Do not guess, you or others could be killed In this publication and on the machine, there are safety or seriously injured.
Page 42: Safety Checklist
If you do not understand messages. Read and understand them. They tell you of anything, ask your employer or JCB dealer to explain potential hazards and how to avoid them. If you do not fully it. Keep the Operator Manual clean and in good understand the warning messages, ask your employer or condition.
Page 43 Sparks in altered in any way which could affect or invalidate any such an area could cause an explosion or fire of these requirements. For advice consult your JCB resulting in death or serious injury. Distributor.
Page 44: Operating Safety
Section 2 - Care and Safety Safety Notices Safety Checklist Operating Safety WARNING You could be killed or seriously injured if you operate WARNING a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protection Structure (ROPS)/Falling Machine Condition Objects Protection Structure (FOPS) has been in an A defective machine can injure you or others.
Page 45 If that machine potentially explosive happens you could lose control of the machine. atmosphere, i.e. combustible vapours, gas or dust, 2-2-3-6 without first consulting your JCB Distributor. INT-2-1-14 WARNING Visibility CAUTION Accidents can be caused by working in poor visibility. Regulations Use your lights to improve visibility.
Page 46 5-5-1-1_2 5-1-4-5 WARNING WARNING Use only the JCB approved attachments that are specified for your machine. Operating with non- Scaffolding specified attachments can overload the machine, Overloaded scaffolding can collapse. Never load causing possible damage and machine instability scaffolding beyond the regulation capacity.
Page 47: Maintenance Safety
Section 2 - Care and Safety Safety Notices Safety Checklist Maintenance Safety DANGER Forks/Working Platform WARNING Using the forks alone as a working platform is hazardous; you can fall off and be killed or injured. Communications Never use the forks as a working platform. Bad communications can cause accidents.
Page 48 Section 2 - Care and Safety Safety Notices Safety Checklist WARNING WARNING If you try to charge a frozen battery, or jump start and Fluid Under Pressure run the engine, the battery could explode. Do not use Fine jets of fluid at high pressure can penetrate the a battery if its electrolyte is frozen.
Page 49 Section 2 - Care and Safety Safety Notices Safety Checklist WARNING CAUTION Rams Oil is toxic. If you swallow any oil, do not induce The efficiency of the rams will be affected if they are vomiting, seek medical advice. Used engine oil not kept free of solidified dirt.
Page 50 To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear WARNING goggles when using a brush to clean components. Certain seals and gaskets (e.g. crankshaft oil seal) on HYD-1-3_2 JCB machines contain fluoroelastomeric materials such Viton, Fluorel Technoflon. WARNING...
Page 51 Prior to any work being carried out on systems incorporating accumulators, the system Jacking pressure must be exhausted by a JCB distributor, as A machine can roll off jacks and crush you unless the the sudden release of the hydraulic fluid or gas may wheels have been blocked.
Page 52: Safety Decals
Keep all decals clean and readable. Replace lost or damaged decals. Each decal has a part number printed on it, use this number to order a new decal from your JCB distributor. INT-3-3-3_1 WARNING If you need eye-glasses for reading, make sure you wear them when reading the safety decals.
Page 53 Section 2 - Care and Safety Safety Notices Safety Decals Safety Decal Recognition Table 1. Decal Descriptions and Part Numbers Euro. Part No. USA Part No. Description Location Series 1 Location Series 2 machines machines Euro Fig 1. ( 2-13) Euro Fig 3.
Page 54 Section 2 - Care and Safety Safety Notices Safety Decals T006620-1 Fig 2. Safety Decals - USA Series 1 Machines 817/70020 C036050-1 Fig 3. Safety Decals - European Series 2 Machines 2-14 9803/9340-8 2-14...
Page 55 Section 2 - Care and Safety Safety Notices Safety Decals T006630 Fig 4. Safety Decals - USA Series 2 Machines 2-15 9803/9340-8 2-15...
Page 56 Section 2 - Care and Safety Safety Notices Safety Decals Page left intentionally blank 2-16 9803/9340-8 2-16...
Page 57 9803/9340-8 Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 58: Section 3 - Routine Maintenance
Section 3 - Routine Maintenance Notes: 9803/9340-8...
Page 59 Section 3 - Routine Maintenance Contents Page No. Routine Maintenance Service Requirements ................3-1 Health and Safety ..................3-3 Service Schedules ..................3-7 Fluids, Lubricants and Capacities ............3-11 Cleaning the Machine ................3-16 Checking for Damage ................3-18 Seat Belt ....................3-19 Checking the ROPS/FOPS Structure ............
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Page 61: Service Requirements
Remember, only your JCB Distributor has access to the carried out by a JCB trained specialist. Only JCB vast resources available at JCB to help support you. In Distributor Service Engineers have been trained by JCB to addition, your Distributor is able to offer a variety of...
Page 62: Routine Maintenance Service Requirements
Safety Executive (H.S.E.) legal requirements along with providing Annual Inspections to meet your Insurance Company Policy conditions. Only your JCB Distributor has the ability to meet the definition described covering a "Competent Person" to carry out these necessary tests and inspections. This...
Page 63: Health And Safety
There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene Hygiene practices. JCB lubricants are not a health risk when used properly for Used Oil their intended purposes. Used engine crankcase lubricants contain harmful However, excessive or prolonged skin contact can remove contaminants.
Page 64 Section 3 - Maintenance Routine Maintenance Health and Safety First Aid - Oil Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention. Swallowing If oil is swallowed do not induce vomiting. Get medical advice.
Page 65 Section 3 - Maintenance Routine Maintenance Health and Safety Battery Warning Symbols The following warning symbols may be found on the WARNING battery. Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the Symbol Meaning battery away from sparks and flames.
Page 66 Section 3 - Maintenance Routine Maintenance Health and Safety WARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4 DANGER Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery.
Page 67: Service Schedules
Section 3 - Maintenance Routine Maintenance Service Schedules Service Schedules Introduction How to Use the Service Schedules T3-012_3 A poorly maintained machine is a hazard. Doing the In the example shown, A shows all service requirements to regular maintenance and lubrication jobs listed in these be carried out every 10 hours and B shows the schedules will help keep the machine in safe running requirements to be carried out every 500 hours.
Page 68 Section 3 - Maintenance Routine Maintenance Service Schedules Pre Start Cold Checks, Service Points and Fluid Levels Operation 1000 2000 ENGINE Oil level - Check Oil and Filter - Change Air Cleaner Element - Change Air Cleaner Hose Security - Check and Adjust Air Cleaner Dust Valve - Clean Coolant Level/Antifreeze Strength...
Page 69 Section 3 - Maintenance Routine Maintenance Service Schedules Operation 1000 2000 - Clean Suction Strainer Loader Valve and Controls - Check Slew Gearbox Oil Level (Side shift machines only) - Check - Clean Breather ELECTRICS Battery Electrolyte Level - Check Battery Charge Condition - Check Wiring for Chaffing...
Page 70 Section 3 - Maintenance Routine Maintenance Service Schedules Functional Test and Final Inspection Operation 1000 2000 ENGINE - Check and Adjust Idle Speed Exhaust System Security/Fouling - Check Exhaust Smoke (excessive) - Check Throttle System and Control Cable - Check and Adjust TRANSMISSION Creeping in Neutral - Check and Adjust...
Page 71: Fluids, Lubricants And Capacities
3-39) Rear Axle 1.4 (0.3) JCB HD90 Gear Oil API GL 5 Grease Points JCB Special HP Grease or JCB MPL Lithium complex NLGI No. 2 Grease consistency including extreme pressure additives or Lithium based NLGI No. 2 consistency including extreme pressure additives.
Page 72 The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion. The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below. 50% Concentration (Standard) Protects against damage down to -40 °C (-39 °F) 60% Concentration (Extreme Conditions Only) Protects against damage down to -56 °C (-68 °F)
Page 73 Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities Fuels CAUTION Consult your fuel supplier or JCB distributor about the Acceptable and Unacceptable Fuels suitability of any fuel you are unsure of. T3-048 GEN-9-2 Important: No warranty liability whatsoever will be accepted for failure of fuel injection equipment where the failure is attributed to the quality and grade of the fuel used.
Page 74 Note: If performance related issues are to be reported to – Lubrizol 539N. Dosage (on Swedish low sulphur fuel) JCB Service, and the engine has been run on biodiesel, 250 ppm. then the fuel system must be filled with standard diesel (at –...
Page 75 Section 3 - Maintenance Routine Maintenance Fluids, Lubricants and Capacities Sulphur Content Effects of Fuel Contaminates T3-032 T3-033 High sulphur content can cause engine wear. (High The effect of dirt, water and other contaminants in diesel sulphur fuel is not normally found in North America, can be disastrous for injection equipment: Europe or Australia.) If you have to use high sulphur fuel you must change the engine oil more frequently.
Page 76: Cleaning The Machine
Section 3 - Maintenance Routine Maintenance Cleaning the Machine Cleaning the Machine Introduction CAUTION T3-024 The engine or certain components could be damaged Clean the machine using water and or steam. Do not allow high pressure washing systems; special mud, debris etc. to build upon the machine. precautions must be taken if the engine is to be washed using a high pressure system.
Page 77 Section 3 - Maintenance Routine Maintenance Cleaning the Machine Cleaning the Machine WARNING To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using wire brush clean components. HYD-1-3 WARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc.
Page 78: Checking For Damage
Section 3 - Maintenance Routine Maintenance Checking for Damage Checking for Damage T3-013 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 79: Seat Belt
Section 3 - Maintenance Routine Maintenance Seat Belt Seat Belt Checking the Seat Belt Condition and Security T3-008 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 80: Checking The Rops/Fops Structure
ROPS/FOPS certification. INT-2-1-9_6 Check the structure for damage. If necessary, have the structure repaired by suitably qualified personnel (consult your JCB distributor). If the damage is severe it will be necessary to obtain a complete new structure. 3-20...
Page 81: Loader Arm Safety Strut
Stop the engine. Take care not to stand directly under any raised part of the machine. Fit the strut: a Remove the strut from its stowage position C. Fig 2. Mini CX 4x4 3-21 9803/9340-8 3-21...
Page 82 Section 3 - Maintenance Routine Maintenance Loader Arm Safety Strut Removing the Safety Strut WARNING You could be killed or injured if the loader control is accidentally operated. Make sure no-one comes near the machine while you remove the safety strut. 2-3-1-3 Raise the loader arms to take the weight off the safety strut A.
Page 83: Service Access
Carefully lift the floor plate away from the machine. Fig 4. Mini CX Mini CX 4x4 - Unlock the handle B on top of the cover and lift the handle to release the cover. Fig 6. Fig 5. Mini CX 4x4...
Page 84: Battery Cover
Service Access Battery Cover The battery is mounted in a compartment under the operator's seat. Stop the engine. Remove the battery cover A (Mini CX shown, Mini CX 4x4 Similar). Disconnect the battery terminals. Disconnect the earth terminal first. 707961 Fig 7.
Page 85: Greasing (10 Hours)
Note: The machine must always be greased after Loader Arm Pivot Points - Mini CX pressure washing or steam cleaning. Greasing should be done with a grease gun. Normally, two Switch off the engine and ensure it cannot be started while strokes of the gun should be sufficient.
Page 86 Section 3 - Maintenance Routine Maintenance Greasing (10 Hours) Loader Arm Pivot Points - Mini CX 4x4 Note: Grease points 6, 11 and 12 are on the opposite side of the machine. Switch off the engine and ensure it cannot be started while Total 12 grease points.
Page 87 Section 3 - Maintenance Routine Maintenance Greasing (10 Hours) Backhoe and Stabilisers - Mini CX Switch off the engine and ensure it cannot be started while you are doing this job. Note: Grease points 14, 15, 17 and 22 are on the opposite side of the machine.
Page 88 Section 3 - Maintenance Routine Maintenance Greasing (10 Hours) Backhoe and Stabilisers - Mini CX 4x4 Total 11 grease points. Switch off the engine and ensure it cannot be started while you are doing this job. Fig 13. Mini CX 4x4...
Page 89: Lubrication
Section 3 - Maintenance Routine Maintenance Lubrication Lubrication The following points should be lightly lubricated with engine oil every 100 operating hours. Oiling Control Levers Oil the clevis A at the bottom of each loader control rod. 707891 Fig 14. 3-29 9803/9340-8 3-29...
Page 90: Electrical System
Section 3 - Maintenance Routine Maintenance Electrical System Electrical System Battery Checking the Electrolyte Level T3-020_2 Maintenance free batteries used in normal temperate Battery Disconnection/Connection climate applications should not need topping up. However, T3-019_3 in certain conditions (such as prolonged operation at WARNING tropical temperatures or if the alternator overcharges) the electrolyte level should be checked as described below.
Page 91: Jump Starting The Engine
Connect the Booster Cables will be energised when the external power supply is connected. Set all the machine switches to their OFF a Remove the battery compartment cover. (Mini CX positions before connecting the external power shown, Mini CX 4x4 similar).
Page 92 Section 3 - Maintenance Routine Maintenance Electrical System Start the engine. See Starting the Engine, Operation Section of Operator’s Manual. Disconnect the Booster Cables a Disconnect the negative booster cable from the machine frame earth, then disconnect if from the booster supply.
Page 93: Checking The Oil Level
Section 3 - Maintenance Routine Maintenance Engine Engine Checking the Oil Level Changing the Oil and Filter CAUTION WARNING Hot oil and engine components can burn you. Make sure the engine is cool before doing this job. Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice.
Page 94 Section 3 - Maintenance Routine Maintenance Engine 707680 Fig 19. Change the filter: a Unscrew the filter canister D; remember that it will be full of oil. b Clean the filter head E. c Add clean engine lubricating oil to the new filter canister.
Page 95: Changing The Air Filter Element
Section 3 - Maintenance Routine Maintenance Engine Changing the Air Filter Element a Smear the seal on the new element with grease. b Insert the new element into the canister. CAUTION c Remove the element and check for a continuous Do not run the engine when the element has been witness mark on the inside base of the canister.
Page 96: Engine Cooling System
Section 3 - Maintenance Routine Maintenance Engine Cooling System Engine Cooling System Checking the Coolant Level Changing the Coolant Park the machine on level ground. Stop the engine WARNING and let it cool down. The cooling system is pressurised when the coolant is Raise the engine cover Opening and Closing the hot.
Page 97 Section 3 - Maintenance Routine Maintenance Engine Cooling System Cleaning the Coolant Radiator Park the machine on level ground within reach of a compressed air line. Stop the engine and remove the key. Raise the engine cover. After allowing the engine to cool down use compressed air to remove debris from the radiator and oil cooler.
Page 98: Checking The Alternator Belt Tension
Section 3 - Maintenance Routine Maintenance Engine Cooling System Checking the Alternator Belt Tension Adjusting the Alternator Belt Park the machine on level ground. WARNING Stop the engine. Make sure the engine cannot be started. Disconnect the battery before doing this job. 2-3-3-5 WARNING Loosen bolts A and B which secure the alternator.
Page 99: Fuel System
CAUTION Low Temperature Fuels Consult your fuel supplier or JCB distributor about the suitability of any fuel you are unsure of. Special winter fuels may be available for engine operation at temperatures below 0°C (32°F). These fuels have a GEN-9-2 lower viscosity.
Page 100: Filling The Tank
Diesel fuel is flammable; keep naked flames away from the fuel system. Do not smoke while refuelling or Consult your JCB distributor for advice about the use of working on the fuel system. Do not refuel with the Fatty Acid Methyl Ester fuels, as improper application may engine running.
Page 101: Draining The Fuel Filter
Section 3 - Maintenance Routine Maintenance Fuel System Draining the Fuel Filter The fuel filter is located on the left hand side of the engine compartment. WARNING Fuel oil is highly inflammable. Stop the engine immediately if a fuel leak is suspected. Completely wipe off any spilt fuel which could cause a fire.
Page 102 Section 3 - Maintenance Routine Maintenance Fuel System Changing the Fuel Filter Element Fit new seals J (3 off) to base G, bowl B and element F, fit 'O' ring H to the centre of the element F. WARNING Fit element F, bowl B, base G, to the head K. Fuel oil is highly inflammable.
Page 103: Hydraulic System
Section 3 - Maintenance Routine Maintenance Hydraulic System Hydraulic System WARNING Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid.
Page 104: Changing The Hydraulic Filter
Section 3 - Maintenance Routine Maintenance Hydraulic System Changing the Hydraulic Filter Stop the engine and wait for 5 minutes. Loosen the breather cap C and allow all pressure to dissipate. Fig 31. ( 3-44) Remove the filler cap B. Fig 31.
Page 105 Refit plug P. Operate the slew service fully in each direction five times. Remove plug P and re-check oil level. If level is low, repeat steps 3 to 5 until all air is expelled. Fig 32. Mini CX 4x4 3-45 9803/9340-8 3-45...
Page 106: Transmission
Clean the area around the fill/level plug A, then remove the plug. Oil should be level with the bottom of the hole. Add recommended oil if necessary. Fluids, Lubricants and Capacities ( 3-11) Clean the plug before refitting it. Fig 33. Mini CX 3-46 9803/9340-8 3-46...
Page 107: Tyres And Wheels
Section 3 - Maintenance Routine Maintenance Tyres and Wheels Tyres and Wheels Tyre Inflation b Inflate the tyre to the recommended pressure. Do not over-inflate. T3-010_2 These instructions are for adding air to a tyre which is already inflated. If the tyre has lost all its air pressure, call in a qualified tyre mechanic.
Page 108: Tyre Table
Section 3 - Maintenance Routine Maintenance Tyre Table Tyre Table Front Tyres Standard Mini CX Mini CX 4x4 Size 23 x 8.5-12 23 x 8.5-12 Pressure 3 bar (43.5 lbf/in²) 3 bar (43.5 lbf/in²) Manufacturer Solideal SD SKS Front Tyres...
Page 109 9803/9340-8 Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 110 Section A - Attachments Notes: 9803/9340-8...
Page 111: Section A - Optional Attachments
Section A - Optional Attachments Contents Page No. Hoses and Couplings Quick Release Couplings ................. A-1 Connecting/Disconnecting Hydraulic Hoses ..........A-3 Shovels Maintenance ..................... A-5...
Page 112 Section A - Optional Attachments Page left intentionally blank A-ii A-ii...
Page 113: Quick Release Couplings
Section A - Attachments Hoses and Couplings Quick Release Couplings T4-001_2 Connecting and Disconnecting coupling sleeve and prevent correct connection and disconnection. Flat face quick release couplings allow the operator to – Don't clamp on the smooth diameter of the coupling remove and install attachments swiftly and efficiently.
Page 114 Section A - Attachments Hoses and Couplings Quick Release Couplings Connecting Quick Release Couplings Remove any residual hydraulic pressure trapped in the service line hose. Wipe the two faces of the male and female couplings and make sure they are clean. Make sure that ball 1-C in the female coupling is located in one of its slots.
Page 115: Connecting The Hoses
Section A - Attachments Hoses and Couplings Connecting/Disconnecting Hydraulic Hoses Connecting/Disconnecting Hydraulic Hoses Some attachments are hydraulically powered. The Disconnecting the Hoses following paragraphs describe how to connect and disconnect the hydraulic hoses safely. Vent the hydraulic pressure Venting Hydraulic Pressure ( A-3).
Page 116 Section A - Attachments Hoses and Couplings Connecting/Disconnecting Hydraulic Hoses Page left intentionally blank 9803/9340-8...
Page 117: General Purpose
Section A - Attachments Shovels Maintenance General Purpose Daily Maintenance Clean with the rest of the machine. Check for damage. 4-in-1 Shovel Daily Maintenance Clean with the rest of the machine. Check for damage. Repair or replace as necessary. Check for signs of hydraulic leaks in hoses, adapters A174600-B1 Fig 1.
Page 118 Section A - Attachments Shovels Maintenance Page left intentionally blank 9803/9340-8...
Page 119 9803/9340-8 Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 120 Section B - Attachments Notes: 9803/9340-8...
Page 121 Section B - Body & Framework Contents Page No. Floor Plates Removal and Replacement ..............B-1 Loader Arm Removal and Replacement ..............B-3 Dipper Removal and Replacement ..............B-5 Boom Removal and Replacement ..............B-7 Kingpost Centremount Kingpost ................B-9 Sideshift Kingpost ...................
Page 122 Section B - Body & Framework Page left intentionally blank B-ii B-ii...
Page 123: Floor Plates
Section B - Body & Framework Floor Plates Removal and Replacement To gain access to the pumps, motor, valves and pipework, it may be necessary to remove the floor plates. Front Floor Plate - Series 1 Machines Removal and Replacement Remove the drive pedal and interlock pedal pads A by releasing their clamping screws.
Page 124 Section B - Body & Framework Floor Plates Removal and Replacement Page left intentionally blank 9803/9340-8...
Page 125: Loader Arm
Removal Replacement Replacement is a reversal of the removal procedure. WARNING Grease all pins and securing bolts with JCB Special MPL grease. Lifting Equipment You can be injured if you use faulty lifting equipment. Reconnect all hoses and bleed the hydraulic system then Make sure that lifting equipment is in good condition.
Page 126: Removal And Replacement
Section B - Body & Framework Loader Arm Removal and Replacement 707800-1 Fig 1. 9803/9340-8...
Page 127: Removal And Replacement
Remove the bucket or other attachments from the machine Replacement is a reversal of the removal procedure. and park the machine on clean level ground. Place the Grease all pins and securing bolts with JCB Special MPL excavator end in the position shown. Stop the engine and grease.
Page 128 Section B - Body & Framework Dipper Removal and Replacement 707771-1 Fig 1. 9803/9340-8...
Page 129 Replacement is a reversal of the removal procedure. Grease all pins and securing bolts with JCB Special MPL Remove the circlip retaining the boom ram eye end pivot grease.
Page 130 Section B - Body & Framework Boom Removal and Replacement Page left intentionally blank 9803/9340-8...
Page 131: Kingpost
Replacement is a reversal of the removal procedure. Dipper ( B-5). Apply JCB Special MPL grease to all pivot pins. Note: Unless the kingpost is to be renewed, it is not necessary to remove the boom and dipper to release the When assembly is complete, operate excavator services kingpost from the machine.
Page 132: Sideshift Kingpost
Replacement is a reversal of the removal procedure. Dipper ( B-5). Apply JCB Special MPL grease to all pivot pins. Note: Unless the kingpost is to be renewed, it is not necessary to remove the boom and dipper to release the Tighten the hydraclamp nuts C to nip the units then back kingpost from the machine.
Page 133: Service Tools
Tool Detail Reference, Section 1. These tools are available from JCB Service. Note: Tools other than those listed will be required. It is Some tools are available as kits or sets, the part numbers expected that such general tools will be available in any for parts within such kits or sets are not listed here.
Page 134: Tool Detail Reference Section B - Body And Framework
Section B - Body & Framework Service Tools Tool Detail Reference Section B - Body and Framework Tool Detail Reference Section B - Body and Framework Fig 1. Rivet Nuts 826/01099 M6 x 16mm Rivet Nut 826/01101 M6 x 19mm Rivet Nut 826/01103 M8 x 18mm Rivet Nut 826/01102 M8 x 21mm Rivet Nut 826/01104 M10 x 23mm Rivet Nut...
Page 135 9803/9340-8 Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 136 Section C - Electrics Notes: 9803/9340-8...
Page 137 Section C - Electrics Contents Page No. Technical Data General Electrical Data ................C-1 Test Methods Using a Multimeter ..................C-5 Service Procedures Battery ...................... C-9 Harness Data Wire and Harness Number Identification ..........C-13 Harness Drawings .................. C-15 Circuit Diagrams Early Series 1 machines .................
Page 138 Section C - Electrics Page left intentionally blank C-ii C-ii...
Page 139: Technical Data
Section C - Electrics Technical Data General Electrical Data 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 according to battery type Alternator 12V, 40 Amp output...
Page 140 Section C - Electrics Technical Data General Electrical Data Fuses - Mini CX Fuses - Mini CX 4x4 The electrical circuits are protected by fuses. The fuses The electrical circuits are protected by fuses. The fuses are located in the battery compartment.
Page 141 Section C - Electrics Technical Data General Electrical Data Relays - Mini CX Relays - Mini CX 4x4 The relays are located in the battery compartment. The relays are located in the battery compartment. Neutral Start Neutral Start Auxiliary Handbrake Neutral...
Page 142 Section C - Electrics Technical Data General Electrical Data Page left intentionally blank C - 4 9803-9340-8 C - 4...
Page 143: Test Methods
Section C - Electrics Test Methods Using a Multimeter TC-002 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 a FLUKE 85 or AVO 2003 digital multimeter, or a moving pointer (analogue) multimeter.
Page 144: Measuring Dc Voltage
Section C - Electrics Test Methods Using a Multimeter Make sure that the test leads are plugged into the Measuring Resistance correct sockets. The black test lead should be plugged into the black socket (sometimes, this socket Make sure there is no power to the part of the circuit is also marked by a "-", or "E"...
Page 145: Measuring Continuity
Section C - Electrics Test Methods Using a Multimeter Measuring Continuity Measuring Frequency Make sure there is no power to the part of the circuit The AVO 2003 and the analogue meter are not capable of you are checking for continuity. measuring frequency, therefore a Fluke 85 digital multimeter must be used.
Page 146 Section C - Electrics Test Methods Using a Multimeter Testing a Diode or a Diode Wire c On an analogue meter. Select the Ohms 1000s (1k) range. A diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end. The Connect the black probe to the end of the diode is sealed in heatshrink sleeving.
Page 147: Service Procedures
Section C - Electrics Service Procedures Battery TC-001_3 Maintenance WARNING Batteries give off an explosive gas. Do not smoke To ensure that the battery provides optimum performance when handling or working on the battery. Keep the the following steps should be observed: battery away from sparks and flames.
Page 148 Section C - Electrics Service Procedures Battery GETS ONTO YOUR SKIN Set the CHECK/LOAD switch 1-A to CHECK to read the battery no-load voltage which should be at least 12.4 volts. Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help. Set the CHECK/LOAD switch 1-A to LOAD and hold down for 5-10 seconds until the meter reading 5-3-4-3_1...
Page 149: Specific Gravity Testing
Section C - Electrics Service Procedures Battery Specific Gravity Testing Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell. The specific gravity of the electrolyte gives an idea of the state of charge of the battery.
Page 150 Section C - Electrics Service Procedures Battery Page left intentionally blank C-12 9803-9340-8 C-12...
Page 151: Harness Data
719/37100 mated with a flying lead coloured black (colour code B) then the number printed on the wire would be B-819 9/371. The wire's unique identification number. The wire functions and numbers allocated to them are consistent through out the JCB range of products. Wire Numbers and Functions ( C-14).
Page 152 Section C - Electrics Harness Data Wire and Harness Number Identification Wire Numbers and Functions Wires 800-999 These numbers are reserved for switched supplies to Wires 000-199 electrical loads, i.e. to lights, etc. These numbers are reserved for ignition feeds, heater start Wires In Splices circuits and start circuits.
Page 153: Harness Drawings
Section C - Electrics Harness Data Harness Drawings C-15 9803-9340-8 C-15...
Page 154 Section C - Electrics Harness Data Harness Drawings C-16 9803-9340-8 C-16...
Page 155 Section C - Electrics Harness Data Harness Drawings HANDBRAKE BUZZER RELAY/ HORN SWITCH AU,AV PRIMARY FUSE A,B,D SPLICE NEUTRAL RELAY TERM WIRE SIZE DEST TYPE TERM WIRE SIZE DEST TYPE BB,BC TERM WIRE SIZE DEST TYPE 310D 303B MY 12 WIRE SIZE DEST...
Page 156 Section C - Electrics Harness Data Harness Drawings C-18 9803-9340-8 C-18...
Page 157 Section C - Electrics Harness Data Harness Drawings T006090 Fig 7. Mainframe Harness - Series 2 machines C-19 9803-9340-8 C-19...
Page 158 Section C - Electrics Harness Data Harness Drawings C-20 9803-9340-8 C-20...
Page 159: Circuit Diagrams
Section C - Electrics Circuit Diagrams Early Series 1 machines C-21 9803-9340-8 C-21...
Page 160 Section C - Electrics Circuit Diagrams Early Series 1 machines C-22 9803-9340-8 C-22...
Page 161: Later Series 1 Machines
Section C - Electrics Circuit Diagrams Later Series 1 machines C-23 9803-9340-8 C-23...
Page 162 Section C - Electrics Circuit Diagrams Later Series 1 machines C-24 9803-9340-8 C-24...
Page 163: Series 2 Machines
Section C - Electrics Circuit Diagrams Series 2 machines C-25 9803-9340-8 C-25...
Page 164 Section C - Electrics Circuit Diagrams Series 2 machines C-26 9803-9340-8 C-26...
Page 165: Service Tools
Tool Detail Reference, Section 1. These tools are available from JCB Service. Note: Tools other than those listed will be required. It is Some tools are available as kits or sets, the part numbers expected that such general tools will be available in any for parts within such kits or sets are not listed here.
Page 166: Tool Detail Reference Section C - Electrics
Section C - Electrics Service Tools Tool Detail Reference Section C - Electrics Tool Detail Reference Section C - Electrics Fig 1. 892/00283 Tool Kit Case 892/00281 AVO Meter 892/00286 Surface Temperature 892/00284 Microtach Digital Tachometer 892/00282 Shunt - open type 892/00285 Hydraulic Oil Temperature Probe C-28 9803-9340-8...
Page 167 9803/9340-8 Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 168 Section E - Hydraulics Notes: 9803/9340-8...
Page 169 Series 1 Machines, JCB (+) pattern controls .......... E-43 Series 1 Machines, ISO (+) pattern controls .......... E-45 Series 2 Machines, JCB (+) pattern controls - 2WD ....... E-47 Series 2 Machines, ISO (+) pattern controls - 2WD ....... E-49 Series 2 Machines, JCB (+) pattern controls - 4WD .......
Page 170 Section E - Hydraulics Contents Page No. Oil Cooler Oil Cooler Connections ................. E-155 Service Tools Numerical List ..................E-157 Tool Detail Reference Section E- Hydraulics ........E-160 E-ii E-ii...
Page 171: Technical Data
Section E - Hydraulics Technical Data General Data Note: System Cleanliness is to be to ISO 16/13 - K Hydraulic Contamination ( T E-60) Loader Pump - Series 1 Machines Type Gear Displacement 10.8 cc/rev (0.66 in /rev) Flow at 2100 rev/min (excavating speed) 22 l/min (4.8 UK gal/min, 5.8 US gal/min) Flow at 2800 rev/min (maximum power) 30 l/min (6.6 UK gal/min, 7.9 US gal/min)
Page 172 Section E - Hydraulics Technical Data General Data Transmission Pump - Series 2 Machines, 4WD Type Axial piston variable displacement Displacement 28 cc/rev (1.71 in /rev) Control Hydraulic, solenoid operated Charge Pump Displacement 6.1 cc/rev (0.37 in /rev) Charge Pressure (oil temperature at 50° C) 40 bar (580 lbf/in High Pressure Relief Valve Setting 350 bar (5075 lbf/in...
Page 173 Section E - Hydraulics Technical Data General Data Relief Valve Operating Pressures Pressures are given at normal working temperature of 50 deg C. lbf/in Main Relief Valve (MRV) at 2200 rev/min 2900 Auxiliary Relief Valves (ARV) Loader Valve Block - Non Self Level Shovel Crowd 3190 Lift Ram Raise...
Page 174 Section E - Hydraulics Technical Data General Data Rams Dimensions Ram Location Bore Rod Diameter Stroke (mm) (in) (mm) (in) (mm) (in) Lift 1.97 1.18 18.98 Shovel 1.97 1.18 14.60 Boom 2.36 1.18 16.14 Dipper 2.36 1.18 16.14 Bucket 2.36 1.18 11.57 Stabiliser...
Page 175: Service Procedures
Section E - Hydraulics Service Procedures Hydraulic Contamination TE-002_3 Hydraulic Fluid Quality cleaning unit. Fig 1. ( E-5). General Bulletin 011 also refers. This machine uses a large volume of fluid in the hydraulic Procedure system for power transmission, equipment lubrication, rust prevention and sealing.
Page 176 Section E - Hydraulics Service Procedures Hydraulic Contamination Contaminant Standards Dirt that damages your system is in many cases too small to be seen with the eye. The particle size is measured in microns. 1 micron = 0.001 mm (0.0000394 in). Listed below are a few typical comparisons: –...
Page 177: Cleaning Operation
Section E - Hydraulics Service Procedures Cleaning Operation Cleaning Operation The purpose of cleaning the hydraulic oil is to remove At low engine revs, operate the services slowly to extend the rams, this will expel the dirty oil from the contaminants of all types and sludge.
Page 178 Section E - Hydraulics Service Procedures Cleaning Operation Page left intentionally blank 9803-9340-8...
Page 179: Operation Description
Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols TE-001 General (Basic and Functional Symbols) Table 2. Rams Complex hydraulic components and circuits can be Single acting described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used.
Page 180 Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols Table 4. Control Valves Throttling orifice - normally Used to enclose several closed valves indicating they are supplied as one unit 3-Position, 4-port spring Throttling orifice - normally centered pilot operated valve open 3-position, 6-port spring centered pilot operated valve...
Page 181 Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols Table 5. Energy Transmissions and Conditioning Working line, return or feed Reservoir - return line below fluid level Pilot control Drain lines Header tank Flexible pipe Pressure sealed tank Line junction Accumulator Crossing lines...
Page 182 Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols Table 6. Control Mechanisms Solenoid one winding Rotating shaft - one direction Solenoid two windings Rotating shaft - two directions Detent Electric motor operated Locking device Internal pressure pilot operated Over centre device External pressure pilot...
Page 183: Control Valves
E-13) - In circuit diagrams the pipework is usually shown connected to the box which represents the Three typical JCB style spools are known as 'D' spools, 'F' unoperated condition. (Hydraulic circuit diagrams are spools and 'N' spools. usually shown in the unoperated condition).
Page 184 Section E - Hydraulics Operation Description Introduction to Hydraulic Schematic Symbols Example of Schematic Circuit Fig 7. Simple Schematic Circuit Some of the symbols described on the preceding pages Example Circuit Key have been arranged into a simple schematic circuit. Fig 7.
Page 185: General Description
Diagrams starting on page E/10-1. The diagram shows the pressurised oil to the loader and excavator valves and to standard JCB pattern excavator controls. For the optional the transmission motor(s). When either the loader or ISO pattern controls the excavator spools are in different excavator valve is operated, pressurised oil is delivered to positions (refer to detailed diagrams).
Page 186 Section E - Hydraulics Operation Description General Description 708121 Fig 8. Machine Neutral Circuit E-16 9803-9340-8 E-16...
Page 187: Transmission Pump Operation - Series 1 Machines
Section E - Hydraulics Operation Description Transmission Pump Operation - Series 1 Machines Transmission Pump Operation - Series 1 Machines The illustration Fig 10. ( E-18) shows a section allow oil to circulate within the pump/motor loop so that the through the transmission pump.
Page 188 Section E - Hydraulics Operation Description Transmission Pump Operation - Series 1 Machines 707360-1 Fig 10. E-18 9803-9340-8 E-18...
Page 189: Transmission Pump Operation - Series 2 Machines
Section E - Hydraulics Operation Description Transmission Pump Operation - Series 2 Machines Transmission Pump Operation - Series 2 Machines The transmission pump P1 is a variable displacement axial piston pump 10, and associated control circuits. Forward/reverse control is provided by a solenoid operated directional control valve 3, which acts on the swash angle control piston 2.
Page 190 Section E - Hydraulics Operation Description Transmission Pump Operation - Series 2 Machines 860740-1 Fig 12. Axial Piston Pump The axial piston pump is a variable displacement pump 10, which uses the swash plate design principle. In this type of pump, the flow is directly proportional to the driven speed and to the swash plate angle, which is infinitely variable from zero to full swash angle.
Page 191: Charge Pump
Section E - Hydraulics Operation Description Transmission Pump Operation - Series 2 Machines Charge Pump The charge (or boost) pump 8 is a gear pump which provides the control pressure for the internal pump control circuits. Filtration is provided in the charge pump circuit by an external filter F.
Page 192 Section E - Hydraulics Operation Description Transmission Pump Operation - Series 2 Machines Directional Control Valve (DCA) Pilot pressure is fed to the DCA 3 from the DA control valve. Forward or reverse selection energises the appropriate solenoid 3a or 3b, causing spool movement. Pilot pressure oil is directed to the corresponding end of the swash control piston.
Page 193: Transmission Motor Operation 2Wd
Section E - Hydraulics Operation Description Transmission Motor Operation 2WD Transmission Motor Operation 2WD Fig 18. ( E-23) Fig 19. ( E-24) Rotor Housing The basic components of the transmission motor are the rotor and rollers which are located within a machined Rotor housing, this being called the Geroler assembly, the valve Valve Plate...
Page 194 Section E - Hydraulics Operation Description Transmission Motor Operation 2WD 707420-1 Fig 19. E-24 9803-9340-8 E-24...
Page 195: Transmission Operation - Series 1 Machines
Section E - Hydraulics Operation Description Transmission Operation - Series 1 Machines Transmission Operation - Series 1 Machines Neutral Cooler Fig 20. ( E-25) By-pass (Tow) Valve With the engine running, charge pump P2 draws oil Transmission Pump through the suction strainer S and feeds the oil into the Charge Pump transmission circuit, via non-return valves Pd and Pe, to make up any oil loss.
Page 196 Section E - Hydraulics Operation Description Transmission Operation - Series 1 Machines Forward Charge pump P2 continues to maintain oil within the system via non-return valve Pe. Fig 21. ( E-26) The pump swash plate is tilted by the control pedal linkage Cooler causing flow to pass to the motor feed A and the machine By-pass (Tow) Valve...
Page 197 Section E - Hydraulics Operation Description Transmission Operation - Series 1 Machines Reverse Charge pump P2 continues to maintain oil within the system via non-return valve Pd. Fig 22. ( E-27) The pump swash plate is tilted by the control pedal linkage Cooler causing flow to pass to the motor feed B and the machine By-pass (Tow) Valve...
Page 198: Transmission Operation - 2Wd Series 2 Machines
Section E - Hydraulics Operation Description Transmission Operation - 2WD Series 2 Machines Transmission Operation - 2WD Series 2 Machines Neutral Cooler Fig 23. ( E-28) Transmission Pump With the engine running, charge pump 8 draws oil through Motor the suction strainer S and feeds the oil into the Motor Shuttle Valve transmission circuit to provide control pressure for the pump operation.
Page 199 Section E - Hydraulics Operation Description Transmission Operation - 2WD Series 2 Machines Forward occur in the high pressure side of the loop circuit, the high pressure relief valve in 5a will open briefly releasing oil which will then flow into the pump case via the charge Fig 24.
Page 200 Section E - Hydraulics Operation Description Transmission Operation - 2WD Series 2 Machines Reverse occur in the high pressure side of the loop circuit, the high pressure relief valve in 5b will open briefly releasing oil which will then flow into the pump case via the charge Fig 25.
Page 201: Transmission Operation - 4Wd Series 2 Machines
Section E - Hydraulics Operation Description Transmission Operation - 4WD Series 2 Machines Transmission Operation - 4WD Series 2 Machines Neutral Cooler Fig 26. ( E-32) Transmission Pump With the engine running, charge pump 8 draws oil through Motor the suction strainer S and feeds the oil into the Motor transmission circuit to provide control pressure for the pump operation.
Page 202 Section E - Hydraulics Operation Description Transmission Operation - 4WD Series 2 Machines E-32 9803-9340-8 E-32...
Page 203 Section E - Hydraulics Operation Description Transmission Operation - 4WD Series 2 Machines Forward released into the pump case through the charge pressure relief valve 7 where it returns to tank via oil cooler C. Fig 27. ( E-34) When the operator selects forward drive, solenoid 3a is Cooler energised causing direction control valve 3 to direct pilot Transmission Pump...
Page 204 Section E - Hydraulics Operation Description Transmission Operation - 4WD Series 2 Machines E-34 9803-9340-8 E-34...
Page 205 Section E - Hydraulics Operation Description Transmission Operation - 4WD Series 2 Machines Reverse Direction Control Valve Fig 28. ( E-36) Pressure Cut-off Valve When the operator selects forward drive, solenoid 3b is High Pressure Relief Valve energised causing direction control valve 3 to direct pilot High Pressure Relief Valve pressure from the DA valve 6 to the swash control piston Displacement Angle Control Valve...
Page 206 Section E - Hydraulics Operation Description Transmission Operation - 4WD Series 2 Machines E-36 9803-9340-8 E-36...
Page 207: Typical Valve Spool Operation
Section E - Hydraulics Operation Description Typical Valve Spool Operation Typical Valve Spool Operation The following illustrations show the bucket spool but the Neutral Circuit operation of other spools is similar. The illustration Fig 29. ( E-37) shows the oil flow through the valve section when no service is selected.
Page 208 Section E - Hydraulics Operation Description Typical Valve Spool Operation Spool Open Selected - 1 The oil entering the valve block flows past the spool A and is then diverted by the spool to load hold check valve B which at this stage remains closed. The valve opens only The illustration Fig 30.
Page 209 Section E - Hydraulics Operation Description Typical Valve Spool Operation Spool Open Selected - 2 Oil returning from the opposite end of the tilt ram enters the valve block and flows past spool A into the exhaust gallery and back to tank. In this instance the exhaust oil flows past The illustration Fig 31.
Page 210 Section E - Hydraulics Operation Description Typical Valve Spool Operation Spool Closed Selected pressurised oil to flow out of the valve block to operate the ram. The illustration Fig 32. ( E-40) shows the service Oil returning from the opposite end of the tilt ram enters the selected.
Page 211: Main Relief Valve Operation
Section E - Hydraulics Operation Description Main Relief Valve Operation Main Relief Valve Operation The Main Relief Valve is located in the inlet section of the excavator valve block. When the pressure in the supply line A is below the setting of the relief valve the valve spool B remains on its seat Fig 33.
Page 212 Section E - Hydraulics Operation Description Main Relief Valve Operation Page left intentionally blank E-42 9803-9340-8 E-42...
Page 213: Circuit Diagrams
Section E - Hydraulics Circuit Diagrams Series 1 Machines, JCB (+) pattern controls E-43 9803-9340-8 E-43...
Page 214 Section E - Hydraulics Circuit Diagrams Series 1 Machines, JCB (+) pattern controls E-44 9803-9340-8 E-44...
Page 215: Series 1 Machines, Iso (+) Pattern Controls
Section E - Hydraulics Circuit Diagrams Series 1 Machines, ISO (+) pattern controls E-45 9803-9340-8 E-45...
Page 216 Section E - Hydraulics Circuit Diagrams Series 1 Machines, ISO (+) pattern controls E-46 9803-9340-8 E-46...
Page 217: Series 2 Machines, Jcb (+) Pattern Controls - 2Wd
Section E - Hydraulics Circuit Diagrams Series 2 Machines, JCB (+) pattern controls - 2WD E-47 9803-9340-8 E-47...
Page 218 Section E - Hydraulics Circuit Diagrams Series 2 Machines, JCB (+) pattern controls - 2WD E-48 9803-9340-8 E-48...
Page 219: Series 2 Machines, Iso (+) Pattern Controls - 2Wd
Section E - Hydraulics Circuit Diagrams Series 2 Machines, ISO (+) pattern controls - 2WD E-49 9803-9340-8 E-49...
Page 220 Section E - Hydraulics Circuit Diagrams Series 2 Machines, ISO (+) pattern controls - 2WD E-50 9803-9340-8 E-50...
Page 221: Series 2 Machines, Jcb (+) Pattern Controls - 4Wd
Section E - Hydraulics Circuit Diagrams Series 2 Machines, JCB (+) pattern controls - 4WD E-51 9803-9340-8 E-51...
Page 222 Section E - Hydraulics Circuit Diagrams Series 2 Machines, JCB (+) pattern controls - 4WD E-52 9803-9340-8 E-52...
Page 223: Series 2 Machines, Iso (+) Pattern Controls - 4Wd
Section E - Hydraulics Circuit Diagrams Series 2 Machines, ISO (+) pattern controls - 4WD E-53 9803-9340-8 E-53...
Page 224 Section E - Hydraulics Circuit Diagrams Series 2 Machines, ISO (+) pattern controls - 4WD E-54 9803-9340-8 E-54...
Page 225: Towing/Winching
Apply the parking brake and block all four wheels. Before Towing/Winching Turn the transmission tow valve C 90º anti-clockwise It is only possible to tow or winch the JCB MINI very slowly to reactivate the hydraulic circuit. for a short distance. If at all possible repair the disabled machine where it stands.
Page 226 (0.6 mile). Before Towing/Winching After Towing/Winching It is only possible to tow or winch the JCB MINI very slowly for a short distance. If at all possible repair the disabled Apply the parking brake and block all four wheels. machine where it stands.
Page 227 Section E - Hydraulics Towing/Winching Preparing for Towing/Winching 864761-1 Fig 4. 864800-1 Fig 5. E-57 9803/9340-8 E-57...
Page 228 Section E - Hydraulics Towing/Winching Preparing for Towing/Winching Series 2 Machines with Wheel Mounted Hydraulic Motors In addition to carrying out the procedure detailed on the previous page it will be necessary to release the hydraulic brake on each rear wheel motor. Remove the knobs from the backhoe control levers.
Page 229: Problem Solving
Section E - Hydraulics Problem Solving Hydrostatic Transmission The purpose of this section is to help you trace Make sure that the hydraulic fluid is at correct working transmission problems to a faulty unit (pump, motor, etc). temperature (50 ºC, 122 ºF). Once you have traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions Whatever the fault, check the condition of the...
Page 230 Section E - Hydraulics Problem Solving Hydrostatic Transmission KEY TO CAUSE REMEDY PAGE REF. Pump neutral position set incorrectly Adjust neutral position. Transmission Pump Neutral Adjustment - Series 1 Machines ( E-62) High pressure relief valve faulty Check high pressure relief valve. Clean or Pump Pressure replace valve if faulty.
Page 231 Section E - Hydraulics Problem Solving Hydrostatic Transmission Hydrostatic Transmission Circuit - Series 1 Machines 707631-1 Fig 1. Fig 1. ( E-61) Fig 1. ( E-61) Main Relief Pressure Test Point. For location Filter Fig 2. ( E-62) Transmission Pump Charge Relief Pressure Test Point.
Page 232 Section E - Hydraulics Problem Solving Hydrostatic Transmission Transmission Pump Neutral Adjustment Remove the front floor plate. - Series 1 Machines Check that the control pedal and cable moves freely. Lubricate if necessary. This procedure may be carried out if the machine creeps when the drive pedal is in the neutral position.
Page 233 Section E - Hydraulics Problem Solving Hydrostatic Transmission Checking Motor Speed - Series 1 Insert a flow meter, load valve and pressure gauge into a motor feed line. Machines With the load valve off, start the engine and operate The pump output and general efficiency of the drive the pump swash plate in the appropriate direction.
Page 234 Section E - Hydraulics Problem Solving Hydrostatic Transmission Checking Motor Leakage Rate (2WD) 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 235 Section E - Hydraulics Problem Solving Hydrostatic Transmission Pump Pressure Test Points - Series 1 Machines The upper view shows the top of the pump, the lower view shows the right hand side of the pump. Forward port Reverse port Forward relief valve Reverse relief valve Charge relief test point...
Page 236 Section E - Hydraulics Problem Solving Hydrostatic Transmission Pump Pressure Test Points - Series 2 Machines The illustration shows the pump viewed from beneath.. Drive circuit inlet/outlet test port Drive circuit inlet/outlet test port Charge pressure test port Actuator test port Actuator test port WARNING Fluid Under Pressure...
Page 237 Section E - Hydraulics Problem Solving Hydrostatic Transmission Testing High Pressure Relief Valves Alternative Method The following procedure is the recommended method with WARNING the machine raised off the ground. The alternative method During the following procedures do not get beneath can be used if the safety instructions are followed.
Page 238 Section E - Hydraulics Problem Solving Hydrostatic Transmission Series 2 Machines Adjust the appropriate valve as necessary. E-68 9803-9340-8 E-68...
Page 239 Section E - Hydraulics Problem Solving Hydrostatic Transmission Page left intentionally blank E-69 9803-9340-8 E-69...
Page 240: Loader/Excavator Circuit
Section E - Hydraulics Problem Solving Loader/Excavator Circuit Loader/Excavator Circuit The purpose of this section is to help you trace hydraulic Make sure that the hydraulic fluid is at correct working temperature (50 ºC, 122 ºF). 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 Whatever the fault, check the condition of the...
Page 241 Spool return spring or cap out of alignment Remove cap, check that spring is in correct position. Temperature distribution within control Warm up entire system before using service. valves not uniform Incorrect attachments fitted, eg Jack Ensure attachments are JCB approved for the Hammer Mini CX. E-71 9803-9340-8 E-71...
Page 242 Section E - Hydraulics Problem Solving Loader/Excavator Circuit Page left intentionally blank E-72 9803-9340-8 E-72...
Page 243: Pump Assembly Series 1 Machines
Section E - Hydraulics Pumps Pump Assembly Series 1 Machines Removal Disconnect the forward/reverse cable clevis and damper unit from the pump operating lever at F. Disconnect the battery. Remove the front floor plate. Remove bracket fixing bolts G and lift the bracket, cable Unscrew the hydraulic filler cap to release pressure in the and damper clear of the pump unit.
Page 244 Section E - Hydraulics Pumps Pump Assembly Series 1 Machines Replacement Using suitable lifting equipment carefully lower the pump unit into position. Offer the drive shaft through the flywheel aperture and locate the splines into the engine drive coupling. It may be necessary to rock the pump unit from side to side to engage the splines.
Page 245: Transmission Pump - Series 1 Machines
Section E - Hydraulics Pumps Transmission Pump - Series 1 Machines Transmission Pump - Series 1 Machines 707510-1 Fig 2. E-75 9803-9340-8 E-75...
Page 246: Dismantling And Assembly
Section E - Hydraulics Pumps Transmission Pump - Series 1 Machines Dismantling and Assembly Turn the adapter assembly over. Remove ‘O’ ring 11. Inspect the gerotor pocket and needle bearing 12 The numerical sequence shown on the illustration is located in the charge pump adapter. The needles in intended as a guide to dismantling Fig 2.
Page 247 Section E - Hydraulics Pumps Transmission Pump - Series 1 Machines Remove the rotating assembly 20 by carefully plate is a press fit and not removable. Repeat steps retaining it in the housing assembly 40. Lift the 26 and 27. housing and rotating assembly and turn over assemblies allowing the rotating assembly to slide Note: The cam plate control shaft will exit either side of the...
Page 248 Section E - Hydraulics Pumps Transmission Pump - Series 1 Machines Assembly renewed, a shim kit must be used in place of the crush ring. Before reassembling the pump, replace all worn and damaged parts, assemblies, seals and ‘O’ rings. Lubricate Place bearing cup 30 into trunnion cover 29 over the the seals and ‘O’...
Page 249 Section E - Hydraulics Pumps Transmission Pump - Series 1 Machines Hold the housing 40 in the vertical position then carefully install the rotating kit 20 by first aligning with the splines on the input shaft. With splines aligned, install the rotating kit into the pump housing. Ensure all parts are kept in their proper position.
Page 250: Transmission Pump - Series 2 Machines
Section E - Hydraulics Pumps Transmission Pump - Series 2 Machines Transmission Pump - Series 2 Machines Removal and Replacement Fit the two securing bolts H and tighten to 343 Nm (35 kgf m; 253 lbf ft). Remove the lifting equipment. Note: Bear the following in mind when working on the Working underneath the machine, connect the transmission pump.
Page 251 Section E - Hydraulics Pumps Transmission Pump - Series 2 Machines Transmission Pump - Series 2 Machines Drive Shaft Oil Seal Removal Wrap tape around the pump shaft splines to prevent damage to the seal lips. Remove retaining ring A. Fit screws into the two rubber lined holes in the shaft seal.
Page 252 Section E - Hydraulics Pumps Transmission Pump - Series 2 Machines Charge Pump Oil Seal 864660-1 Fig 10. Removal Remove the service pump (not shown). Remove four cover fixing screws Fig 11. ( E-82). 864671B Fig 12. 864671A Fig 11. Pry off the cover Fig 12.
Page 253 Section E - Hydraulics Pumps Transmission Pump - Series 2 Machines Remove the ‘O’ ring Fig 14. ( E-83). Replacement Renew the Kantsil ring D. Check that the unloading channel E is clear and the locating pin F is undamaged Fig 17.
Page 254 Section E - Hydraulics Pumps Transmission Pump - Series 2 Machines Fit the service pump (not shown). 864691B Fig 19. Fit the charge pump housing Fig 20. ( E-84). 864691C Fig 20. Fit ‘O’ ring and cover plate Fig 21. ( E-84).
Page 255 Section E - Hydraulics Pumps Transmission Pump - Series 2 Machines Control Piston Cover Seals Removal Remove lock nut A whilst holding adjustment screw B to prevent it moving. Measure the distance that the adjustment screw protrudes from the cover C. Mark the position of the cover relative to the pump housing.
Page 256 Section E - Hydraulics Pumps Transmission Pump - Series 2 Machines High Pressure Relief Valve Dismantling and Assembly The components of the high pressure relief valve are shown at A. There is a second relief valve underneath the pump. Use a suitable protection sleeve B when assembling backup ring C and ‘O’...
Page 257 Section E - Hydraulics Pumps Transmission Pump - Series 2 Machines Pressure Cut-off Valve Dismantling and Assembly The illustration shows the components of the valve. It is possible to dismantle the valve for cleaning and re- sealing without disturbing the adjustment screw. If it is necessary to fully dismantle the valve, first measure the protrusion of the adjustment screw so that it can be reset to the original position.
Page 258 Section E - Hydraulics Pumps Transmission Pump - Series 2 Machines Control Unit Removal and Replacement Remove the securing screws and pry off the control unit A from the pump housing. When replacing, use new gasket B and ‘O’ ring C. Dismantling and Assembly The control unit may be dismantled for cleaning.
Page 259: Service Pump
Section E - Hydraulics Pumps Service Pump Service Pump Removal and Replacement Replacement Lubricate and install a new ‘O’ ring on the pump flange. Removal Offer the pump drive shaft through the transmission pump Disconnect the battery. Remove the front floor plate. aperture and locate the splines into the drive coupling.
Page 260 Section E - Hydraulics Pumps Service Pump Dismantling and Assembly - Series 1 Machines 707440-1 Fig 31. Work in a clean area; cleanliness is extremely important back plate. Body will remain with either front plate or when repairing hydraulic pumps. Before dismantling, plug back plate.
Page 261 Section E - Hydraulics Pumps Service Pump Remove seal 10 and back-up gasket 11 from wear If edge of gear teeth are sharp, break edge with plate. emery cloth. Remove shaft seal 14 and washer 15 from front plate Assembly with a blunt punch from the back side.
Page 262 Section E - Hydraulics Pumps Service Pump Service Pump - Series 2 Machines T006150-1 Fig 32. Work in a clean area; cleanliness is extremely important Remove circlip 19 and withdraw shaft seal 20 from when repairing hydraulic pumps. Before dismantling, plug front plate.
Page 263 Section E - Hydraulics Pumps Service Pump Assembly During assembly replace seals 7 and 9, seal supports 8 and 10, shaft seal 20 and ‘O’ rings 5 and 6 with new parts. Apply a thin coat of hydraulic oil to gear and bearing components 11 to 18 and assemble in their correct positions.
Page 264 To remove the coupling it is necessary to remove the pump unit and flywheel housing. The coupling is bolted to the engine flywheel with three cap screws D. Coat threads of cap screws D with JCB Threadlocker and Sealer Sealing and Retaining Compounds ( 1-29) and torque tighten to 49 Nm (36 lbf ft, 5 kgf m).
Page 265 Section E - Hydraulics Pumps Service Pump Start-up Procedure - Series 1 Machines Install a 0 - 40 bar (0 - 600 lbf/in2, 0 - 42 kgf/cm2) pressure gauge in the charge pressure test point B. The following start-up procedure should always be Remove the ESOS fuse to prevent the engine from followed when starting up a new installation or when starting.
Page 266 Section E - Hydraulics Pumps Service Pump Start-up Procedure - Series 2 Machines Check that the pump inlet lines are filled with fluid, by slackening the hose connections at the transmission and service pump, then re-tighten the connections. The following start-up procedure should always be followed when starting up a new installation or when Bleed air from the pump casing by slackening plugs A and restarting an installation in which either a pump or motor...
Page 267 Section E - Hydraulics Pumps Service Pump 864780-1 Fig 35. E-97 9803-9340-8 E-97...
Page 268 Section E - Hydraulics Pumps Service Pump Page left intentionally blank E-98 9803-9340-8 E-98...
Page 269: Drive Motors
Unscrew and remove bolts or cap screws D. Withdraw the motor forwards clear of the drive splines. Replacement Replacement is the reversal of the removal procedure. Apply JCB High Strength Threadlocker to bolts or cap screws D before fitting Sealing and Retaining Compounds ( 1-29).
Page 270: Dismantling And Assembly
Section E - Hydraulics Drive Motors Axle Drive Motor Dismantling and Assembly 707570-1 Fig 2. The numerical sequence shown is a guide to dismantling. assembly. Before starting the dismantling procedures, For assembly the sequence should be reversed. drain the oil from inside the motor. Dismantling Place the motor in a vice with the output shaft down.
Page 271 Section E - Hydraulics Drive Motors Axle Drive Motor Lift valve housing 2 straight up. If done carefully the bearing housing. Do not damage the bore of the pins 20, springs 21, balance ring assembly 22, and housing. valve 25 will remain on the valve plate 26. Note: Note: Individual parts of the shaft and bearing Carefully remove ‘O’...
Page 272 Section E - Hydraulics Drive Motors Axle Drive Motor Clamp housing in a vice. Wrap tape over the end of the shaft to prevent cutting the seals. Apply petroleum jelly to inside diameter of dust and shaft seal. It may be necessary to use a press to install shaft and bearing assembly.
Page 273 Section E - Hydraulics Drive Motors Axle Drive Motor Install new ‘O’ ring 5 onto retaining plug 4 and screw into the valve housing. Torque to 8 to 11 Nm (75 to 100 lbf in). Install 2 springs 21 and 2 pins 20 in the holes located in the bore of the valve housing 2.
Page 274: Wheel Drive Motors
(not shown). Support the motor and unscrew and remove bolts D. Withdraw the motor forwards clear of the hub. Replacement Replacement is the reversal of the removal procedure. Apply JCB High Strength Threadlocker to bolts D before fitting Sealing and Retaining Compounds ( 1-29).
Page 275 E. Withdraw the motor forwards clear of the hub. Replacement Replacement is the reversal of the removal procedure. Apply JCB High Strength Threadlocker to bolts E before fitting Sealing and Retaining Compounds ( 1-29). Tighten to the correct torque.
Page 276 Section E - Hydraulics Drive Motors Wheel Drive Motors Wheel Drive Motor - Brake Dismantling Remove and discard the brake cover (141) Fig 9. ( E-106). 865850C Fig 11. Install the mandrel onto the spring washer. Lubricate the bolt thread and nut faces. Tighten the screw into the brake piston down to the thread root.
Page 277 Section E - Hydraulics Drive Motors Wheel Drive Motors 865860B 865870A Fig 13. Fig 16. Extract the brake piston (107) Fig 14. ( E-107). Remove brake housing (101) Fig 17. ( E-107). 865860C Fig 14. 865870B Fig 17. Remove discard ‘O’...
Page 278 After degreasing do not touch the surface with hands or fingers. Using a clean brush apply a thin film of JCB Activator on the part of the cover surface which will be in contact with the brake housing. DO NOT apply any...
Page 279 Place the brake housing onto the cover and position using some new screws Fig 26. ( E-109). 865890B Fig 24. Place a continuous bead of JCB Multigasket on the brake housing as shown below Sealing and Retaining Compounds ( 1-29). Ensure there no gaps Fig 25.
Page 280 Section E - Hydraulics Drive Motors Wheel Drive Motors 865900B Fig 27. Note: Note that the sealed joint remains fragile for six hours after assembly. Avoid any shock to the joint and do not test the motor or brake during this time. Install the torque reduction shims (115).
Page 281 Section E - Hydraulics Drive Motors Wheel Drive Motors Install a new ‘O’ ring (106) on the piston (107). The ‘O’ ring should be tight on the piston and not twisted Fig 29. ( E-111). 865920C Fig 31. Compress the spring and install the snap ring in line with mark made...
Page 282 Section E - Hydraulics Drive Motors Wheel Drive Motors 865930A Fig 33. 865930C Fig 36. Compress the spring washer and remove the snap Install shims (105) previously calculated ring Fig 34. ( E-112). Fig 37. ( E-112). 865930B Fig 34. 865940A Fig 37.
Page 283 Section E - Hydraulics Drive Motors Wheel Drive Motors Install the snap ring in line with the mark made during Install a new cover (141) on the entry chamfer dismantling Fig 39. ( E-113). Fig 42. ( E-113). 865940C 865950B Fig 39.
Page 284 Section E - Hydraulics Drive Motors Wheel Drive Motors 865950D Fig 44. E-114 9803-9340-8 E-114...
Page 285 Section E - Hydraulics Drive Motors Wheel Drive Motors Wheel Drive Motor - Bearing Support Dismantling Stand motor brake cover Fig 45. ( E-115). 865960C Fig 47. Remove bearing support (070) Fig 48. ( E-115). 865960A Fig 45. Mark the position of the cam assembly (026) in relation valving cover...
Page 286 Section E - Hydraulics Drive Motors Wheel Drive Motors Discard the ‘O’ ring (027) from the valving cover (041) Fig 50. ( E-116). 865970D Fig 52. Using a mandrel and press, apply a force of 20,000N 865970B Fig 50. (4,496lbf) on the roller bearings then remove the snap ring (077) Fig 53.
Page 287 Section E - Hydraulics Drive Motors Wheel Drive Motors Fix a suitable contact plate to the bearing support Remove inner race from bearing Fig 55. ( E-117). Fig 58. ( E-117). 865980C 865990B Fig 55. Fig 58. Position the contact plate on supports under the Extract the outer bearing race using a two legged press.
Page 288 Section E - Hydraulics Drive Motors Wheel Drive Motors 866000A 866000D Fig 61. Fig 64. Extract the bearing outer race Fig 62. ( E-118). Extract the inner race (074) from the bearing. It may be necessary to apply a little heat to the lip seal which will then be destroyed Fig 65.
Page 289 Section E - Hydraulics Drive Motors Wheel Drive Motors Coat the bearing outer race (073) with grease Fig 69. ( E-119). 866010B Fig 66. Install the bearing outer race (074) in the bearing 866020B support housing up to the stop. Check that it is in its Fig 69.
Page 290 Section E - Hydraulics Drive Motors Wheel Drive Motors Install the bearing (073) inside its outer race Fig 72. ( E-120). 866030C Fig 74. Install bearing (074) outer race 866030A Fig 75. ( E-120). Fig 72. Position the shaft under a press and on a suitable support to prevent damage to the wheel studs Fig 73.
Page 291 Section E - Hydraulics Drive Motors Wheel Drive Motors Release the press force and rotate the bearing support 5 turns to the right and left. Re-apply the press force Fig 77. ( E-121). 866040D Fig 79. Re-apply the press force on the bearing then 866040B Fig 77.
Page 292 Check that it is not possible to turn the thrust ring by Coat the external diameter of the seal support with hand. Check also that the snap ring outer diameter is JCB Multigasket Fig 85. ( E-122). not larger than the thrust ring.
Page 293 Section E - Hydraulics Drive Motors Wheel Drive Motors Coat the external diameter of the back up ring support with JCB Multigasket Fig 89. ( E-123). 866060D Fig 86. Visually check the correct position of the seal support 866070C in the bearing support. Clean off excess sealant Fig 89.
Page 294 Section E - Hydraulics Drive Motors Wheel Drive Motors Install the back-up ring Fig 92. ( E-124). 866080D Fig 94. 866080B Install the cam assembly (026) on the valving cover, Fig 92. lining up the marks made during dismantling. The big chamfers should be oriented towards the bearing Ensure that the ‘O’...
Page 295 Section E - Hydraulics Drive Motors Wheel Drive Motors Make sure the shaft motor ports are perpendicular to mounting axis motor shown Fig 97. ( E-125). 866090C Fig 97. Install and tighten the mounting screws (042) to 131- 159 Nm (97-117 lbf ft) Fig 98.
Page 296 Section E - Hydraulics Drive Motors Wheel Drive Motors Wheel Drive Motor - Roller Block Dismantling After removing the cam, remove the roller block Fig 99. ( E-126). 866100C Fig 101. 866100A Fig 99. Assembly Install a new ‘O’ ring (027) Fig 100.
Page 297 Section E - Hydraulics Drive Motors Wheel Drive Motors Wheel Drive Motor - Valve Lubricate the sealing faces of the valve disc Fig 104. ( E-127). Dismantling Mark the position of the valve in relation to the valving cover Fig 102. ( E-127).
Page 298 Section E - Hydraulics Drive Motors Wheel Drive Motors Wheel Drive Motor - End Cover Seal Dismantling Position the motor on the bearing support. Remove screws (066) Fig 106. ( E-128). 866130C Fig 108. Assembly 866130A Install a new ‘O’ ring (045) Fig 109.
Page 299 Section E - Hydraulics Drive Motors Wheel Drive Motors 866140B Fig 110. Install and tighten the screws (066) to 200-230 Nm (140-165 lbf ft) Fig 111. ( E-129). 866140C Fig 111. E-129 9803-9340-8 E-129...
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Page 301: Loader Valve
Section E - Hydraulics Valves Loader Valve Removal Disconnect all hydraulic hoses from the valve ports (one inlet A, four work ports B and one outlet C). Cover exposed connections to prevent ingress of dirt. Mark the hoses to Remove front floor plate Floor Plates ( B-1).
Page 302 Section E - Hydraulics Valves Loader Valve Dismantling and Assembly When Assembling Note: Lubricate all seals and 'O' rings with hydraulic fluid When Dismantling on assembly. CAUTION: Absolute cleanliness is essential when Slide the valve section onto the tie rods C in the stripping and assembling hydraulic components.
Page 303: Excavator Valve
Section E - Hydraulics Valves Excavator Valve Excavator Valve Removal and Replacement Torque Settings Removal Item kgf m lbf ft 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 304 Section E - Hydraulics Valves Excavator Valve 708220-1 Fig 3. E-134 9803-9340-8 E-134...
Page 305: Dismantling And Assembly
Section E - Hydraulics Valves Excavator Valve Dismantling and Assembly ISO (+) Pattern Controls JCB (+) Pattern Controls When Dismantling End Cover End Cover CAUTION: Absolute cleanliness is essential when Main Relief Valve Main Relief Valve stripping and assembling hydraulic components.
Page 306 Section E - Hydraulics Valves Excavator Valve 708160-1 Fig 4. E-136 9803-9340-8 E-136...
Page 307: Typical 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 Threadlocker & Sealer to threads of screw 10 Sealing and Retaining Compounds ( 1-29). Check Valves Each spool has an identical load hold check valve, items 19 to 22.
Page 308: Stabiliser 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 Threadlocker & Sealer to threads of screw 10 Sealing and Retaining Compounds ( 1-29). Check Valves Each spool has an identical load hold check valve, items 20 to 23.
Page 309: Excavator Auxiliary Valve
Section E - Hydraulics Valves Excavator Auxiliary Valve Excavator Auxiliary Valve Removal and Replacement Disconnect the control pedal linkage from the top of the valve spool 1. Removal Disconnect all hydraulic hoses 2 from the valve ports. Cover exposed connections to prevent ingress of dirt. WARNING Mark the hoses to ensure correct reconnection.
Page 310: Pressure Testing
Section E - Hydraulics Valves Pressure Testing Pressure Testing Main Relief Valve (MRV) - In situ With the engine running at maximum speed, check the setting of the M.R.V. B by lowering the loader arm until the rams are fully closed and noting the maximum gauge Remove front floor plate Floor Plates ( B-1).
Page 311 Section E - Hydraulics Valves Pressure Testing Auxiliary Relief Valve (ARV) - Using The pressure should be as given in Technical Data. Hand Pump If required, adjust the pressure by removing dome nut A, slackening lock nut B and turning screw C. Insert the A.R.V.
Page 312 Section E - Hydraulics Valves Pressure Testing Steering Priority Valve Removal 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 313 Section E - Hydraulics Valves Pressure Testing Loader Change-over Valve Operate the control levers to vent the hydraulic pressure. Disconnect the hydraulic hoses 1 and 2 from the valve Removal ports. Cover exposed connections to prevent ingress of dirt. Mark the hoses to ensure correct reconnection. WARNING Unplug the electrical connection to the solenoid.
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Page 315: Typical Ram
INT-1-3-7 Replacement is a reversal of the removal procedure. Position the machine to give access to the ram pivots. Grease all pins and securing bolts with JCB Special HP Stop the engine and remove the starter key. Grease Lubricants ( 3-3).
Page 316 Section E - Hydraulics Rams Typical Ram Dismantling and Assembly 707710-1 Fig 2. E-146 9803-9340-8 E-146...
Page 317 Place the ram assembly on a locally manufactured strip/ rebuild bench. Apply JCB Activator to the threads of the piston head 6. Allow to dry for 15 minutes before bringing into contact with Slacken the end cap 1 using a special spanner Service JCB Threadlocker.
Page 318 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...
Page 319 Section E - Hydraulics Rams Typical Ram JCB Ram Sealing Procedure TE-005 Fit new rod seals. Use seal fitting tool 4-A to fit rod seals, the size (diameter) and position of pins 4-B is determined by the diameter and radial width of the rod seal being fitted.
Page 320 Section E - Hydraulics Rams Typical Ram Care must be taken to ensure the seal is square before it c Ensure the O-ring is fitted into the internal seal is pressed in. groove on the piston head. Screw the piston head onto the thread of the piston rod, refer to the Sleeve 9-A must be used to protect the rod seals relevant section for torque figure and completion...
Page 321: Slew Ram
Lift the ram clear of the machine. Replacement Replacement is a reversal of the removal procedure. Grease all pins and securing bolts with JCB Special HP Grease. Torque pivot locking bolts A to 56 Nm (5.7 kg fm, 42 lbf ft).
Page 322 Section E - Hydraulics Rams Slew Ram Dismantling and Assembly 707900-1 Fig 13. E-152 9803-9340-8 E-152...
Page 323 Section E - Hydraulics Rams Slew Ram Note: The following procedure applies only to the slew rams. Dismantling Place the ram assembly on a locally manufactured strip/ rebuild bench. Slacken the end cap 1 using a special spanner Service S216250-1 Fig 14.
Page 324 Section E - Hydraulics Rams Slew Ram Note: Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working. S161750Y-1 Fig 17. Before fitting the rod seals check the seal grooves are free of contamination and sharp edges.
Page 325: Oil Cooler
Section E - Hydraulics Oil Cooler Oil Cooler Connections Removal and Replacement If the oil cooler is removed or refitted, the following procedure must be carried out to ensure that no damage is caused to the fittings on the cooler. When loosening or tightening the cooler hoses, ensure the cooler adapter is held firm as shown.
Page 326 Section E - Hydraulics Oil Cooler Oil Cooler Connections Page left intentionally blank E-156 9803-9340-8 E-156...
Page 327: Service Tools
Tool Detail Reference, Section 1. These tools are available from JCB Service. Note: Tools other than those listed will be required. It is Some tools are available as kits or sets, the part numbers expected that such general tools will be available in any for parts within such kits or sets are not listed here.
Page 328 Section E - Hydraulics Service Tools Numerical List Part Description Tool Detail Reference Number 892/00055 Blanking Plug Fig 9. ( E-161) 892/00056 Blanking Plug Fig 9. ( E-161) 892/00057 Blanking Plug Fig 9. ( E-161) 892/00059 Blanking Plug Fig 9. ( E-161) 892/00060 Blanking Plug...
Page 329 Section E - Hydraulics Service Tools Numerical List Part Description Tool Detail Reference Number 992/09300 Spanner Fig 13. ( E-162) 992/09400 Spanner Fig 13. ( E-162) 992/09500 Spanner Fig 13. ( E-162) 992/09600 Spanner Fig 13. ( E-162) 992/09700 Spanner Fig 13.
Page 330 Section E - Hydraulics Service Tools Tool Detail Reference Section E- Hydraulics Tool Detail Reference Section E- Hydraulics 892/00263 5/8 in BSP x 5/8 in F BSP x Test Point 892/00264 3/4 in BSP x 3/4 in F BSP x Test Point 892/00265 1 in M BSP x 1 in F BSP x Test Point Fig 3.
Page 331 Section E - Hydraulics Service Tools Tool Detail Reference Section E- Hydraulics 1604/0006 Adapter 3/4 in M x 3/4 in M BSP 1612/0006 Adapter 3/4 in F x 3/4 in M BSP 892/00271 Adapter 3/4 in F x 5/8 in M BSP 892/00272 Adapter 5/8 in F x 3/4 in M BSP 816/20008 Adapter 3/4 in F x 1/2 in M BSP 892/00275 Adapter 1/2 in F x 3/4 in M BSP...
Page 332 Section E - Hydraulics Service Tools Tool Detail Reference Section E- Hydraulics 892/00059 3/4 in BSP 892/00060 1 in BSP'T' Fig 12. Female Connectors Fig 10. Male Cone Blanking Plug 892/00074 3/8 in BSP x 3/8 in BSP 892/00075 1/2 in BSP x 1/2 in BSP 816/00294 1/4 in BSP 816/00189 3/8 in BSP 892/00077 3/4 in BSP x 3/4 in BSP...
Page 333 Section E - Hydraulics Service Tools Tool Detail Reference Section E- Hydraulics 10mm 20mm 110mm 175mm Fig 14. Piston Seal Assembly Tool 892/01027 Fig 15. Ram Seal Protection Sleeves 892/01017 For 30 mm Rod Diameter 892/01018 For 40 mm Rod Diameter E-163 9803-9340-8 E-163...
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Page 335 9803/9340-8 Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 336 Section F - Transmission Notes: 9803/9340-8...
Page 337: Section F - Transmission
Section F - Transmission Contents Page No. Wheels Wheel Removal and Replacement ............F-1 Front Axle Removal and Replacement ............... F-3 Front Axle Removal and Replacement ............... F-7 Dismantling and Assembly ................ F-9 Service Tools Numerical List ..................F-11 Tool Detail Reference Section ..............F-12...
Page 338 Section F - Transmission Page left intentionally blank F-ii F-ii...
Page 339: Wheel Removal And Replacement
Section F - Transmission Wheels Wheel Removal and Replacement Removal The procedure is the same for all four wheels. WARNING A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked.
Page 340 Section F - Transmission Wheels Wheel Removal and Replacement Page left intentionally blank 9803-9340-8...
Page 341: Front Axle
Section F - Transmission Front Axle Removal and Replacement Removal WARNING A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under Disconnect the battery, to prevent the engine being started while you are beneath the machine.
Page 342: Front Axle
Section F - Transmission Front Axle Removal and Replacement 9803-9340-8...
Page 343 Section F - Transmission Front Axle Removal and Replacement 9803-9340-8...
Page 344 Section F - Transmission Front Axle Removal and Replacement 9803-9340-8...
Page 345 Section F - Transmission Front Axle Removal and Replacement Removal After fitting, tighten trunnion bolts B so that the nylon bush is free to rotate then tighten lock nuts to 70 Nm (7.1 kgf m, 52 lbf ft). It should be possible to rock the axle up and down WARNING by hand but there should be no fore and aft movement.
Page 346 Section F - Transmission Front Axle Removal and Replacement 708281-1 Fig 1. 9803-9340-8...
Page 347: Dismantling And Assembly
Section F - Transmission Front Axle Dismantling and Assembly Dismantling and Assembly Hub Dismantling Remove wear washer 15. Check stub axle 14, bushes 16 and washer 15 for wear Park the machine on level ground and lower the and renew as necessary. The thickness of washer 15 attachments.
Page 348 Section F - Transmission Front Axle Dismantling and Assembly 760151-1 Fig 2. F-10 9803-9340-8 F-10...
Page 349: Service Tools
Tool Detail Reference, Section 1. These tools are available from JCB Service. Note: Tools other than those listed will be required. It is Some tools are available as kits or sets, the part numbers expected that such general tools will be available in any for parts within such kits or sets are not listed here.
Page 350: Tool Detail Reference Section
Section F - Transmission Service Tools Tool Detail Reference Section Tool Detail Reference Section 732930 Fig 1. Axle Case Spreader 892/01161 732920 Fig 2. Pinion Setting Tool 892/01162 F-12 9803-9340-8 F-12...
Page 351 9803/9340-8 Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 352 Section G - Brakes Notes: 9803/9340-8...
Page 353: Section G - Brakes
Section G - Brakes Contents Page No. Parking Brake Removal and Replacement ..............G-1 Dismantling and Assembly ............... G-2 Testing the Parking Brake ................. G-3 Adjusting the Parking Brake ..............G-4...
Page 354 Section G - Brakes Page left intentionally blank G-ii G-ii...
Page 355: Parking Brake
Section G - Brakes Parking Brake Removal and Replacement Removal Park the machine on level ground and block all four wheels to prevent the machine from moving. Stop the engine and remove the starter key. Remove the rear floor plate. Release the parking brake lever and slacken the outer cable lock nuts at the calliper.
Page 356: Dismantling And Assembly
Section G - Brakes Parking Brake Dismantling and Assembly Dismantling and Assembly Dismantling Manoeuvre operating lever H from the calliper housing. Unscrew nuts A and remove sleeves B. Check parts for wear and renew as necessary. Make sure pads E slide freely on sleeves F. Withdraw bolts C and sleeves D.
Page 357: Testing The Parking Brake
Section G - Brakes Parking Brake Testing the Parking Brake Testing the Parking Brake WARNING WARNING Before testing the park brake make sure the area Non approved modifications to drive ratios, machine around the machine is clear of people. weight or wheel and tyre sizes may adversely affect the performance of the parking brake.
Page 358: Adjusting The Parking Brake
Section G - Brakes Parking Brake Adjusting the Parking Brake Adjusting the Parking Brake The parking brake is adjusted by means of the lock nuts which secure the operating cable to the brake carrier. These are accessible from underneath the machine. Park the machine on level ground.
Page 359 9803/9340-8 Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 360: Section H - Steering
Section H - Steering Notes: 9803/9340-8...
Page 361 Section H - 1 Contents Page No. Hydraulic Steering Unit Description ....................H-1 Removal and Replacement ..............H-2 Dismantling and Assembly ............... H-4 Power Track Rod Removal and Replacement ..............H-7 Dismantling and Assembly ............... H-8...
Page 362: Section H
Section H - 1 Page left intentionally blank H-ii H-ii...
Page 363: Hydraulic Steering Unit
Section H - Steering Hydraulic Steering Unit Description Steering is hydraulically controlled by a power track rod. Hydraulic oil is delivered from the steering pump via the flow/relief valve section to the steering unit. When the steering is turned the steering valve is actuated and a pressure demand signal sent to the priority inlet spool.
Page 364: Removal And Replacement
Section H - Steering Hydraulic Steering Unit Removal and Replacement Removal and Replacement Removal Disconnect and plug the hydraulic hoses C, labelling each to ensure correct position on replacement. Stop the engine and turn the steering wheel to vent Undo and remove bolts D and lift out steering unit E. residual pressure.
Page 365 Section H - Steering Hydraulic Steering Unit Removal and Replacement Page left intentionally blank 9803-9340-8...
Page 366: Dismantling And Assembly
Section H - Steering Hydraulic Steering Unit Dismantling and Assembly Dismantling and Assembly 10221A-1 Fig 2. 9803-9340-8...
Page 367 Section H - Steering Hydraulic Steering Unit Dismantling and Assembly Dismantling The illustrations show a typical steering unit. Use the numerical sequence as a guide to dismantling. The relief valve (items 29 - 35) is not used in this application. 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 368 Section H - Steering Hydraulic Steering Unit Dismantling and Assembly Invert unit and place on a suitable hollow support so that body does not rest on protruding sleeve, thus preventing displacement of the new seals. Place ball 23 into check valve hole and fit bush 22. Fit new 'O' ring 10.
Page 369: Power Track Rod
Replacement Replacement is a reversal of the removal procedure. WARNING Apply JCB High Strength Threadlocker to threads of bolts Make the machine safe before working underneath it. C and tighten to correct torque. Park the machine on level ground, lower the attachments to the ground.
Page 370 Section H - Steering Power Track Rod Removal and Replacement 708270-1 Fig 1. 9803-9340-8...
Page 371: Dismantling And Assembly
Section H - Steering Power Track Rod Dismantling and Assembly Dismantling and Assembly 449580-1 Fig 2. 9803-9340-8...
Page 372 Section H - Steering Power Track Rod Dismantling and Assembly Dismantling Ensure that all metal components are free from scoring, nicks and burrs. A damaged rod will impair the life of the gland and wiper seals. It is possible to dismantle the ram without removing it from the machine.
Page 373 9803/9340-8 Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
Page 374 Section K - Engine Notes: 9803/9340-8...
Page 375 Section K - Engine Contents Page No. Technical Data Technical Data up to machine no. 1042315 ..........K-1 Technical Data from machine no. 1042316 ..........K-2...
Page 376 Section K - Engine Page left intentionally blank K-ii K-ii...
Page 377: Technical Data
Section K - Engine Technical Data Technical Data up to machine no. 1042315 General Data Model KD 103-10 Type 3 cylinder in-line, compression ignition, naturally aspirated Engine Code KD 51135U Bore (nominal) 75 mm (2.9 in) Stroke 72 mm (2.8 in) Swept Volume 954 cm (58.2 in...
Page 378 Section K - Engine Technical Data Technical Data from machine no. 1042316 Technical Data from machine no. 1042316 General Data Model 403C-11 Type 3 cylinder in-line, compression ignition, naturally aspirated Engine Code HH 51266U Bore (nominal) 77 mm (3.03 in) Stroke 81 mm (3.19 in) Swept Volume...

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