manual de servicio - jcb - 214ss - 4x4x4.pdf

8/10/2019 Manual de servicio - JCB - 214SS - 4x4x4.pdf

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General Information 1

Care & Safety 2

Routine Maintenance 3

Attachments A

Body & Framework BElectrics C

Controls D

Hydraulics E

Transmision F

Brakes

GEngine K

ServiceManual

3CX, 4CX,

& Variants

From M/c No. 400001 To 460000

Publicación No. 9803/3260 Issue 9



Introduction

This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training

by JCB Technical Training Department.

These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated

with the maintenance and repair of hydraulic earthmoving equipment.

Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of

course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe

connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all

else SAFETY MUST COME FIRST!

The manual is compiled in sections, the first three are numbered and contain information as follows:

1 = General Information - includes torque settings and service tools.

2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.

3 = Routine Maintenance - includes service schedules and recommended lubricants for all themachine.

The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:

A = Attachments

B = Body & Framework ...etc.

The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in laterissues of the manual.

Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each

alphabetically coded section.

All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapidreference.

Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry

threads, hence for lubricated threads may be reduced by one third.

With the exception of slewing operations 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facingforwards.

Throughout this manual abbreviations are used to identify various machine types. The abbreviations and their full explanation

are as follows:

AWS - All Wheel Steer2WS - 2 Wheel Steer

2WD - 2 Wheel Drive

4WD - 4 Wheel Drive

The contents page at the beginning of each section will clearly identify using parenthesis () when a procedure/description is

pertinent to a particular machine, for example:

Loader Arm Safety Strut (AWS Machines)

- Fitting and Removing

Loader Arm Safety Strut (2WS Machines)

- Fitting and Removing

9803/3260 Issue 2*

*

*



i

Section 1 General Information

9803/3260

Section 1

i

Issue 4*

Contents Page No.

Machine Identification Plate 1 - 1

Typical Machine Identification Number 1 - 1

Typical Engine Identification Number 1 - 1

Unit Identification 1 - 2

Torque Settings 2 - 1

Service Tools Numerical List 3 - 1

Service Tools

- Attachments 4 - 1

- Body & Framework 4 - 1- Electrics 4 - 5

- Hydraulics 4 - 6

- Transmission 4 - 10

- Engine 4 - 13

Sealing and Retaining Compounds 5 - 1

*



1 - 1

Machine Identification Plate

Your machine has an identification plate X mounted on the

loader tower as shown. The serial numbers of the machineand its major units are stamped on the plate.

The serial number of each major unit is also stamped on the

unit itself. If a major unit is replaced by a new one, the serial

number on the identification plate will be wrong. Either

stamp the new number of the unit on the identification plate,or simply stamp out the old number. This will prevent the

wrong unit number being quoted when replacement parts

are ordered.

The machine and engine serial numbers can help identify

exactly the type of equipment you have.

Typical Machine

Identification Number

SLP 3CX T S R E 0430001

A B C D E F G

A World Manufacturer Identification

B Machine Model

C Steer Type (T= 2WS, F=4WS)

D Build Type (S=Sideshift, C=Centremount, L=Loader)

E Year of Manufacture:R = 1994 1 = 2001

S = 1995 2 = 2002

T = 1996 3 = 2003

V = 1997 4 = 2004W = 1998 5 = 2005

X = 1999 6 = 2006

Y = 2000 7 = 2007

F Manufacturer Location (E = England)

G Machine Serial Number:

Typical Engine

Identification Number

AB 50262 U 500405 P

A B C D E

A Engine Type

AB = 4 cylinder turbo

B Build Number

C Country of Origin

D Engine Sequence Number

E Year of Manufacture


9803/3260

Section 1

1 - 1

Issue 2

S218130X



1 - 2

Unit Identification

Engine Serial Plate

The engine serial number is stamped on a label which is

fastened to the left side of the cylinder block (looking fromthe rear).

Syncro Shuttle Serial Plate

The Syncro Shuttle serial number is stamped on a label

which is mounted to the rear face of the unit.

Front Axle Serial Plate (All Wheel Steer Machines)

The front axle serial number is stamped on a plate mounted

on the axle.

Front Axle Serial Plate (2 Wheel Steer Machines)

The front axle serial number is stamped on a plate mounted

on the the axle.


9803/3260

Section 1

1 - 2

Issue 2*

S088471

*

S145300

*



1 - 3

Unit Identification (cont'd)

Rear Axle Serial Plate (All Wheel Steer Machines)

The rear axle serial number is stamped on a plate mounted

to the front face of the axle, as shown.

Rear Axle Serial Plate (2 Wheel Steer Machines)

The rear axle serial number is stamped on a plate mounted

to the front face of the axle, as shown.

Powershift Serial Plate

The powershift serial number is stamped on a plate which is

mounted to the side of the unit as shown.


9803/3260

Section 1

1 - 3

Issue 2*

S156570

S146790

S143050

*



2 - 1

Torque Settings

Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the

figures stated. For lubricated threads the values should be REDUCED by one third.

UNF Grade 'S' Bo lts

Bolt Size Hexagon (A/F) Torque Settings

in (mm) in Nm kgf m lbf ft

1/4 (6.3) 7/16 14 1.4 10

5/16 (7.9) 1/2 28 2.8 203/8 (9.5) 9/16 49 5.0 36

7/16 (11.1) 5/8 78 8.0 58

1/2 (12.7) 3/4 117 12.0 87

9/16 (14.3) 13/16 170 17.3 125

5/8 (15.9) 15/16 238 24.3 175

3/4 (19.0) 11/8 407 41.5 3007/8 (22.2) 15/16 650 66.3 480

1 (25.4) 11/2 970 99.0 71511/4 (31.7) 17/8 1940 198.0 1430

11/2 (38.1) 21/4 3390 345.0 2500

Metric Grade 8.8 Bol ts

Bolt Size Hexagon (A/F) Torque Settings

(mm) mm Nm kgf m lbf ft

M5 (5) 8 7 0.7 5

M6 (6) 10 12 1.2 9

M8 (8) 13 28 3.0 21

M10 (10) 17 56 5.7 42

M12 (12) 19 98 10 72M16 (16) 24 244 25 180

M20 (20) 30 476 48 352

M24 (24) 36 822 84 607

M30 (30) 46 1633 166 1205

M36 (36) 55 2854 291 2105

Rivet Nut Bol ts/Screws

Bolt Size Torque Settings (for steel rivet nuts)(mm) Nm kgf m lbf ft

M3 (3) 1.2 0.12 0.9

M4 (4) 3.0 0.3 2.0

M5 (5) 6.0 0.6 4.5M6 (6) 10.0 1.0 7.5M8 (8) 24.0 2.5 18.0

M10 (10) 48.0 4.9 35.5

M12 (12) 82.0 8.4 60.5

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.


9803/3260

Section 1

2 - 1

Issue 1

SXXXXXX SXXXXXXSXXXXXX



3 - 1

1406/0011 Bonded Washer 4 - 7

1406/0014 Bonded Washer 4 - 7

1406/0018 Bonded Washer 4 - 71406/0021 Bonded Washer 4 - 6, 4 - 7

1406/0029 Bonded Washer 4 - 71604/0003 Male Adapter 4 - 7

1604/0004 Male Adapter 4 - 7

1604/0006 Male Adapter 4 - 6, 4 - 7

1604/0008 Adapter 4 - 61606/0003 Male Adapter 4 - 7

1606/0004 Male Adapter 4 - 7

1606/0007 Male Adapter 4 - 7

1606/0008 Male Adapter 4 - 7

1606/0009 Male Adapter 4 - 7

1606/0012 Male Adapter 4 - 6, 4 - 71606/0014 Male Adapter 4 - 7

1606/0015 Male Adapter 4 - 6, 4 - 7

1606/0017 Male Adapter 4 - 7

1612/0006 Adapter 4 - 6

2401/0103 'O' Ring 4 - 7

4101/0202 Lock and Seal 5 - 14101/0402 Loctite 932 5 - 1

4101/0502 Loctite 262 5 - 1

4101/0602 High Strength Retainer 5 - 1

4102/0502 High Strength Gasketing 5 - 1

4102/1201 Multi-Gasket 5 - 1

4102/1901 Loctite 577 5 - 14104/0101 Activator N (Aerosol) 5 - 1

4104/0102 Activator N (Bottle) 5 - 1

4104/1538 JCB Cleaner & Degreaser 5 - 1

816/00017 Adapter 4 - 8

816/00189 Blanking Cap 4 - 8816/00190 Blanking Cap 4 - 8816/00193 Blanking Cap 4 - 8

816/00196 Blanking Cap 4 - 8

816/00197 Blanking Cap 4 - 8

816/00294 Blanking Cap 4 - 8

816/00439 Male Adapter 4 - 7

816/00440 Male Adapter 4 - 7816/15007 Male Adapter 4 - 7

816/15008 Male Adapter 4 - 7

816/15118 Pressure Test Adapter 4 - 6

816/20008 Adapter 4 - 6

816/20013 Adapter 4 - 6

816/50005 Adapter 4 - 8

816/50043 Adapter 4 - 8816/55038 Pressure Test 'T' Adapter 4 - 6

816/55040 Pressure Test 'T' Adapter 4 - 6

816/60096 Adapter 4 - 8

825/00410 Crowfoot Wrench 4 - 5

825/99833 Adapter for 825/00410 4 - 5826/01099 Rivet Nut 4 - 1

826/01101 Rivet Nut 4 - 1

826/01102 Rivet Nut 4 - 1

826/01103 Rivet Nut 4 - 1

826/01104 Rivet Nut 4 - 1

826/01105 Rivet Nut 4 - 1892/00011 Spool Clamp 4 - 8

892/00039 Spool Clamp & A.R.V. Clamp 4 - 8

892/00041 De-glazing Tool 4 - 13892/00047 Adapter 4 - 8

892/00048 Adapter 4 - 8892/00049 Adapter 4 - 8

892/00051 Adapter 4 - 8

892/00055 Blanking Plug 4 - 8

892/00056 Blanking Plug 4 - 8892/00057 Blanking Plug 4 - 8

892/00058 Blanking Plug 4 - 8892/00059 Blanking Plug 4 - 8

892/00060 Blanking Plug 4 - 8

892/00071 Male Adapter 4 - 7

892/00074 Female Connector 4 - 8892/00075 Female Connector 4 - 8

892/00076 Female Connector 4 - 8

892/00077 Female Connector 4 - 8

892/00078 Connector 4 - 6

892/00137 Micro-Bore Hose 1/4in. BSP, 3 Metres 4 - 7

892/00167 Gland Seal Fitting Sleeve 4 - 9892/00174 Measuring Cup 4 - 12

892/00176 Extractor 4 - 9

892/00177 Extractor Collets 4 - 9

892/00178 Extractor Collets 4 - 9

892/00179 Bearing Press 4 - 10

892/00180 Seal Fitting Tool 4 - 9892/00182 Bearing Pad Driver 4 - 11

892/00223 Hand Pump 4 - 7

892/00224 Impulse Extractor 4 - 12

892/00225 Adapter for Extractor 4 - 12

892/00231 Gland Seal Fitting Sleeve 4 - 9

892/00232 Gland Seal Fitting Sleeve 4 - 9892/00233 Gland Seal Fitting Sleeve 4 - 9

892/00253 Pressure Test Kit 4 - 6



892/00257 Pressure Test Adapter 4 - 6892/00258 Pressure Test Adapter 4 - 6892/00259 Pressure Test Adapter 4 - 6



892/00262 Pressure Test 'T' Adapter 4 - 6, 4 - 7

892/00263 Pressure Test 'T' Adapter 4 - 6

892/00264 Pressure Test 'T' Adapter 4 - 6892/00265 Pressure Test 'T' Adapter 4 - 6

892/00268 Flow Monitoring Unit 4 - 6

892/00269 Sensor Head 4 - 6

892/00270 Load Valve 4 - 6

892/00271 Adapter 4 - 6

892/00272 Adapter 4 - 6

892/00273 Sensor Head 4 - 6892/00274 Adapter 4 - 7

892/00275 Adapter 4 - 6

892/00276 Adapter 4 - 6

892/00277 Adapter 4 - 6

892/00278 Gauge 4 - 7892/00279 Gauge 4 - 7

892/00282 Shunt 4 - 5

892/00283 Tool Kit Case 4 - 5

892/00284 Tachometer 4 - 5

892/00285 Hydraulic Oil Temperature Probe 4 - 5

892/00286 Surface Temperature Probe 4 - 5892/00293 Connector Pipe 4 - 6

892/00294 Connector Pipe 4 - 6

892/00295 End Float Setting Tool 4 - 10892/00298 Fluke Meter 4 - 5

892/00301 Flow Test Adapter 4 - 10


9803/3260

Section 1

3 - 1

Issue 5

Service Tools Numerical ListPage No. Page No.



3 - 2



892/00309 ARV Test Kit (Excavator Valve) 4 - 7

892/00333 Heavy Duty Socket 4 - 11

892/00334 Gland Seal Fitting Tool 4 - 9

892/00335 ARV Cartridge Removal Tool 4 - 7892/00706 Test Probe 4 - 7

892/00812 Drive Coupling Spanner 4 - 10




892/00822 Splined Bolt Socket 4 - 12892/00825 End Float Setting Tool 4 - 10

892/00836 Lifting Wire Assembly 4 - 13

892/00842 Glass Lifter 4 - 2

892/00843 Folding Stand 4 - 2

892/00844 Long Knife 4 - 3892/00845 Cartridge Gun 4 - 2892/00846 Glass Extractor (Handles) 4 - 3

892/00847 Nylon Spatula 4 - 4

892/00848 Wire Starter 4- -3

892/00849 Braided Cutting Wire 4- -3

892/00882 Alternator Pulley Socket 4 - 5

892/00891 Wheel Hub Seal - Fitting Tool 4 - 12926/15500 Rubber Spacer Blocks 4 - 4

990/00083 End Float Setting Tool 4 - 10

992/00800 Extractor 4 - 4

992/01003 Plug 4 - 7

992/04000 Torque Multiplier 4 - 12

992/04800 Flange Spanner 4 - 12

992/07601 Spanner 4 - 11992/07603 Replacer - Bearing Cup 4 - 11

992/07604 Replacer - Bearing Cone 4 - 11

992/07606 Measuring Cup - Pinion Bearing 4 - 11

992/07607 Preload Spacer 4 - 11

992/07609 Bearing Adapter 4 - 11992/07614 Bearing Adapter 4 - 11

992/00800 Pivot Pin Extractor Tool 4 - 4

992/09100 Spool Clamp 4 - 8

992/09200 Charging Tool 4 - 1

992/09300 Ram Spanner 4 - 8

992/09400 Ram Spanner 4 - 8992/09500 Ram Spanner 4 - 8

992/09600 Ram Spanner 4 - 8

992/09700 Ram Spanner 4 - 8992/10000 Ram Spanner 4 - 8

992/10100 Spool & A.R.V. Clamp 4 - 8992/10200 Body 4 - 7

992/12300 12V Mobile Oven 4 - 2

992/12400 Static Oven - 2 Cartridge 4 - 2

992/12600 Static Oven - 6 Cartridge 4 - 2

992/12800 Cut-Out Knife 4 - 3

992/12801 "L" Blades 4 - 3993/59300 2/4WD Pressure Test Tool 4 - 10

993/59500 Impulse Extractor Adapter 4 - 12

993/68100 Slide Hammer Kit 4 - 4

993/69800 Seal Kit 4 - 6

993/85700 Battery Tester 4 - 5

4104/1310 Hand Cleaner 4 - 2

The following parts are replacement items for kits and would

normally be included in the kit numbers quoted on pages

1/3-1 and 1/3-2.

Service Tools Numerical List Page No.

Replacement item for kit no. 892/00180892/00181 4 - 9

Replacement items for kit no. 892/00253

892/00201 Replacement Gauge 4 - 6

892/00202 Replacement Gauge 4 - 6

892/00203 Replacement Gauge 4 - 6892/00254 Replacement Hose 4 - 6


05/900137 Spring 4 - 1

1406/0011 Bonded Washer 1/4 in. BSP, 2 off 4 - 11410/0001 Washer 4 - 11604/0002 Adapter 1/4in. x 1/4in. BSP, 1 off 4 - 1

2401/0006 'O' Ring 4 - 1

2401/0104 'O' Ring 4 - 1

823/00242 Washer 4 - 1

823/00248 Washer 4 - 1

826/00696 Screw 4 - 1892/00135 Adapter 4 - 1

892/00150 Pressure Gauge 4 - 1

992/09206 Bleed Screw 4 - 1

992/09207 Snap Ring 4 - 1

Hammermaster 260 only

892/00823 Charging Device 4 - 1892/00824 Adapter 4 - 1


892/00340 Test Block Body 4 - 7

892/00341 Setting Body 4 - 7892/00343 Spanner 4 - 7

892/00345 Anti-Cavitation Lock Out Bung 4 - 7

993/68300 Adjusting Pin 4 - 7


993/68101 Slide Hammer 4 - 4993/68102 End Stops 4 - 4

993/68103 Adaptor - M20 x 5/8" UNF 4 - 4

993/68104 Adaptor - M20 x 1" UNF 4 - 4993/68105 Adaptor - M20 x M20 4 - 4

993/68106 Adaptor - M20 x M24 4 - 4993/68107 Bar - M20 x M20 X 800MM 4 - 4

993/68108 Adaptor - M20 x 7/8" UNF 4 - 4

993/68109 Adaptor - M20 x M12 4 - 4

993/68110 Adaptor - M20 x 5/8" UNF (Shoulder) 4 - 4

993/68111 Adaptor - M20 x 1/2" UNF 4 - 4


9803/3260

Section 1

3 - 2

Issue 6*

Service Tools Numerical List (cont'd)Page No.

*



4 - 1


9803/3260

Section 1

4 - 1

Issue 1

Service Tools (cont'd)

Section A - Attachments

Section B - Body & Framework

3 992/09200 Nitrogen Charging Tool for

Roadbreakers

4 892/00150 :Pressure Gauge

5 892/00135 :Adapter

6 1406/0011 :Washer7 1604/0002 :Adapter

8 992/09206 :Bleed Screw

9 823/00248 :Washer

10 2401/0006 :'O' Ring

11 05/900137 :Spring

12 1410/0001 :Washer13 992/09207 :Snap Ring

14 2401/0104 :'O' Ring

15 826/00696 :Screw

16 823/00242 :Washer

Hammermaster 260 only

892/00823 :Charging Device

892/00824 :Adapter

826/01099 M6 x 16mm Rivet Nut






Installation Tool Available from:

Bollhoff Fastenings Ltd.

Midacre

The Willenhall Estate

Rose Hill

WillenhallWest Midlands, WV13 2JW



Cartridge Gun - hand operated - essential for theapplication of sealants, polyurethane materials etc.

JCB part number -

892/00845



4 - 2


9803/3260

Section 1

4 - 2

Issue 2*

S186250

S186240

S186300

Hand Cleaner - special blend for the removal of

polyurethane adhesives.

JCB part number - 4104/1310(454g; 1 lb tub)

12V Mobile Oven - 1 cartridge capacity - required topre-heat adhesive prior to use. It is fitted with a male

plug (703/23201) which fits into a female socket

(715/04300).

JCB part number - 992/12300

240V Static Oven - available with 2 or 6 cartridge

capacity - required to pre-heat adhesive prior to use.

No plug supplied. Note: 110V models available upon

request - contact JCB Technical Service.

JCB part number:992/12400 - 2 Cartridge x 240V

992/12600 - 6 Cartridge x 240V

Folding Stand for

Holding Glass -

essential for preparing

new glass prior to

installation.

JCB part number -892/00843

Glass Lifter - minimum 2 off - essential for glass

installation, 2 required to handle large panes of glass.

Ensure suction cups are protected from damage

during storage.


S186260

S186280

S186270

*



Cut-Out Knife - used to

remove broken glass.


Wire Starter - used toaccess braided cutting wire

(below) through original

polyurethane seal.


Glass Extractor (Handles) - used with braided cutting

wire (below) to cut out broken glass.


Braided Cutting Wire - consumable heavy duty cut-out

wire used with the glass extraction tool (above).


(approx 25 m length)

'L' Blades - 25 mm (1 in) cut - replacement blades for

cut-out knife (above).

JCB part number - 992/12801 (unit quantity = 5 off)

Long Knife - used to give extended reach for normally

inaccessible areas.


4 - 3


9803/3260

Section 1

4 - 3

Issue 2*



S186320

S186310

S186360S186330

S186350

S186340

*



Slide Hammer Kit - 993/68100

1 :993/68101 Slide Hammer

2 :993/68102 End Stops

3 :993/68103 Adaptor - M20 x 5/8" UNF

4 :993/68104 Adaptor - M20 x 1" UNF5 :993/68105 Adaptor - M20 x M20

6 :993/68106 Adaptor - M20 x M24

7 :993/68107 Bar - M20 x M20 X 800MM

8 :993/68108 Adaptor - M20 x 7/8" UNF

9 :993/68109 Adaptor - M20 x M12

10 :993/68110 Adaptor - M20 x 5/8" UNF (Shoulder)11 :993/68111 Adaptor - M20 x 1/2" UNF

4 - 4


9803/3260

Section 1

4 - 4

Issue 6*



Nylon Spatula -

general tool used for

smoothing sealants - also

used to re-install glass inrubber glazing because metal tools

will chip the glass edge.

JCB part number - 892/00847S186470

Rubber Spacer Blocks - used to provide the correct

set clearance between glass edgeand cab frame.


(unit quantity = 500 off)

S186550

S196910

12

2 2

3

5

7

8

64

9

11

10

992/00800 - Pivot Pin Extractor for Front Axle*

S218880



993/85700 Battery Tester

AVO Test Kit

1 892/00283 Tool Kit Case

2 892/00298 Fluke Meter 85

3 892/00286 Surface Temperature Probe

4 892/00284 Venture Microtach Digital

Tachometer

5 892/00282 100 amp Shunt - open type

6 892/00285 Hydraulic Temperature Probe

825/00410 15 mm Crowfoot Wrench

825/99833 Adapter

4 - 5


9803/3260

Section 1

4 - 5

Issue 4*

S216200


Section C - Electrics

892/00882 Socket for Alternator Pulley Nut

(machines from serial number 430001)

S216770S239510

S188231

*



Pressure Test Adapters

892/00255 1/4 in BSP x Test Point

892/00256 3/8 in BSP x Test Point

892/00257 1/2 in BSP x Test Point892/00258 5/8 in BSP x Test Point

816/15118 3/4 in BSP x Test Point892/00259 1 in BSP x Test Point

892/00260 1.1/4 in BSP x Test Point

892/00261 5/8 in UNF x Test Point

Pressure Test 'T' Adapters

892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point

816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point

892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point

892/00265 1 in M BSP x 1 in F BSP x Test Point

Hydraulic Circuit Pressure Test Kit

892/00253 Pressure Test Kit:892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in2 )

:892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in2 )

:892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in2 )

:892/00254 Replacement Hose

993/69800 Seal Kit for 892/00254 (can also be used with

probe 892/00706)

4 - 6


9803/3260

Section 1

4 - 6

Issue 3*

S188131

S188121

S200141


Section E - Hydraulics

Flow Test Equipment

892/00268 Flow Monitoring Unit

892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)

892/00293 Connector Pipe892/00270 Load Valve

1406/0021 Bonded Washer

1604/0006 Adapter 3/4 in M x 3/4 in M BSP1612/0006 Adapter 3/4 in F x 3/4 in M BSP

892/00271 Adapter 3/4 in F x 5/8 in M BSP




892/00276 Adapter 3/4 in F x 3/8 in M BSP892/00277 Adapter 3/8 in F x 3/4 in M BSP

892/00273 Sensor Head 0 - 380 l/min

892/00294 Connector Pipe

1606/0015 Adapter 1.1/4 in M BSP x 1 in M BSP

892/00078 Connector 1 in F x 1 in F BSP1604/0008 Adapter 1 in M x 1 in M BSP1606/0012 Adapter 1 in M x 3/4 in M BSP

816/20013 Adapter 3/4 in F x 1 in M BSP

S188151

*



4 - 7


9803/3260

Section 1

4 - 7

Issue 4*



Components for Loader Valve Block A.R.V. Testing

1 2401/0103 'O' Ring

2 1406/0018 Bonded Washer

3 992/01003 Plug

4 992/10200 Body for Hamworthy A.R.V.

Components for Excavator Valve Block A.R.V. Testing

892/00309 A.R.V. Pressure Test Kit

1 : 892/00340 Test Block Body2 : 892/00341 Setting Body

3 : 993/68300 Adjusting Pin

4 : 892/00343 Spanner

5 : 892/00345 Anti-cavitation Lock Out Bung

6 892/00335 A.R.V. Cartridge Removal Tool

Hand Pump Equipment

892/00223 Hand Pump892/00137 Micro-bore Hose 1/4 in BSP x 3 metres

892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper

892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point

892/00706 Test Probe

892/00278 Gauge 0 - 40 bar (0 - 600 lbf/in2 )

892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in2 )

Bonded Washers

1406/0011 1/4 in. BSP1406/0018 1/2 in. BSP

1406/0014 5/8 in. BSP

1406/0021 3/4 in. BSP

1406/0029 1.1/4 in. BSP

Male Adapters - BSP x NPT (USA only)

816/00439 3/8 in. x 1/4 in.

816/00440 1/2 in. x 1/4 in.

816/15007 3/8 in. x 3/8 in.

816/15008 1/2 in. x 3/8 in.

Male Adapters - BSP x BSP

1606/0003 3/8 in. x 1/4 in.

1604/0003 3/8 in. x 3/8 in.

892/00071 3/8 in. x 3/8 in. taper1606/0004 1/2 in. x 1/4 in.

1606/0007 1/2 in. x 3/8 in.

1604/0004 1/2 in. x 1/2 in.

1606/0017 5/8 in. x 1/2 in.

1606/0008 3/4 in. x 3/8 in.

1606/0009 3/4 in. x 1/2 in.1604/0006 3/4 in. x 3/4 in.

1606/0012 3/4 in. x 1 in.

1606/0014 3/4 in. x 1.1/4 in.

1606/0015 1 in. x 1.1/4 in.

S196400

S193850

S196700

S188140

S193860

1

2

6

4

5

3

*



4 - 8


9803/3260

Section 1

4 - 8

Issue 2*



Female Cone Blanking Plug

892/00055 1/4 in. BSP

892/00056 3/8 in. BSP

892/00057 1/2 in. BSP

892/00058 5/8 in. BSP

892/00059 3/4 in. BSP892/00060 1 in. BSP

S193870

Male Cone Blanking Cap

816/00294 1/4 in. BSP

816/00189 3/8 in. BSP

816/00190 1/2 in. BSP

816/00197 5/8 in. BSP

816/00196 3/4 in. BSP816/00193 1 in. BSP S193880

892/00047 3/8 in. BSP (A) x 1/4 in. BSP (B)

892/00048 1/2 in. BSP (A) x 1/4 in. BSP (B)892/00049 5/8 in. BSP (A) x 1/4 in. BSP (B)

816/50043 3/4 in. BSP (A) x 1/4 in. BSP (B)

892/00051 1 in. BSP (A) x 1/4 in. BSP (B)

816/50005 1/2 in. BSP (A) x 1/2 in. BSP (B)

816/60096 3/4 in. BSP (A) x 3/4 in. BSP (B)

816/00017 1 in. BSP (A) x 1 in. BSP (B)S193890

Female Connectors

892/00074 3/8 in. BSP x 3/8 in. BSP

892/00075 1/2 in. BSP x 1/2 in. BSP

892/00076 5/8 in. BSP x 5/8 in. BSP

892/00077 3/4 in. BSP x 3/4 in. BSP

S193900

992/09100 Excavator Spool Clamp

992/10100 Hamworthy Loader Spool & A.R.V. Clamp

892/00011 Spool Clamp892/00039 Spool Clamp (Hamworthy A.R.V.)

S216210

Hexagon Spanners for Ram Pistons and End Caps

992/09300 55mm A/F

992/09400 65mm A/F992/09500 75mm A/F

992/09600 85mm A/F

992/09700 95mm A/F

992/10000 125mm A/F

S193930

*

*



4 - 9


9803/3260

Section 1

4 - 9

Issue 2*



892/00176 Bearing Extractor for Hamworthy Pumps

892/00177 Bearing Collets (A) for 1900 Series Pumps

892/00178 Bearing Collets (A) for 2200 Series Pumps

S\216220

892/00180 Seal Fitting Tool for fitting 'O' ring and kin ring to

Danfoss Orbitrol Unit

892/00181 Replacement Plastic Boss

S216230

Gland Seal Protection Sleeves

892/00231 For 60 mm Rod Diameter




S216240

892/00334 Gland Seal Fitting Tool

S216250

*



4 - 10


9803/3260

Section 1

4 - 10

Issue 4*


Section F - Transmission

892/00179 Bearing Press (use

with appropriate adapters)

892/00295 End Float Setting Tool 892/00825 Reverse Clutch End Float Setting Tool

(Powershift transmission only)

S188190 S190760

990/00083 End Float Setting Tool

S188180

892/00812 Drive Coupling Spanner for front

and rear axle yoke couplings

and for 4WD output

coupling on SyncroShuttle

S196720

S188200

993/59300 2/4 WD Pressure Test

Adaptor & Clamp

S196750

A 892/00304 Flow Test Adapter

B 892/00301 Flow Test Adapter

C 892/00302 Flow Test Adapter

S188210

*



4 - 11


9803/3260

Section 1

4 - 11

Issue 1



992/07604 Replacer - Crownwheel Bearing

and Differential Bearing Cones

992/07614 Adapter Set - Bull Pinion Bearing

Remover/Replacer

992/07601 Spanner for Half Shaft Nuts

992/07609 Adapter - Steer/Drive Axle Pinion

Bearing Cone

992/07607 Spacer - Pinion Bearing Preload

992/07606 Measuring Cup - Pinion Bearing

892/00817 17 mm A/F x 3/4in. square drive




892/00182 Bearing Pad Driver

992/07603 Replacer - Pinion Head Bearing Cup

S188160

S216260

S216270

S216280

S216290

S216300 S216310

S216320 S216330



4 - 12


9803/3260

Section 1

4 - 12

Issue 3*

892/00174

Measuring Cup - Pinion HeadBearing

892/00822

Splined Bolt Socket for

driveshafts

992/04000

Torque Multiplier (use in conjunction with a torque wrench to give a 5:1

multiplication when tightening pinion nuts)

992/04800

Flange Spanner - for locking pinionflange while pinion nut is slackened or

torque set

S197040

892/00224

Impulse Extractor Set for Hub Bearing Seals

S197030

S197070

S190770

892/00225 Adapter - Impulse Extractor

Small 17mm to 25mm

Medium 25mm to 45mm

Large 45mm to 80mm993/59500 Adapter - Impulse Extractor (syncroshuttle and powershift transmission)

S197060

892/00891

Fitting Tool Assembly for

Wheel Hub Seals

S227760



*



892/00836

Lifting Wire Assembly (for

engine removal)

4 - 13


9803/3260

Section 1

4 - 13

Issue 2*

S219080



892/00041 De-glazing Tool for Cylinder Bores (toassist bedding-in of new piston rings)

S192390

Section K - Engine

Fixture for Syncro Shuttle & Powershift Gearbox removal &replacement

Drawing available from:

JCB Service

Rocester

StaffordshireST14 5LS

Note: When removing/replacing a Syncro Shuttle Gearbox,

use items 1, 2 and 3.

When removing/replacing a Powershift Gearbox, use items1 and 4.

For details of other engine service tools refer to PerkinsService Manual, Publication No. 9806/0100

*



5 - 1

Sealing and Retaining Compounds

JCB Multi-Gasket A medium strength sealant suitable for allsizes of gasket flanges, and for hydraulic fittings

of 25-65mm diameter. 4102/1201

JCB High Strength Gasketing For all size of flanges where the strength

of the joint is important. 4102/0502

JCB High Strength Retainer For all retaining parts which are unlikely to

be dismantled. 4101/0602

JCB Lock and Seal A medium strength locking fluid for sealing

and retaining nuts, bolts, and screws up to

50mm diameter, and for hydraulic fittingsup to 25mm diameter. 4101/0202

Loctite 577 A medium strength thread sealing compound. 4102/1901

Loctite 262 A medium to high strength locking fluid for

retention and sealing of ram piston heads. 4101/0502

Loctite 932 A locking fluid for use on threads larger

than 50mm dia. 4101/0402

Loctite Activator N A cleaning primer which speeds the curing

rate of anaerobic products. 4104/0101 Aerosol4104/0102 Bottle

Direct Glazing Kit For one pane of glass, comprises items

marked † below plus applicator nozzle etc. 993/55700

† Ultra Fast Adhesive For direct glazing 4103/2109 310 ml

† Active Wipe 205 For direct glazing 4104/1206 30 ml

4104/1203 250 g

† Black Primer 206J For direct glazing 4201/4906 30 ml

Clear Silicone Sealant To seal butt jointed glass 4102/0933

Black Polyurethane Sealant To finish exposed edges of laminated glass 4102/2309 310 ml

JCB Cleaner & Degreaser For degreasing components prior to use of anaerobic

adhesives and sealants. 4104/1538 Aerosol


9803/3260

Section 1

5 - 1

Issue 3*

*

*



i

Section 2 Care & Safety

9803/3260

Section 2

i

Issue 2

Contents Page No.

Safety Notices 1 - 1

General safety 2 - 1

Operating safety 3 - 1

Maintenance safety 4 - 1



1 - 1


9803/3260

Section 2

1 - 1

Issue 1

Safety Notices

In this publication and on the machine, there are safety notices. Each notice starts with a

signal word. The signal word meanings are given below.

! DANGERDenotes an extreme hazard exists. If proper precautions are not taken, it is highly

probable that the operator (or others) could be killed or seriously injured.INT-1-2-1

!WARNINGDenotes a hazard exists. If proper precautions are not taken, the operator (or others)

could be killed or seriously injured.INT-1-2-2

! CAUTIONDenotes a reminder of safety practices. Failure to follow these safety practices could

result in injury to the operator (or others) and possible damage to the machine.INT-1-2-3



2 - 1

All construct ion and agricultural equipment can be

hazardous. When a JCB machine is correctly operated andproperly maintained, it is a safe machine to work with. But

when it is carelessly operated or poorly maintained it can

become a danger to you (the operator) and others.

Do not work with the machine until you are sure that you can

control it.

Do not start any job until you are sure that you and those

around you will be safe.

If you are unsure of anything, about the machine or the job,

ask someone who knows. Do not assume anything.

Remember

BE CAREFUL

BE ALERT

BE SAFEGEN-1-6

General Safety

!WARNING

DecalsYou can be injured if you do not obey the decal safety

instructions. Keep decals clean. Replace unreadable or

missing decals with new ones before operating the machine.

Make sure replacement parts include warning decals wherenecessary.INT-1-3-4

!WARNING

Care and Alertness All the time you are working with or on the machine, take

care and stay alert. Always be careful. Always be alert forhazards.INT-1-3-5

!WARNING

ClothingYou can be injured if you do not wear the proper clothing.Loose clothing can get caught in the machinery. Wear

protective clothing to suit the job. Examples of protective

clothing are: a hard hat, safety shoes, safety glasses, a well

fitting overall, ear-protectors and industrial gloves. Keep

cuffs fastened. Do not wear a necktie or scarf. Keep long

hair restrained.INT-1-3-6

!WARNING

Lifting EquipmentYou can be injured if you use faulty lifting equipment. Makesure that lifting equipment is in good condition. Make sure

that lifting tackle complies with all local regulations and issuitable for the job. Make sure that lifting equipment is

strong enough for the job.INT-1-3-7

!WARNING

Raised AttachmentsRaised attachments can fall and injure you. Do not walk or

work under raised attachments unless they are safely

blocked.INT-1-3-8


9803/3260

Section 2

2 - 1

Issue 1




3 - 1

Operating Safety

!WARNING

Machine Condition A defective machine can injure you or others. Do not operate

a machine which is defective or has missing parts. Makesure the maintenance procedures in this handbook are

completed before using the machine.INT-2-1-2

!WARNING

ControlsYou or others can be killed or seriously injured if you operate

the control levers from outside the cab. Operate the controllevers only when you are correctly seated inside the cab.INT-2-1-3

!WARNING

Machine LimitsOperating the machine beyond its design limits can damage

the machine, it can also be dangerous. Do not operate the

machine outside its limits. Do not try to upgrade themachine performance with unapproved modifications.INT-2-1-4

!WARNING

Engine/Steering FailureIf the engine or steering fails, stop the machine as quickly as

possible. Do not operate the machine until the fault has been

corrected.INT-2-1-5

!WARNING

EngineThe engine has rotating parts. Do not open the engine cover

while the engine is running. Do not use the machine with the

cover open.INT-2-1-6

!WARNING

Entering/Leaving Always face the machine when entering and leaving the cab.

Use the step(s) and handrails. Make sure the step(s),

handrails and your boot soles are clean and dry. Do not

jump from the machine. Do not use the machine controls ashandholds, use the handrails.INT-2-1-7

!WARNING

ROPS/FOPS Structure

The machine is fitted with a Roll Over Protection Structure(ROPS) and a Falling Objects Protection Structure (FOPS).You could be killed or seriously injured if you operate the

machine with a damaged or missing ROPS/FOPS. If the

ROPS/FOPS has been in an accident, do not use the

machine until the structure has been renewed. Modifications

and repairs that are not approved by the manufacturer may

be dangerous and will invalidate the ROPS/FOPScertification.INT-2-1-9/3

!WARNING

Exhaust GasesBreathing the machine exhaust gases can harm and

possibly kill you. Do not operate the machine in closedspaces without making sure there is good ventilation. If

possible, fit an exhaust extension. If you begin to feel

drowsy, stop the machine at once. Get out of the cab into

fresh air.INT-2-1-10

!WARNING

Communications

Bad communications can cause accidents. Keep peoplearound you informed of what you will be doing. If you will be

working with other people, make sure any hand signals that

may be used are understood by everybody. Work sites can

be noisy, do not rely on spoken commands.INT-2-2-3

!WARNING

Ramps and TrailersWater, mud, ice, grease and oil on ramps or trailers can

cause serious accidents. Make sure ramps and trailers are

clean before driving onto them. Use extreme caution when

driving onto ramps and trailers.INT-2-2-6

! DANGER

SparksExplosions and fire can be caused by sparks from the

exhaust or the electrical system. Do not use the machine in

closed areas where there is flammable material, vapour or

dust.INT-2-2-10


9803/3260

Section 2

3 - 1

Issue 2*

*



3 - 2

Operating Safety (cont'd)

!WARNING

The transmission is in 4 wheel drive until de-selected byhydraulic pressure to 2 wheel drive. If the machine is to be

raised and the engine/transmission run, make sure all four

wheels are off the ground and supported by axle stands. If

only the rear wheels are raised, the machine could still drive

through the front axle.Trans 2-2/1

!WARNING

Powershift TransmissionDo not change from a high gear to a low gear (for instance,

4th to 1st) in one sudden movement whilst the machine is

moving. Otherwise the machine will rapidly decelerate, youor others could be killed or seriously injured. When selecting

lower gears, allow the engine speed to drop before each

gear change.2-1-1-9/1


9803/3260

Section 2

3 - 2

Issue 2*

*



4 - 1

Maintenance Safety

!WARNING

RepairsDo not try to do repairs or any other type of maintenance

work you do not understand. To avoid injury and/or damageget the work done by a specialist engineer.GEN-1-5

!WARNING

Modifications and WeldingNon-approved modifications can cause injury and damage.

Parts of the machine are made from cast iron; welds on cast

iron can weaken the structure and break. Do not weld castiron. Contact your JCB distributor for advice before

modifying the machine.INT-3-1-2/1

!WARNING

Metal SplintersYou can be injured by flying metal splinters when driving

metal pins in or out. Use a soft faced hammer or drift toremove and fit metal pins. Always wear safety glasses.INT-3-1-3

!WARNING

Electrical CircuitsUnderstand the electrical circuit before connecting or

disconnecting an electrical component. A wrong connection

can cause injury and/or damage.INT-3-1-4

!WARNING

CommunicationsBad communications can cause accidents. If two or more

people are working on the machine, make sure each is

aware of what the others are doing. Before starting the

engine make sure the others are clear of the danger areas;examples of danger areas are: the rotating blades and belt

on the engine, the attachments and linkages, and anywhere

beneath or behind the machine. People can be killed or

injured if these precautions are not taken.INT-3-1-5

!WARNING

PetrolDo not use petrol in this machine. Do not mix petrol with the

diesel fuel; in storage tanks the petrol will rise to the top and

form flammable vapours.INT-3-1-6

!WARNING

Battery

A battery with frozen electrolyte can explode if it is used orcharged. Do not use a machine with a frozen battery. Tohelp prevent the battery from freezing, keep the battery fully

charged.INT-3-1-7

!WARNING

Battery GasesBatteries give off explosive gases. Keep flames and sparks

away from the battery. Do not smoke close to the battery.Make sure there is good ventilation in closed areas where

batteries are being used or charged. Do not check the

battery charge by shorting the terminals with metal; use ahydrometer or voltmeter.INT-3-1-8

!WARNING

Battery TerminalsThe machine is negatively earthed. Always connect the

negative pole of the battery to earth.

When connecting the battery, connect the earth (-) lead last.

When disconnecting the battery, disconnect the earth (-)

lead first.INT-3-1-9

!WARNING

Hydraulic FluidFine jets of hydraulic fluid at high pressure can penetrate the

skin. Do not use your fingers to check for hydraulic fluid

leaks. Do not put your face close to suspected leaks. Hold apiece of cardboard close to suspected leaks and then

inspect the cardboard for signs of hydraulic fluid. If hydraulic

fluid penetrates your skin, get medical help immediately.INT-3-1-10/1

! DANGER

Hydraulic PressureHydraulic fluid at system pressure can injure you. Before

disconnecting or connecting hydraulic hoses, stop theengine and operate the controls to release pressure trapped

in the hoses. Make sure the engine cannot be started while

the hoses are open.INT-3-1-11/1


9803/3260

Section 2

4 - 1

Issue 1



4 - 2

Maintenance Safety (cont 'd)

!WARNING

Diesel FuelDiesel fuel is flammable; keep naked flames away from the

machine. Do not smoke while refuelling the machine orworking on the engine. Do not refuel with the engine

running. There could be a fire and injury if you do not follow

these precautions.INT-3-2-2

!WARNING

OilOil is toxic. If you swallow any oil, do not induce vomiting,seek medical advice. Used engine oil contains harmful

contaminants which can cause skin cancer. Do not handle

used engine oil more than necessary. Always use barrier

cream or wear gloves to prevent skin contact. Wash skin

contaminated with oil thoroughly in warm soapy water. Do

not use petrol, diesel fuel or paraffin to clean your skin.INT-3-2-3

!WARNING

Soft Ground A machine can sink into soft ground. Never work under a

machine on soft ground.INT-3-2-4

!WARNING

Tyres and RimsOver-inflated or over-heated tyres can explode. Follow the

instructions in this handbook for inflating the tyres. Do not

weld or cut rims. Get a tyre/wheel specialist to do any repair

work.INT-3-2-6

!WARNING

Hot CoolantThe cooling system is pressurised when the engine is hot.

Hot coolant can spray out when you remove the radiator

cap. Let the system cool before removing the radiator cap.

To remove the cap; turn it to the first notch and let the

system pressure escape, then remove the cap.INT-3-2-9

!WARNING Always wear safety glasses when dismantling assemblies

containing components under pressure from springs. Thiswill protect against eye injury from components accidently

flying out.GEN 6-2

! CAUTION

Rams

The efficiency of the rams will be affected if they are notkept free of solidified dirt. Clean dirt from around the ramsregularly. When leaving or parking the machine, close all

rams if possible to reduce the risk of weather corrosion.INT-3-2-10

! CAUTION

CleaningCleaning metal parts with incorrect solvents can cause

corrosion. Use only recommended cleaning agents andsolvents.INT-3-2-11

! CAUTION

'O' rings, Seals and GasketsBadly fitted, damaged or rotted 'O' rings, seals and gaskets

can cause leakages and possible accidents. Renew

whenever disturbed unless otherwise instructed. Do not useTriochloroethane or paint thinners near 'O' rings and seals.INT-3-2-12

!WARNING

Fires

If your machine is equipped with a fire extinguisher, makesure it is checked regularly. Keep it in the operator's cab

until you need to use it.

Do not use water to put out a machine fire, you could spread

an oil fire or get a shock from an elecrical fire. Use carbon

dioxide, dry chemical or foam extinguishers. Contact your

nearest fire department as quickly as possible. Firefighters

should use self-contained breathing apparatus.INT-3-2-7/1

!WARNING

Jacking A machine can roll off jacks and crush you unless the wheels

have been chocked. Always chock the wheels at the

opposite end of the machine that is to be jacked. Do notwork underneath a machine supported only by jacks. Always

support a jacked-up machine on axle stands before working

underneath it.INT-3-2-8


9803/3260

Section 2

4 - 2

Issue 2*

*



4 - 3

Maintenance Safety (cont 'd)

!WARNING

Hydraulic Hoses

Damaged hoses can cause fatal accidents. Inspect thehoses regularly for:

- Damaged end fittings- Chafed outer covers

- Ballooned outer covers

- Kinked or crushed hoses

- Embedded armouring in outer covers

- Displaced end fittings.INT-3-3-2

!WARNING

Safety StrutRaised loader arms can drop suddenly and cause serious

injury. Before working under raised loader arms, fit the

loader arm safety strut.2-1-1-6

!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 notrely solely on the machine hydraulics or jacks to support the

machine when working under it.

Disconnect the battery, to prevent the engine being started

while you are beneath the machine.GEN-1-1

!WARNINGWaxoyl contains turpentine substitute, which is flammable.

Keep flames away when applying Waxoyl. Waxoyl can take

a few weeks to dry completely. Keep flames away during thedrying period.

Do not weld near the affected area during the drying period.

Take the same precautions as for oil to keep Waxoyl off your

skin. Do not breathe the fumes. Apply in a well-ventilated

area.5-3-1-9

!WARNINGMake the machine safe before working underneath it. Park

the machine on level ground, lower the arms. Apply the

parking brake, put the transmission in neutral and stop theengine. Chock both sides of all four wheels.

Disconnect the battery, to prevent the engine being started

while you are beneath the machine.GEN-1-2

!WARNINGTo avoid burning, wear protective gloves when handling hotcomponents. To protect your eyes, wear goggles when

using a wire brush to clean components.HYD 1-3

!WARNING

JCB Extradig Dipper LubricantJCB Extradig dipper lubricant contains 1.53% lead. The

repeated swallowing of very small quantities can causechronic lead poisoning. Do not smoke or touch food while

handling this lubricant. Dispose of waste (rags etc.) in

accordance with local regulations.2-1-1-8

!WARNING

Fluoroelastomeric MaterialsCertain seals and gaskets (e.g. crankshaft oil seal) on JCBmachines contain fluoroelastomeric materials such as Viton,

Fluorel and Technoflon. Fluoroelastomeric materials

subjected to high temperatures can produce highly corrosive

hydrofluoric acid. THIS ACID CAN SEVERELY BURN.

New fluoroelastomeric components at ambient temperaturerequire no special safety precautions.

Used fluoroelastomeric components whose temperatures

have not exceeded 300°C require no special safetyprecautions. If evidence of decomposition (e.g. charring) is

found, refer to the next paragraph for safety instructions DONOT TOUCH COMPONENT OR SURROUNDING AREA.

Used fluoroelastomeric components subjected to

temperatures greater than 300°C (e.g. engine fire) must be

treated using the following safety procedure. Make sure that

heavy duty gloves and special safety glasses are worn:

1 Ensure that components have cooled then remove and

place material into plastic bags.

2 Thoroughly wash contaminated area with 10% calcium

hydroxide or other suitable alkali solution, if necessary usewire wool to remove burnt remains.

3 Thoroughly wash contaminated area with detergent and

water.

4 Contain all removed material, gloves etc. used in thisoperation in sealed plastic bags and dispose of in

accordance with Local Authority Regulations.

DO NOT BURN FLUOROELASTOMERIC MATERIALS.

If contamination of skin or eyes occurs, wash the affectedarea with a continuous supply of clean water or with calcium

hydroxide solution for 15-60 minutes. Get medical attention

immediately.INT-3-3-5/1


9803/3260

Section 2

4 - 3

Issue 2*

*



Lubricants & Capacities 1 - 1

Service Schedules 2 - 1

Greasing- Loader Arms 3 - 1

- 6-in-1 Clamshovel 3 - 2- Backhoe Quick-Hitch 3 - 2- Loader Quick-Hitch 3 - 2- Stabilisers (Centremount Machines) 3 - 2- Backhoe (Sideshift Machines) 3 - 3- Backhoe (Centremount Machines) 3 - 4- Knuckle Boom (4CN (216) Models) 3 - 5- Front Axle (2-Wheel Drive Machines) 3 - 6- Front Axle (4-Wheel Drive Machines) 3 - 7- Front Axle (All Wheel Steer Machines) 3 - 8- Rear Axle (All Wheel Steer Machines) 3 - 9- Extending Dipper 3 - 10- Hydraulic Pump Driveshaft (2WS Machines) 3 - 10- Front and Rear Propshafts 3 - 11- Backhoe Quick Hitch (Hydraulic) 3 - 11

Oiling- Parking Brake Cable 4 - 1- Control Levers 4 - 1- Boom Lock 4 - 1

Loader Arm Safety Strut- Fitting and Removing 5 - 1

Slew Gearbox (Sideshift Machines)- Draining Water & Checking Oil Level 6 - 1

Hydraulic Fluid- Check Level 7 - 1

Hydraulic Tank Breather- Clean 7 - 1

Hydraulic Filter- Renew Element 7 - 2- Renew Element (from M409448) 7 - 3

Syncro Shuttle Transmission- Check Level 8 - 1- Renew Filter 8 - 1- Change Oil & Clean Strainer 8 - 1

Powershift Transmission- Check Level 8 - 2- Renew Filter 8 - 2- Change Oil & Clean Strainer 8 - 2

Front Axle Oil Level- Check Differential Oil Level 9 - 1- Change Differential Oil 9 - 1

- Check Hub Oil Level 9 - 1- Change Hub Oil 9 - 1

i

Section 3 Routine Maintenance

9803/3260

Section 3

i

Issue 5*

Contents Page No.

*



Rear Axle Oil Level (AWS Machines)- Check Differential Oil Level 9 - 2- Change Differential Oil 9 - 2- Check Hub Oil Level 9 - 2- Change Hub Oil 9 - 2

Rear Axle (2WS Machines)- Check the Oil Level 9 - 3- Change the Oil 9 - 3

Engine Oil and Filter (To Serial No. 430000)- Check Level 10 - 1- Change Oil & Filter 10 - 1

Engine Oil and Filter (From Serial No. 430001)- Check Level 10 - 2- Change Oil & Filter 10 - 2

Fuel Filter (Glass Bowl Type)- Drain 10 - 3- Renew Element 10 - 3

Fuel Filter (Spin-on Cartridge Type))- Drain 10 - 3- Renew Element 10 - 3

Fuel Sediment Bowl- Drain 10 - 4- Clean 10 - 4

Fuel System- Bleeding 10 - 4

Cooling System- Antifreeze 12 - 1- Check Level 12 - 1- Drain & Refill 12 - 2

Fan Belt- Check Tension 13 - 1- Adjust 13 - 1

Cab Heater Filter (To Serial No. 430000)

- Clean 13 - 1

Cab Heater Filter (From Serial No. 430001)- Clean 13 - 2

Air Filter Pre-Cleaner- Empty 14 - 1

Air Filter- Renew Outer Element 14 - 2- Renew Inner Element 14 - 2

Parking Brake

- Check Adjustment 15 - 1- Pad Renewal 15 - 1

ii


9803/3260

Section 3

ii

Issue 4*

Contents Page No.

*

*

*

*



Service Brakes (To Serial No. 430000)- Checking The Foot Brake Fluid Level 15 - 2

Service Brakes (From Serial No. 430001)- Checking The Foot Brake Fluid Level 15 - 2

Battery- First Aid 16 - 1- Checking Electrolyte Level 16 - 1- Cleaning the Battery 16 - 1- Jump Starting (Safety) 16 - 2- Jump Starting (Procedure) 16 - 2

Boom Lock (To Serial No. 430000)- Checking the Hydraulic Fluid Level 17 - 1

Boom Lock (From Serial No. 433724)- Checking the Hydraulic Fluid Level 17 - 1

Hydraulic Oil Cooler- Clean 18 - 1

Bulb Replacement- Headlight Bulb 19 - 1- Front Sidelight Bulb 19 - 1- Worklight Bulb 19 - 2- Front Indicator Light Bulb 19 - 2- Rear Brake/Sidelight Bulb 19 - 3- Fog Light Bulb 19 - 3- Number Plate Light 19 - 4

- Cab Interior Light 19 - 4- Rotating Beacon Bulb 19 - 5- Switch Illumination Bulbs 19 - 5

iii


9803/3260

Section 3

iii

Issue 4*

Contents Page No.

*

*

*



1 - 1

Lubricants & Capacities

ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL

Litres UK Gal SPECIFICATION

Fuel Tank 100 22 Diesel Oil ASTM D975-66T Nos. 1D, 2D

Engine (Oil)➀ JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B,

2 Wheel Steer Machines -10 °C to 50 °C (14 °F to 122 °F) API CD/SE, MIL-L-2104D

- Build AA 9.7 2.1

- Build AA (Hot Climate) 11.0 2.4 JCB Super Universal Agricultural SAE10W/30, MIL-L-2105,

- Build AB 10.0 2.2 -15 °C to 30 °C (5 °F to 86 °F) MIL-L-46152, API CD/SE,

MIL-L-2104C

4 Wheel Steer Machines- Build AB 10.0 2.2 JCB Torque Converter Fluid SAE10W, MIL-L-46152,

-18 °C to 0 °C (0 °F to 32 °F) MIL-L-2104D, API CD/SE

Engine (Coolant) 20.0 4.4 JCB Universal Antifreeze/water ASTM D3306-74

Syncro Shuttle (2WD)➁ 15.75 3.5 JCB Special Transmission Fluid ESP-M2C 33G

Syncro Shuttle (4WD)➁ 16.25 3.6

(machines up to serial number 431230)



(machines from serial number 431230 to TBA)



(machines from serial number TBA - fitted with 12.2 inch convertors)

Powershift➁ 14.75 3.25 JCB Special Transmission Fluid ESP-M2C 33G

Front Axle (4WD)

Housing (2WS) 13 2.86 JCB HD90 Gear Oil API-GL-5

Housing (AWS) ➅ 18 3.96 MIL-L-2105C

Hubs (x2) 2.0 0.44

Rear Axle (AWS)

Housing 18 3.96 JCB Special Gear Oil Plus API-GL-4

Hubs (x2) 2.0 0.44

Rear Axle (2WS) 23 5.0 JCB Special Gear Oil Plus API-GL-4

Slew Gearbox 4.3 0.9 JCB HD90 Gear Oil API-GL-5, MIL-L-2105C

Brake System

- Standard 1.2 0.26 JCB Light Hydraulic Fluid ISO VG15

- Servo 1.4 0.31 ! CAUTION: DO NOT USE ORDINARY BRAKE FLUID

Hydraulic System➂ 135 29.7 JCB High Performance Hydraulic Oil ISO VG46

(Above 38 °C, 100 °F)

JCB Hydraulic Fluid HP32 ISO VG32(Below 38 °C, 100 °F)

Air Conditioning System 1544 g 3.4 lb Refrigerant Freon 12


9803/3260

Section 3

1 - 1

Issue 6*

*

*

*

*



1 - 2


Air Conditioning System 1200 g 2lb 10oz Refrigerant R134a


Boom Lock 1.0 0.22 JCB Light Hydraulic Fluid ISO VG15

Grease Points --- JCB MPL Grease or Lithium based, No. 2

JCB HP Grease➃ consistency.

Extending Dipper --- Waxoyl➄

Electrical --- As a corrosion and moisture inhibitor all exposed connections should be

connections coated liberally with petroleum jelly.

➀ Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle

immediately, glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is

gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up

without load). Engines of new machines are fil led at the factory with JCB 10W/30 Multigrade oil. This oil should be drainedafter the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the

lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or

reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is

replaced by the lubricant recommended. The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on

the dipstick when filling the system. Figures quoted within ±0.5 litre (0.11 U.K. gal).

➁ Note: The figure quoted is TOTAL system capacity. Use the MIN and MAX marks on the dipstick when filling the system.

Figures quoted within ±1.0 litre (0.22 U.K. gal).

➂ Note: The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch level

indicator on hydraulic tank.

➃ Note: JCB HP Grease is a high specification grease, in certain applications this grease must be used, for instance

transmission bearings during an overhaul.

➄ ! WARNING: Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl.

Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period. Do not weld near the

affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe

the fumes. Apply in a well-ventilated area.GEN-1-3

➅ Note: AWS axles with limited slip differential must use JCB Special Gear Oil Plus.


9803/3260

Section 3

1 - 2

Issue 2*

Lubricants & Capacities (continued)

ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL

Litres UK Gal SPECIFICATION*

*

*



2 - 1

Service Schedules

A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular

maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working

condition.

!WARNINGRaised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the

loader arm safety strut.GEN 3-2

Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings

to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure any defects found during the

regular maintenance checks are rectified immediately.

Calendar equivalents:

10 Hours = Daily

50 Hours = Weekly

500 Hours = Six Months

1000 Hours = Yearly

2000 Hours = 2 Years

Pre-start Cold Checks Operation 10 50 †100 500 1000 2000

Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr

ENGINE

Oil level - Check ●

Oil and Filter ➃ - Change ● ● ● ●

Air Cleaner Dust Valve - Clean ● ● ● ●

Air Cleaner Outer Element - Change ● ●

Air Cleaner Inner Element - Change ●

Fuel Filter - Change ● ● ● ●

Fuel Filter - Drain ●

Coolant Quality/Level - Check ● ● ● ● ●

Fuel Sedimenter - Drain and Clean ● ● ● ● ●

Fan Belt Tension/Condition - Check ● ● ● ● ●

Valve Clearances ➂ - Check and Adjust ●

Engine Mounting Bolts for Tightness ➂ - Check ● ● ● ●

Radiator - Clean ● ● ●

All Hoses - Condition - Check ● ● ● ●

Precleaner - Clean ● ● ● ● ● ●

TRANSMISSION, AXLES

AND STEERINGTransmission Oil Level - Check ● ● ●

Transmission Oil - Change ● ●

Transmission Filter - Change ● ● ● ●

Axle Oil Level (incl. Hubs when applicable) ➀ - Check ● ●

Axle Oil (incl. Hubs when applicable) - Change ● ●

Axle Oil (Limited Slip Diff.) - Change ● ● ●

Tyre Pressures/Condition - Check ● ● ● ● ●

Front Hub Bearings ➂ - Check ● ● ● ●

Transmission Strainer - Clean ● ●

Drive Shafts - Security/Grease ● ● ● ●

Steer Axle Movement/Shimming ➂ - Check ● ● ● ●

Steer Axle Pivots and Linkages ➆ - Grease ● ● ● ●


9803/3260

Section 3

2 - 1

Issue 6*

*

*

*



2 - 2

Pre-start Cold Checks Operation 10 50 †100 500 1000 2000

Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr

HYDRAULICS

Oil Level ➁ - Check ● ● ● ●

Oil ➂ - Sample/Change ●

Oil Filter - Change ● ● ● ●

Hoses - Damage or Leaks - Check ● ● ● ● ●

Pipework - Damage or Leaks - Check ● ● ● ● ●

Rams - External Leaks - Check ● ● ● ● ●

Rams - Chrome Condition - Check ● ● ● ●

Hydraulic Oil Cooler - Clean ● ● ●

Boom Lock Fluid Level - Check ● ● ● ● ●

Hydraulic Oil Strainer - Clean ●

Hydraulic Tank Filler Cap (with integral filter) - Change ●

BRAKESBrake System Fluid Level - Check ● ● ● ● ● ●

Brake System Fluid ➂ - Change ●

Parking Brake - Check and Adjust ● ● ● ●

Master Cylinder Rod ➂ - Adjustment Check ● ● ●

ELECTRICS

Battery Electrolyte Level (if applicable) - Check ● ● ●

Wiring for Chaffing/Routing - Check ● ● ● ● ●

Battery Terminals for Condition and Tightness - Check ● ● ● ●

BODYWORK AND CABSlew Actuator Oil Level ➀ - Check ● ● ● ●

Slew Actuator (in below freezing conditions) - Drain Water ● ● ● ● ●

Pins and Bushes - Check and Grease ● ● ● ● ● ●

Door/Window Hinges - Lubricate ● ● ● ● ●

All Cables - Lubricate ● ● ● ●

Cab Heater Filter ➅ - Clean ● ● ●

Extending Dipper - Adjust/Grease ● ● ● ● ●

Hydraclamp Shimming ➂ - Check and Adjust ● ● ● ●

Door - Fit and Catches - Check ● ● ● ●

Cab Seat - Operation - Check ● ● ● ●

Cab Floor Mat - Condition - Check ● ● ● ●

Toe Plate Condition - Check ● ● ●

Front Mudguards - Security (if fitted) - Check ● ●

Windscreen Washer Fluid Level - Check ● ● ● ● ● ●

Condition of Paintwork - Check ● ● ● ●

Machine Generally - Check and Clean ● ● ● ● ● ●

Machine Generally for Leaks and/or Damage ➄ - Check ● ● ● ● ●

ATTACHMENTS

6-in-1 Clam Shovel - Grease ● ● ● ● ● ●

Backhoe & Loader Quick Hitch - Grease ● ● ● ● ● ●

Stabilisers (Centremount Machines) - Grease ● ● ● ● ● ●


9803/3260

Section 3

2 - 2

Issue 5



2 - 3

Functional Test Operation 10 50 †100 500 1000 2000

and Final Inspection Hr Hr Hr Hr Hr Hr

ENGINE

Idle Speed ➂ - Check and Adjust ● ● ● ●

Maximum Governed Speed ➂ - Check and Adjust ● ● ● ●

Stall Speed ➂ - Check ● ● ● ●

Maximum No-Load Speed ➂ - Check and Adjust ● ● ● ●

Exhaust Smoke (excessive) - Check ● ● ● ● ● ●

Exhaust System Security ➂ - Check ● ● ● ●

Air Inlet System Security - Check ● ● ● ●

Throttle System and Control Cable ➂ - Check ● ● ● ●

TRANSMISSION, AXLES AND

STEERING

Steer Modes - Operation - Check ● ● ● ● ● ●

Steer Phasing ➂ - Check ● ● ●

Steering Proximity Switch - Operation ➂ - Check ● ● ● ●

2WD/4WD Selection - Check ● ● ● ●

Wheel Nuts Torque - Check ● ● ● ● ● ●

Forward/Reverse and Gear Change - Operation - Check ● ● ● ●

Hydraulic Speed Control - Operation (if fitted) - Check ● ● ● ●

Steer Circuit Pressure ➂ - Check ● ● ● ●

Transmission Main Line Pressure ➂ - Check ● ● ●

Clutch Disconnect - Check ● ● ● ●

Neutral Start Operation - Check ● ● ● ●

Power Shift Selection (if fitted) - Check ● ● ● ●

Clutch Pack Pressures ➂ - Check ● ● ● ●

HYDRAULICS

MRV Pressure ➂ - Check and Adjust ● ● ● ●

Operation All Services - Check ● ● ● ● ●

Hose Burst Protection Valves (if fitted) - Check ● ● ● ●

Offloader Valve Pressure ➂ - Check and Adjust ● ● ● ●

Auxiliary Circuit & Pressures ➂ - Check and Adjust ● ● ● ●

BRAKES

Foot Brake - Operation - Check ● ● ● ● ● ●

Parking Brake - Operation - Check ● ● ● ● ● ●

Servo Operation (if fitted) - Check ● ● ● ●

ELECTRICS

Starter Motor - Check ● ● ● ●

Alternator - Output - Check ● ● ● ●

Wipers/Washers - Check ● ● ● ● ● ●

Beacon - Operation (if fitted) - Check ● ● ● ● ● ●

Heater - Operation - Check ● ● ● ● ● ●

Warning Lights - Check ● ● ● ● ● ●

Lights and Instruments - Check ● ● ● ● ● ●


9803/3260

Section 3

2 - 3

Issue 4



2 - 4

Functional Test Operation 10 50 †100 500 1000 2000

and Final Inspection Hr Hr Hr Hr Hr Hr

ELECTRICS (continued)

Horn - Operation - Check ● ● ● ● ● ●

Reverse Alarm - Check ● ● ● ● ● ●

Shovel Reset/Return to Dig (if fitted) - Check ● ● ● ● ● ●

Air Conditioner (if fitted) - Check ● ● ● ● ● ●

Operation of Stop Control/E.S.O.S. - Check ● ● ● ● ● ●

BODYWORK AND CAB

Teeth and Side Cutters - Check ● ● ● ●

Doors and Hinges - Fitment/Leaks - Check ● ● ● ●

Locks and Keys - Check ● ● ● ●

Seat/Seat Belts - Check ● ● ● ●

ATTACHMENTS

Attachment Operation - Check ● ● ● ● ● ●

† Note: First 100 Hours Service only, to be completed by your JCB Distributor.

➀ Note: Check for leaks every 50 hours, check level if leaking.

➁ Note: Check the hydraulic fluid level with the loader and backhoe in the travel position.

➂ Note: Jobs which should only be done by a specialist are indicated by a ➂.

➃ Note: If operating under arduous conditions, change the engine oil filter every 250 hours.

➄ Note: Check generally for leaks on ALL systems, for example, hydraulic, engine (coolant, fuel and oil), transmission, brakes,

axles etc. If a leak is evident find the source and repair as required. Make sure that the system is topped up with the

recommended fluid after repair. Examples of machine general damage are paintwork, toe plate, glazing rubbers etc.,

repair any damage as required.

➅ Note: If operating in dusty working environments, clean the cab heater filter more frequently.

➆ Note: The axles are factory greased with a high performace grease, if during service a standard grease is used, then the

interval must be reduced to every 50 hours.


9803/3260

Section 3

2 - 4

Issue 2*

*



Note: The illustration shows an all wheel steer machine, the

loader arms grease points are identical for 2WS and AWS

machines.

Greasing

Loader Arms - for Interval see Service Schedule

For each grease point there is another on the other side of

the machine.

11 grease points each side -

Total 22 grease points.

Normally two strokes of the grease gun should be sufficient.

Stop greasing when fresh grease appears at the joint.

3 - 1


9803/3260

Section 3

3 - 1

Issue 2*

140210

*

2

7

3

9

8

4

6

1

5



Backhoe Quick-Hitch

- for Interval see Service Schedule

For grease points 2 and 3 there is another on the opposite

side of the Quick-Hitch ( 4 and 5 ).

Total 5 Grease Points

Loader Quick-Hitch




Greasing (cont'd)

6 - in - 1 Clamshovel


For each grease point there is another at the other end ofthe bucket.



Stabilisers (Centremount Machines)


3 grease points on each stabiliser -


3 - 2


9803/3260

Section 3

3 - 2

Issue 2*

S137251

S138941S089921

S089961

*

41

2

3

B

2

53

1

2

3

2

1

3

4



3 - 5

Greasing (cont'd)

Knuckle Boom (4CN Models) - for Interval see Service Schedule

18 Grease Points


9803/3260

Section 3

3 - 5

Issue 2*

*



3 - 6

Greasing (cont'd)

Front Axle (2 Wheel Drive Machines) - for Interval see Service Schedule

12 Grease Points


9803/3260

Section 3

3 - 6

Issue 2*

*



3 - 7

Greasing (cont'd)

Front Axle (4 Wheel Drive Machines) - for Interval see Service Schedule

10 Grease Points


9803/3260

Section 3

3 - 7

Issue 3*

*

S199790

1

23

4

5

6

7

8

9 0



3 - 8

Greasing (cont'd)

Front Axle (All Wheel Steer Machines) - for Interval see Service Schedule

12 Grease Points


9803/3260

Section 3

3 - 8

Issue 1

S143010



3 - 9

Greasing (cont'd)

Rear Axle (All Wheel Steer Machines) - for Interval see Service Schedule

10 Grease Points


9803/3260

Section 3

3 - 9

Issue 1

S143050



3 - 10

Greasing (cont'd)

Extending Dipper - for Interval see Service Schedule

!WARNINGWaxoyl contains turpentine substitute, which is

flammable. Keep flames away when applying Waxoyl.

Waxoyl can take a few weeks to dry completely. Keep

flames away during the drying period. Do not weld near

the affected area during the drying period. Take the

same precautions as for oil to keep Waxoyl off your skin.

Do not breathe the fumes. Apply in a well-ventilated

area.GEN-1-3

Extend the dipper.

Coat the working surfaces with Waxoyl.

Hydraulic Pump Driveshaft (2 Wheel Steer Machines)


1 Grease Point (if fitted)


9803/3260

Section 3

3 - 10

Issue 1

S157371

S140080



3 - 11

Greasing (cont'd)

Rear Propshaft - for Interval see Service Schedule

3 Grease Points

Front Propshaft (4 Wheel Drive ) - for Interval see Service

Schedule

3 Grease Points

Backhoe Quick Hitch (Hydraulic) - for Interval see Service

Schedule

! CAUTIONWaxoyl contains turpentine substitute, which is

inflammable. Keep flames away when applying Waxoyl.

Waxoyl can take a few weeks to dry completely. Keep

flames away during the drying period.

Do not weld near the affected area during the drying

period. Take the same precautions as for oil to keep

Waxoyl off your skin. Do not breathe the fumes. Apply in

a well-ventilated area.5-3-1-9

Coat the slide A with Waxoyl .

4 Grease Points


9803/3260

Section 3

3 - 11

Issue 2*

S157500

S157510

1 3

2

3 21

S211750

4

3

2

1

A

*



4 - 1

Oiling

Parking Brake Cable


Oil the clevis at the brake end of the cable and at the base ofthe lever.

Control Levers


Oil the clevis at the bottom of every attachment control

lever.

Boom Lock


Oil the clevis at the back end of the remote boom lock.


9803/3260

Section 3

4 - 1

Issue 1

S094680

S144460

S152200

S104990



5 - 1

Loader Arm Safety Strut

Fitting and Removing

Install the loader arm safety strut as detailed below before

working underneath raised loader arms.

Depending on the age and type of machine, the strut may be

stowed inside the cab, mounted on the left hand fender

cladding, as shown at X. Alternatively, the strut may be

stowed on the loader arm, as shown at Y.

Fitting

!WARNING

The loader arm safety strut must be fitted before any

work is done beneath raised l oader arms. Make sure the

shovel is empty, then fit the safety strut as instructed

below.GEN-1-7

1 Fully raise the loader arms and stop the engine.

2 Release fastener A and withdraw strut C from its

stowage bracket.

3 Push the strut C over the ram piston rod and secure the

strut in position with strap B.

4 Start the engine and slowly lower the loader arms until

the weight of the arms is just taken by the strut.

Removing

1 Raise the loader arms to take the weight off the strut,

then stop the engine.

2 Undo strap B, remove the strut C and return it to its

stowage position.

3 Secure the strut in its stowage position with fastener A.


9803/3260

Section 3

5 - 1

Issue 4*

SXXXXXX

S164101

S161710

X

C

A

C

B

S215110

A

C

Y

*



6 - 1

Slew Gearbox (Sideshift Machines)

Draining Water and Checking Oil Level

- for interval see Service Schedule

Note: In freezing conditions this procedure must be carried

out each working day.

1 Preparation

Park machine on level ground. Extend the dipper and

lower the boom to rest the bucket on the ground.

Engage the parking brake. Stop engine. Remove starterkey.

2 Draining Water

Slacken plug B. Close the plug when water stops

flowing and oil appears.

3 Check Oil Level

Remove fill/level plug A. Top up to bottom of filler hole

with oil specified on page 3/1-1.


9803/3260

Section 3

6 - 1

Issue 2*

SXXXXXX

S148080

SXXXXXX

*



Hydraulic Fluid Level

Check Level - for Interval see Service Schedule

Position the machine on level ground. Set the loader shovel

on the ground. Retract the extending dipper if fitted. Raise

the boom, swing in the dipper and close the bucket. Stop

the engine. Remove the starter key.

Look at the fluid level in the lens A. The level should be at

the red mark (or above). If the fluid is cloudy, water or air has

entered the system. Water or air in the system could

damage the hydraulic pump. Contact your JCB distributor if

the fluid is cloudy.

Note: Earlier machines have a sight tube H, the level should

be between the two marks on the tube.

If required, top up at B with hydraulic fluid specified on page

3/1-1.

7 - 1

Hydraulic Tank Breather

Clean - for Interval see Service Schedule

Remove screw C, washer D and cap E.

Remove filter F and wash in clean fuel.

Clean inside cap E and re-assemble onto valve body G.

Note: On machines from Serial No. M409559 the hydraulic

tank breather (and filter) forms an integral part of the

hydraulic tank filler cap B. Replace the filler cap (and

breather filter) with a new one at the recommended interval

(see Service Schedules ).

The filler cap is threaded and must be screwed onto the fillerneck, torque tighten the cap to 20 Nm (15 lbf ft), - this is

equivalent to hand tight plus a further quarter turn using a

spanner.


9803/3260

Section 3

7 - 1

Issue 2*

S209960

B

A

*

C

D

E

F

G

S145380

H

*



7 - 2

Hydraulic Filter

Renew Element- for Interval see Service Schedule

Position machine as at A and remove tank cap B.

Remove screws C, cover plate D and gasket E, discard the

gasket.

Remove complete element assembly F and seal G.

Remove nut and spring H. Remove element from spindle.

Remove the 'L' shaped seal K.

Clean magnets J (see note).

Fit a new element and gasket E. Refit cover plate D and

tighten screws C to 7Nm (5lbf ft).

Top up hydraulic tank and refit cap B.

Note: The filter core (item J ) on machines from serial number

402727 is non-magnetic.

Note: New machines are fitted with a 10 micron rated

element to eliminate all possible traces of contaminationfrom the hydraulic system. At the initial 100 hour service, fit

a new 25 micron rated element.

If the hydraulic system should become contaminated after

the initial service, then fit a 10 micron filter element for 100

operating hours to remove the contamination. After 100hours fit a new 25 micron element.


9803/3260

Section 3

7 - 2

Issue 2*

S142871

*

*

*



7 - 3

Hydraulic Filter

(from M/C Serial No 409448)

Renew Element

Note: New machines are fitted with a 10 micron rated

element to eliminate all possible traces of contamination

from the hydraulic system. At the initial 100 hour service, fit

a new 25 micron rated element.

If the hydraulic system should become contaminated after

the initial service, then fit a 10 micron filter element for 100

operating hours to remove the contamination. After 100

hours fit a new 25 micron element.

Position the machine as at A on page 7 - 2.

Removal

Remove screws A. Remove the cover plate B and gasket C,

discard the gasket.

Remove the spring D.

Hold handle E and pull the element assembly from the

hydraulic tank.

Hold canister F.

Hold handle E and rotate the element G 90°.

Replacement

Fit a new seal H.

Make sure that seal J is fitted in the new element.

Push the element G into its canister F and rotate the elemen

90° to lock it into position. Check that the element has

locked into position by pulling on handle E.

Install the element assembly in the hydraulic tank.

Fit spring D and new gasket C. Fit cover plate B and tighten

screws A to 5 lbf ft (7 Nm).

Add oil through filler.


9803/3260

Section 3

7 - 3

Issue 1*

A

B

CD

E

G

H

F

S185850

J



8 - 1

Syncro Shuttle Transmission


A- Dipstick/Filler

Oil level should be to the full mark on the dipstick when the

oil is cold i.e. before starting machine operation.

DO NOT OVERFILL

Change Oil & Clean Strainer


Drain oil by removing strainer B. Clean strainer using a

suitable solvent.

When refitting strainer, renew gasket C and apply JCB Lockand Seal to bolts D.

Torque Settings

Item Nm kgf m lbf ft

D 10 1.0 7.4

Renew Filter - for Interval see Service Schedule

Unscrew and discard element E.

Smear seal F with transmission oil, and fit new element hand

tight only.

Fill system to dipstick mark with JCB Special Transmission

Fluid.


9803/3260

Section 3

8 - 1

Issue 1

143030



8 - 2

Powershift Transmission


A - Dipstick/Filler

Oil level should be to the full mark on the dipstick when the

oil is cold i.e. before starting machine operation.

DO NOT OVERFILL

Change Oil & Clean Strainer


Drain oil by removing drain plug B.

Remove and clean strainer G. Clean strainer using a suitable

solvent.

When refitting strainer, renew gasket C and apply JCB Lock

and Seal to bolts D.

Torque Settings


D 10 1.0 7.4

Renew Filter - for Interval see Service Schedule

Unscrew and discard element E.

Smear seal F with transmission oil, and fit new element hand

tight only.

Fill system to dipstick mark with JCB Special Transmission

Fluid.


9803/3260

Section 3

8 - 2

Issue 1

S143040



9 - 1

Front Axle Oil Level

Check Differential Oil Level - for Interval see Service

Schedule

1 Remove fill/level plug A. Oil should be level with the

bottom of the fill/level hole.

2 If necessary, top up with JCB recommended axle oil.

Clean and refit fill/level plug A, torque to 79 Nm (58 lbf

ft).

Change Differential Oil - for Interval see Service Schedule

1 Remove fill/level plug A and drain plug B (see note).

Allow time for the oil to drain out.

Note: On 2WS machines, drain plug B is positioned on the

underside of the axle.

2 Clean and refit drain plug B, torque to 79 Nm (58 lbf ft).

3 Fill the axle with JCB recommended axle oil through the

fill/level hole A. Oil should be level with the bottom of

the fill/level hole.

4 Clean and refit fill/level plug A, torque to 79 Nm (58 lbf

ft).

Check Hub Oil Level - for Interval see Service Schedule

1 Make sure the OIL LEVEL mark on the hub is

horizontal.

2 Remove fill/level plug C. Oil should be level with the



Clean and refit fill/level plug C.

Change Hub Oil - for Interval see Service Schedule

1 Set the machine level, with the tyres just clear of the

ground. Manually rotate the wheels to bring the OIL

LEVEL mark on the hubs to the vertical position, with

the fill/level plugs C at the bottom.

2 Remove fill/level plugs C. Allow time for the oil to drain

out.

3 Set OIL LEVEL marks to the horizontal.

4 Fill the hubs with JCB recommended axle oil through

the fill/level holes C. Oil should be level with the bottom

of the fill/level hole.

5 Clean and refit fill/level plugs C.


9803/3260

Section 3

9 - 1

Issue 2*

S162260

S113430

S113430

*



9 - 2

Rear Axle Oil Level (All Wheel Steer

Machines)

Check Differential Oil Level - for Interval see Service

Schedule

1 Remove fill/level plug A. Oil should be level with the



Clean and refit fill/level plug A.

Change Differential Oil - for Interval see Service Schedule

1 Remove fill/level plug A and drain plug B. Allow time for

the oil to drain out.

2 Clean and refit drain plug B.

3 Fill the axle with JCB recommended axle oil through the

fill/level hole A. Oil should be level with the bottom of

the fill/level hole.

4 Clean and refit fill/level plug A.


9803/3260

Section 3

9 - 2

Issue 2*

S113450

*Check Hub Oil Level - for Interval see Service Schedule

1 Make sure the OIL LEVEL mark on the hub is horizontal.

2 Remove fill/level plug C. Oil should be level with the



Clean and refit fill/level plug C.

Change Hub Oil - for Interval see Service Schedule

1 Set the machine level, with the tyres just clear of the

ground. Manually rotate the wheels to bring the OIL

LEVEL mark on the hubs to the vertical position, with

the fill/level plugs C at the bottom.

2 Remove fill/level plugs C. Allow time for the oil to drain

out.

3 Set OIL LEVEL marks to the horizontal.

4 Fill the hubs with JCB recommended axle oil through

the fill/level holes C. Oil should be level with the bottomof the fill/level hole.

5 Clean and refit fill/level plugs C.



9 - 3

Rear Axle Oil Level (2 Wheel Steer

Machines)

Check Oil Level - for Interval see Service Schedule

Note: It is essential that the machine is parked on level

ground to ensure accurate oil level checking.

1 At the drive head casing remove fill/ level plug A. Oil

should be level with the bottom of the fill/level hole.


Clean and refit fill/level plug A.

Change Oil - for Interval see Service Schedule

1 Set the machine level, with the machine tyres just clear

of the ground. Manually rotate both wheels of the axle

to bring the OIL LEVEL mark on the hubs to the

vertical position, with the fill/level plugs C at thebottom.

2 Remove fill/level plugs C from the hubs and drain plug

B from the drive head casing. Allow time for the oil to

drain out.

3 Clean and refit drain plug B.

4 Set both hub OIL LEVEL marks to the horizontal.

5 Fill the axle with the specified quantity of oil through

drive head casing fill/level plug A. If the machine has

been set level, oil should just dribble out both hub

fill/level points.

6 Clean and refit both hub fill/level plugs C and fill/level

plug A.


9803/3260

Section 3

9 - 3

Issue 1

S113450

S113440

S113400



10 - 1

Engine Oil and Filter


1 Make sure that the oil level is between the two marks

on the dipstick A .

2 If necessary, top up with JCB recommended oil

through filler point B.

3 Replace dipstick and filler cap.

Change Oil & Filter - for Interval see Service Schedule

!CAUTIONOil is toxic. If you swallow any oil, do not induce

vomiting, seek medical advice. Used engine oil contains

harmful contaminants which can cause skin cancer. Do

not handle used engine oil more than necessary. Always

use barrier cream or wear gloves to prevent skin

contact. Wash skin contaminated with oil thoroughly in

warm soapy water. Do not use petrol, diesel fuel or

paraffin to clean your skin.INT-3-2-3

1 Remove drain plug C and discard the 'O' ring. Drain the

oil into a suitable container. Clean and refit the drain

plug with a new 'O' ring. Tighten to 34 Nm (25 lbf ft).

2 Change the filter:

a Unscrew oil filter canister D.

b Clean the filter head E.

c Smear the new filter canister seal F with engine oil.d Screw in the new filter canister - hand tight only.

3 Fill the engine with new oil. Wipe off any spilt oil. Check

the system for leaks.

4 Replace filler cap.

After refilling with oil, extract from the fuse box (adjacent tothe instrument console) the fuse controlling the electric fuel

shut off valve (mounted on the fuel injection pump) then

operate the starter until the oil pressure warning light is

extinguished.

Reinsert the electric shut off valve fuse, run the engine at

idling speed for a few seconds, then check for oil leaks

again.


9803/3260

Section 3

10 - 1

Issue 1

S142900



Engine Oil and Filter (From Serial No.

430001)

Checking the Oil Level - for Interval see Service Schedule

1 Park the machine on firm level ground, engage theparking brake and set the transmission to neutral. Raise

and block the loader arms. Lower the backhoe to the

ground and stop the engine.

2 Open the bonnet.

3 Check that the oil level is between the two marks on

the dipstick A . Add oil if necessary, through filler B.

Make sure that the dipstick and filler cap are fully

inserted and tightened.

10 - 2

Changing the Oil and Filter - for Interval see Service

Schedule

!WARNINGOil is toxic. If you swallow any oil, do not induce

vomiting, seek medical advice. Used engine oil contains

harmful contaminants which can cause skin cancer. Do

not handle used engine oil more than necessary. Always

use barrier cream or wear gloves to prevent skin

contact. Wash skin contaminated with oil thoroughly in

warm soapy water. Do not use petrol, diesel fuel or

paraffin to clean your skin.INT-3-2-3

1 Place a container that can hold at least 12 litres (3 gal)

beneath the engine (to catch the oil).

2 Remove drain plug C and its 'O' ring. Let the oil drain

out, then clean and refit the drain plug with a new 'O'

ring. Tighten to 34 Nm (25 lbf ft).

3 Change the filter:

a Unscrew the filter canister D. Remember that it will

be full of oil.

b Check that adapter G is secure.

c Clean the filter head F.d Add clean engine lubricating oil to the new filter

canister. Allow enough time for the oil to pass

through the filter element.

e Smear the seal E on the new filter with oil. Screw inthe new filter canister - hand tight only.

4 Fill the engine to the max mark on the dipstick with new

oil through the filler. Check for leaks. Make sure the

filler cap is correctly refitted.

5 Obtain oil pressure:

Make sure the engine will not start and turn the starterswitch to operate the starter motor until the oil pressure

light is extinguished. (To make sure the engine will not

start, remove the engine shut-off solenoid fuse, housed

in the fuse box).

6 Check for leaks:Re-insert the engine shut-off solenoid fuse and operate

the engine. Check for leaks. When the engine has

cooled, check the oil level.


9803/3260

Section 3

10 - 2

Issue 3

S209020

A

B

F

G

EC

D



10 - 3

Fuel Filter (Glass Bowl Type)

Drain - for Interval see Service Schedule

Drain off any water in bowl B by turning tap A.

Renew Element - for Interval see Service Schedule

1 Hold bowl B and unscrew bolt C, remove bowl and

filter element E. Wash the bowl in clean fuel.

2 Inspect seals D and 'O' ring seals F, renew if damaged.

3 Fit new element E, seals D, 'O' rings F and bowl B.

Tighten bolt C. Check for leaks.

4 Bleed the fuel system as described on page 3/10-4.

Fuel Filter (Spin-on Cartridge Type)


Drain off any water in the element G by turning tap H.

Renew Element - for Interval see Service Schedule

1 Unscrew the filter element G. The element is hand tight

but may require a strap wrench to remove. The filter willbe full of fuel.

2 To assist with bleeding, fill the new filter element with

fuel before fitting. Install new element G hand tight only.

Check for leaks.

3 Bleed the fuel system as described on page 3/10-4.


9803/3260

Section 3

10 - 3

Issue 2*

S142950

C

F

F D

E

D

B

D

DA

H

G

* *



10 - 4

Fuel Sediment Bowl


Drain off any water in bowl by turning tap G.


1 Hold bowl J and unscrew bolt K . Remove and wash the

bowl in clean fuel.

2 Refit the bowl; make sure seals are seated correctly.

3 Bleed the fuel system as described on page 3/10 - 4.

Note: Do not over-tighten bolt K .

Bleed the Fuel System

! CAUTIONRunning the engine with air in the system could damage

the fuel injection pump. After maintenance, remove air

from the system as detailed below.2-3-3-7

1 Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral. Raise



2 Set the starter key to the IGN position.

!WARNINGHot oil and engine components can burn you. Make sure

the engine is cool before doing this job.2-3-3-2

3 Operate the fuel lift pump priming lever X slowly, for

approximately two minutes. The engine is now ready to

start. If the engine runs smoothly for a short time, and

then begins to run roughly or stops, check again for air

in the fuel system. Check all seals and connections,

especially in the low pressure side of the system.

Note: If no fuel is moved when the fuel lift pump priming

lever X is operated, then the pump diaphragm may have

rested in a 'maximum lift' position. To move the diaphragm,

use the starter key to turn the engine, then try the priming

lever again.


9803/3260

Section 3

10 - 4

Issue 1

S142960

K

J

G

S209040

X




The engine coolant level can be visually checked when the

engine is hot or cold. However if coolant needs to be addedthen make sure that the engine has cooled before removing

the coolant reservoir cap.

1 Park the machine on level ground.

2 Visually check the coolant level reservoir. The coolant

level must be between the two marks indicated on the

reservoir, shown at A.

!WARNING

The cooling system is pressurised when the engine ishot. Hot coolant can spray out when you remove the cap.

Let the system cool before removing the cap.ENG-1-2

3 If necessary, top up with pre-mixed water/anti-freeze.

Re-fit the cap.

12 - 1

Cooling System

An ti freeze

The protection provided by JCB Universal Anti-freeze is

shown below. If any other anti-freeze is used, refer to themanufacturers' instructions and ensure that a corrosion

inhibitor is included.

DO NOT use solutions of more than 60% or less than 50%

or damage to the cooling system will occur.

Solution Maintains circulation Protects against

down to: damage down to:deg C deg F deg C deg F

55% -36 -33 -41 -42

The strength of the anti-freeze solution must be checked at

least once a year, preferably at the beginning of the cold

period.

It is an advantage to leave the anti-freeze in all the year

round as it gives continued protection against corrosion. Always renew the anti-freeze every two years.

A 50% anti-freeze mixture must be used even if frost

protection is not needed. This gives protection against

corrosion and raises the coolant's boiling point.

Note: After adding anti-freeze or topping up with pre-mixed

solution ensure that the cab heater control is in the hot

position and the engine run. This will ensure the coolantmixture circulates through the entire cooling system.


9803/3260

Section 3

12 - 1

Issue 2*

*



12 - 2


9803/3260

Section 3

12 - 2

Issue 1

Cooling System

Drain and Refill - for Interval see Service Schedule

!WARNING

The cooling system is pressurised when the coolant is

hot. Hot coolant will burn you. Make sure the engine is

cool before draining the system.ENG-1-3


2 Wait until the engine has cooled down.

3 Carefully loosen filler cap A and let any pressure

escape, then remove the cap.

4 Remove drain plug C from the cylinder block and drain

the coolant.

5 Remove the bolts holding the front radiator grille in

position. Remove the grille to gain access to the

radiator bottom hose.

6 Remove the radiator hose at D and drain the coolant.

7 Flush the system with clean water.

8 Refit drain points C and D, and the front radiator grille.

9 Fill the system with a correct water/anti-freeze mixture

and refit filler cap A.



13 - 1

Fan Belt

Check Tension - for Interval see Service Schedule

Adjustment


2 Loosen bolts A, B, C, and D holding the alternator.

3 Reposition the alternator until belt deflection at point X

is approximately 10mm (3/8 in.).

! CAUTION

If any leverage is necessary, use a length of wood at the

drive end bracket only; otherwise damage to thealternator may be caused.ENG 1-4

4 Tighten bolts A, B, C, and D ensuring that bolt at the

rear of the alternator is the last to be tightened.

Note: If a new belt is fitted, the belt tension must be

checked again after the first 20 hours of operation.

Cab Heater Filter


!WARNING

The filter may be filled with dust. Wear goggles and a

face mask when removing the filter.2-3-3-6

!WARNING

Make the machine safe before getting beneath it. Lower

the attachments to the ground; engage the parking

brake; remove the starter key, disconnect the battery.2-3-2-2


2 The filter is located beneath the cab. Remove the

retaining screws E. Carefully slide the filter from its

holder.

3 Knock loose dust off the filter. Wash the filter in clean

water. Allow to dry.

Note: Do not squeeze the filter to dry it. Shake off the bulk

of the water, then let the rest drain off. If the filter was

clogged, clean it more often.

4 Carefully slide the filter into its holder. Fit and tighten

the retaining screws E.


9803/3260

Section 3

13 - 1

Issue 1

S099850S145280



13 - 2

Cab Heater Fil ter (From Serial No. 430001)



parking brake and set the transmission to neutral.

Lower the attachments to the ground and stop theengine.

2 Remove the cover retaining screws (2 off) and then

remove the cover, item E.

3 Knock loose dust off the filter F. Carefully blow

compressed air through all the folds of the fi lter, blow in

the opposite direction to the arrows marked on the

filter.

Note: The compressed air must be set at a pressure nogreater than 7 bar (100 lb/in2 ).

4 Refit the cover E and secure with the retaining screws

(2 off).


9803/3260

Section 3

13 - 2

Issue 1

S209400

F

E



14 - 1

AIr Fil ter Pre-Cleaner

Note: DO NOT run the engine with the pre-cleaner removed.

Empty Pre-cleaner - for Interval see Service Schedule

1 Unscrew wingnut C and lift off cover D.

2 Carefully remove the dust bowl E and empty out any

dust. Make sure that no dust is spilt into the air intake.

3 Wipe the bowl clean and re-assemble the pre-cleaner.

Note: To clean oil and grease from the pre-cleaner, wash in

hot water with a little detergent. Dry before refitting.

Note: Certain types of collector bowl may not have indicator

markings, in which case empty the unit when one third full.


9803/3260

Section 3

14 - 1

Issue 2*

S142940

*



14 - 2

Ai r Fi lter

Renew Outer Element - for Interval see Service Schedule

! CAUTION

The outer element must be renewed immediately if the

warning light on the instrument panel illuminates.2-3-3-1

Note: The elements must be renewed only. Do not attempt

to clean them with an airline or by washing. Do not run the

engine with raincap, pre-cleaner or dust valve removed.

1 Unscrew nut A and remove outer element B.

2 Clean inside canister and dust valve C.

3 Fit new element B. Test seating of seal D by smearing

with grease and checking for witness mark at base ofcanister.

4 If the seal is correct, re-insert new outer element and

tighten nut A.

5 Ensure that dust valve C is at the bottom when refitting.

6 Check the security and condition of the induction hose

and its clips. Ensure that the restriction indicator sensor

is connected.

Renew Inner Element - for Interval see Service Schedule

The inner element must be renewed at latest every third time

the outer element is renewed. As a record, mark the innerelement with a felt tip pen each time the outer element isrenewed.

1 Prevent dust from entering the engine by disconnecting

the induction hose H.

2 Unscrew nut A and remove outer element B.

3 Unscrew nut E and remove inner element F.

4 Clean inside canister and dust valve C.

5 Test seating of seal G by smearing with grease prior to

inserting new element F, then removing to check for

witness mark at base.

6 If the seal is correct, re-insert new inner element and

tighten nut E.

7 Insert new outer element B and test seating of seal D

as previously described.

8 If the seal is correct, re-insert new outer element and

tighten nut A.

9 Reconnect the induction hose H. Ensure that the

restriction indicator sensor is reconnected.


9803/3260

Section 3

14 - 2

Issue 2*

S142970

*



15 - 1

Parking Brake

The parking brake should be fully engaged when the lever is

vertical. The parking brake indicator light should light whenthe brake is engaged with the forward/reverse lever away

from neutral (starter switch at IGN).

! CAUTIONThe parking brake must not be used to slow the machine

from travelling speed, except in an emergency,

otherwise the efficiency of the brake will be reduced.

Whenever the parking brake has been used in an

emergency, always renew the brake pads.4-2-1-1/1

!WARNING Asbestos dust can damage your lungs. The brake pads

contain asbestos. Wear a face mask and gloves when

working on or near the brake pads. Dispose of brake

dust and used brake pads in accordance with local

regulations.2-1-1-7

Check Adjustment - for Interval see Service Schedule

Pads should just touch disc as at A . Adjust at handle grip B

if required and then test the parking brake as described on

page G/21 - 1.

Pad Renewal

Renew pads when thickness C of the friction material is 3mm (0.125 in).

Back off all adjustment, slacken nut D and withdraw pads.

Install new pads and set the parking brake as described on

page G/21 - 1.


9803/3260

Section 3

15 - 1

Issue 1

S151890

A

B

C D



Parking Brake - 5 Speed Gearbox Only

To renew the brake pads, the parking brake caliper

assembly must be removed, for this reason we recommendthat only competent maintenance engineers renew the pads.

The parking brake should be fully engaged when the lever is

vertical. The parking brake indicator light should light when

the brake is engaged with the forward/reverse lever away

from neutral (starter switch at IGN).

! CAUTIONThe parking brake must not be used to slow the machine

from travelling speed, except in an emergency,

otherwise the efficiency of the brake will be reduced.

Whenever the parking brake has been used in an

emergency, always renew the brake pads.4-2-1-1/1

!WARNINGBefore adjusting the parking brake, make sure that the

machine is on level ground. Put chocks each side of all

four wheels. Disconnect the battery so that the engine

cannot be started. If you do not take these precautions

the machine could run over you.2-3-2-4

15 - 2

Test the parking brake as described on page G/24-2. If the

machine moved during the test, check the pads and/or takeup the cable slack.

1 Check the Pads

Use feeler gauges and check the gap between the

brake disc A and the face of the brake caliper housing

( B ). The gap should be greater than 1mm (0.040 in.). Ifthe gap is less than 1mm renew the pads.

2 Take Up the Cable Slack

Disengage the parking brake (lever horizontal). Turn

handle grip C clockwise, half a turn. Test the parking

brake. If the brake fails the test, repeat procedure.

3 Renew the Brake Pads

a Disengage the parking brake (lever horizontal). Turn

handle grip C to bring pin D central in its slot.b Remove clevis E, from top hole.

c Loosen and remove bolts F, remove the caliperassembly.

d Remove the old brake pads from the caliper

housing. Fit new pads, align the flat G and raised

portion H appropriately in the caliper housing.

e Refit the caliper assembly to the gearbox, torque

tighten bolts F to 244 Nm (180 lbf ft).f Refit clevis E, in the top hole.

g Set the parking brake as described on page G/24-

2.


9803/3260

Section 3

15 - 2

Issue 4

S234140BS236080

S234140A

1. 0 m m

( 0. 0 4 0 i

n

A236450

B

A

C D

F E

F

G H



15 - 3

Service Brakes

!WARNINGFaulty brakes can kill. If you have to add oil to the brake

reservoir regularly get the brake system checked by your

JCB distributor. Do not use the machine until the fault

has been put right.2-3-2-5

Checking The Foot Brake Fluid Level (to serial number

430000) - for interval see Service Schedules

1 If an adjustable steering column is fitted, slackensteering wheel tilt lock A . Move the steering wheel

towards the rear of the machine.

2 Remove the reservoir cap B and check the level. The

MAX and MIN marks are etched on the side of thereservoir.

!WARNINGUse of incorrect fluid will cause serious damage to the

seals which could in turn cause brake failure.BRAK 1-1

3 If necessary, add fluid. If the system has fallen below

the MIN mark add brake fluid and then bleed the

system (see page G/11-1).

! CAUTIONMake sure the steering column is fully clamped before

driving the machine.5-2-1-3

4 Refit the reservoir cap. If an adjustable steering columnis fitted, adjust the column to give the required position.

Secure the steering column with tilt lock A .

Checking The Foot Brake Fluid Level (from serial number

430001) - for interval see Service Schedules





2 Remove the reservoir cap A and check the level. The

MAX and MIN marks are marked on the side of the

reservoir B. If necessary, add fluid as in Step 3.

If the system has fallen below the MIN mark add brakefluid and then bleed the system (see page G/11-1).



3 If required, carefully pour the recommended fluid (DO

NOT USE ORDINARY BRAKE FLUID) until it reaches

the correct level.

4 Refit the reservoir cap. Wipe up any spillage.


9803/3260

Section 3

15 - 3

Issue 1

S145080

B

A

S208981

A

B

**



16 - 1

Battery

!WARNING

Batteries give off an explosive gas. Do not smoke when

handling or working on the battery. Keep the batteryaway from sparks and flames.

Battery electrolyte contains sulphuric acid. It can burn

you if it touches your skin or eyes. Wear goggles. Handle

the battery carefully to prevent spillage. Keep metallic

items (watches, rings, zips etc) away from the battery

terminals. Such items could short the terminals and burn

you.

Set all switches in the cab to OFF before disconnecting

and connecting the battery. When disconnecting the

battery, take off the earth (-) lead first.

When reconnecting, fit the positive (+) lead first .

Re-charge the battery away from the machine, in a well

ventilated area. Switch the charging circuit off before

connecting or disconnecting the battery. When you have

installed the battery in the machine, wait five minutes

before connecting it up.5-3-4-3

First Aid - Electrolyte

EYESFLUSH WITH WATER FOR 15 MINUTES. GET MEDICAL

HELP FAST.

IF SWALLOWEDDO NOT INDUCE VOMITING. DRINK LARGE QUANTITIES

OF WATER OR MILK. Then drink milk of magnesia, beaten

egg or vegetable oil.

SKINFLUSH WITH WATER. REMOVE AFFECTED CLOTHING.

Cleaning the Battery

Check the battery regularly for dirt, corrosion and damage.

Dirt mixed with electrolyte or moisture on the top of the

battery can cause a discharged condition in the battery. Use

baking soda or ammonia and flush the outside of the battery

with water. Use a special cleaner to prevent corrosion on thebattery terminals.

Checking the Electrolyte Level

!WARNING

Do not top the battery up with acid. The electrolyte couldboil out and burn you.2-3-4-6

Remove covers. Look at the level in each cell. The


9803/3260

Section 3

16 - 1

Issue 2*

*



16 - 2

Battery

Jump Starting - Safety

!WARNING

If you try to charge a frozen battery, or jump-start and

run the engine, the battery could explode

Do not use a battery if its electrolyte is frozen. To

prevent the battery electrolyte from freezing, keep the

battery at full charge.

Batteries give off a flammable gas that can explode.

Do not smoke when checking the battery electrolyte

levels. When starting from another machine, make sure

the two machines do not touch. This prevents any

chance of sparks near the battery. Sparks could ignite

the battery gas. If that happens the battery could

explode.

Even with the starter switch set to off some circuits will

be energized when the external power supply is

connected. Set all the machine switches to their OFF

positions before connecting the external power supply.

Do not connect a booster supply directly across the

starter motor. Doing this could bypass the neutral safety

switch and the engine can start with the transmission ingear. The machine could then run away and kill o r inju re

bystanders.

Use only booster cables which are in good condition

with securely attached connectors. Connect both ends

of one booster cable before connecting the other one.5-2-2-3

Jump Starting - Procedure

1 Make sure that the parking brake has been engaged

and the transmission set to neutral.

2 Lower the loader shovel to the ground, if it is not

already there. If the machine is fitted with hose burst

protection valves, the shovel will not lower, in this

instance, install the loader arm safety strut.

3 Set all switches in the cab to the 'OFF' position.

4 a Connect the positive (+) jump lead from the booster

supply to the positive (+) battery terminal.

b Connect the negative (-) jump lead from the booster

supply to a good frame earth, away from the battery.

Note: A good frame earth is part of the machine mainframe,

free from paint and dirt.

5 Start the engine.

6 a Disconnect the negative (-) jump lead from the

machine frame earth.

b Disconnect the positive (+) jump lead from the

positive (+) battery terminal.


9803/3260

Section 3

16 - 2

Issue 1



18 - 1

Hydraulic Oil Cooler


1 Raise and lock the loader arms, see page 3/5 - 1.

2 Release bolts A and remove the radiator grille.

3 Brush off all debris from the cooler tubes and fins.

Make sure the loosened material is brushed out of the

cooler enclosure.

4 Refit the radiator grille.


9803/3260

Section 3

18 - 1

Issue 1

S145230



19 - 1

Bulb Replacement

Headlight Bulb

1 Release 4 cover screws A, support the light unit and

remove the cover.

2 Release the sealed beam unit B from its electrical

socket (see note).

Note: Because of legislative requirements, some territories

may have a replaceable bulb fitted in the headlight unit, not

a sealed unit.

3 Fit a new sealed unit (see note) and assemble light unit.

Front Sidelight Bulb

1 Release 4 cover screws A, support the light unit and

remove the cover.

2 Release the sealed beam unit B from its electrical

socket (see note).

Note: Because of legislative requirements, some territories

may have a replaceable bulb fitted in the headlight unit, not

a sealed unit.

3 Release sidelight bulb C from its holder.

4 Fit a new sidelight bulb.

5 Refit the sealed unit (see note) and assemble light unit.


9803/3260

Section 3

19 - 1

Issue 1

S152260



19 - 2

Bulb Replacement (cont'd)

Note: Do not touch the new worklight bulb with bare fingers,

otherwise the bulb will be rendered useless.

Worklight Bulb

1 Remove screws H (2 off), support the light unit J

otherwise it could fall and break.

2 Lift and turn light unit J to gain access to connector L.

3 Disconnect at L.

4 Remove bulb by releasing clips M.

5 Do not touch bulb with bare f ingers. Fit a new bulb.

6 Reassemble light unit in the reverse order.

Front Indicator Light Bulb

1 Remove screws A (2 off) to release lens glass.

2 Release bulb by pushing in and turning 1/8 turn

anticlockwise. Remove the bulb.

3 Fit a new bulb. Make sure it is secure.



9803/3260

Section 3

19 - 2

Issue 1

S152250



19 - 3


Rear Brake/Sidelight & Indicator Bulb

Note: The illustration shows a sideshift machine, on

centremount machines the rear light assembly is mounted in

the cab roof.

1 Remove screws A (2 off) to release lens glass.

2 Release bulb by pushing in and turning 1/8 turn anti-

clockwise. Remove the bulb.



Fog Light Bulb (if fitted)

1 Remove screws B (2 off) to release lens glass.

2 Release bulb by pushing in and turning 1/8 turn

anticlockwise. Remove the bulb.




9803/3260

Section 3

19 - 3

Issue 2*

S152230

*



19 - 4


Note: The following text is not applicable to machines in the

U.S.A.

Number Plate Light Bulb

1 Remove screw B to release light cover.

2 Ease spring contact C to release the bulb.

3 Fit a new bulb. Make sure the bulb is seated in the

spring contact holes.


Cab Interior Light Bulb

1 Carefully lever light unit F from the roof, using a

screwdriver in the slot at one end.

2 Ease the spring contact G to release the bulb.

3 Fit a new bulb. Make sure the bulb is seated in the

spring contact holes.

4 Refit light unit F, take care not to trap the wires.


9803/3260

Section 3

19 - 4

Issue 2*

S152220

*



19 - 5


Note: Do not touch the new beacon bulb with bare fingers,

otherwise the bulb will be rendered useless.

Note: The following text is not applicable to machines in the

U.S.A.

Rotating Beacon Bulb

1 Remove screws A (3 off) and remove cover B.

2 Release spring clip C and ease bulb from holder D.

3 Disconnect bulb at E.

4 Do not touch bulb wi th bare f ingers. Fit a new bulb.

Make sure the bulb is seated correctly and the springclip C is secure.


Switch Illumination Bulbs

1 Unscrew the centre portion J of the switch.

2 Carefully remove the bulb using a pair of tweezers. It is

a straight pull from the holder, do not twist the bulb.

3 Fit a new bulb.

4 Refit the centre portion of the switch.


9803/3260

Section 3

19 - 5

Issue 2*

S152240

*



i

Section A Attachments

9803/3260

Section A

i

Issue 3*

Contents Page No.

Hydraulic Tool Circuit (H.T.C.)

Schematic Hydraulic Circuit 1 - 1

Circuit Description 1 - 2Flow Diverter Valve Removal and Replacement 1 - 3

Flow Diverter Valve Dismantling and Assembly 1 - 4

Flow Testing & Pressure Testing 1 - 5

Extradig Dipper Wear Pads - Upper/Lower

Inspecting the Top Wear Pads 2 - 1

Adjusting the Bottom Wear Pads 2 - 2

A uxiliary Valve

Removal and Replacement 5 - 1

Dismantling and Assembly 6 - 1

Pressure Testing 7 - 1

Schematic Hydraulic Circuits

Low Flow Circuit 10 - 1

High Flow Circuit 11 - 1

Extending Dipper fitted with Rockbreaker 12 - 1

*



1 - 1

Schematic Hydraulic Circuit

Component Key

1 Hydraulic Tank

2 Pump (Section 2)

3 Steering Priority Valve

4 Priority Flow Divider

5 Excavator Auxiliary Valve Block

6 Loader Valve Block

7 B.H.T.M.A. Class 'C' Quick Release Couplings

8 HTC Switch


9803/3260

Section A

1 - 1

Issue 1*


S209080



1 - 2

Circuit Descript ion

Oil from section P2 of hydraulic pump 2 enters the steering

priority valve 3 (associated circuits not shown). From here

the oil passes to flow diverter valve 4. This valve establishesa priority (and controlled) flow to the hydraulic tool circuit(HTC). If the hydraulic tool circuit has not been selected, the

oil passes from port B of valve 4 to the auxiliary backhoe

valve 5. From here the oil passes via the loader valve 6 to

tank 1.

When the HTC is selected a solenoid inside valve 4 is

energised, this causes the flow of oil inside the valve to be

diverted to port P and on to the HTC via quick release

couplings 7. Return oil from the HTC passes directly to tank

via hose C. The flow of oil from port P is regulated

regardless of changes in load pressure or pump flow. Any

excess oil is distributed to port B for use in other actuators

(eg. extending dipper).

The diverter valve 4 also incorporates a relief valve; when the


9803/3260

Section A

1 - 2

Issue 1*


S209070



1 - 3

Flow Diverter Valve

Removal and Replacement

!WARNINGMake the machine safe before working underneath it.

Park the machine on level ground, lower the arms. Apply

the parking brake, put the transmission in neutral and

stop the engine. Chock both sides of all four wheels.

Disconnect the battery, to prevent the engine being

started while you are beneath the machine.

GEN-1-2

Removal


parking brake and set the transmission to neutral. Lower

the backhoe and loader end to the ground and stop the

engine.

2 Operate the loader valve block control levers back and

forth to vent residual hydraulic pressure.

3 Disconnect all hydraulic hoses from the valve block and

plug all orifices to prevent ingress of dirt. Label each

hose before disconnecting, this will ensure correct

refitting.

4 Remove the electrical solenoid connector.

Replacement

Replacement is a reversal of the removal sequence.

!WARNING

Fine jets of hydraulic fluid at high pressure can

penetrate the skin. Do not use your fingers to check for

hydraulic fluid leaks. Do not put your face close to

suspected leaks. Hold a piece of cardboard close to

suspected leaks and then inspect the cardboard for

signs of hydraulic fluid. If hydraulic fluid penetrates your

skin, get medical help immendiately.

INT-3-1-10/1

Make sure that the hoses are correctly installed. The hose

connections from the flow diverter valve are as follows:

Port E = to the steering priority valve.

Port P = to the HTC quick release coupling

Port B = to the excavator auxiliary valve block

Port T = to the hydraulic tank

Note: The flow diverter valve ports should be stamped 'E',

'P', 'B' and 'T'.

After replacement check the flow setting and the relief valve

pressure settings (see pages A/1 - 5 and A/1 - 6).


9803/3260

Section A

1 - 3

Issue 1*


S209060



Flow Testing & Pressure Testing

1 - 5


9803/3260

Section A

1 - 5

Issue 1*


A209090



1 - 6

Flow Testing & Pressure Testing

!WARNING

Hydraulic Fluid

Fine jets of hydraulic fluid at high pressure can

penetrate the skin. Do not use your fingers to check for

hydraulic fluid leaks. Do not put your face close to

suspected leaks. Hold a piece of cardboard close to

suspected leaks and then inspect the cardboard for

signs of hydraulic fluid. If hydraulic fluid penetrates your

skin, get medical help immediately.

INT-3-1-10/1

!WARNING

Hydraulic Pressure

Hydraulic f luid at system pressure can injure you. Beforedisconnecting or connecting hydraulic hoses, stop the

engine and operate the controls to release pressure

trapped in the hoses. Make sure the engine cannot be

started while the hoses are open.

INT-3-1-11/1

Prepare the Machine



Lower the backhoe and loader end to the ground and

stop the engine.

2 Operate the loader valve block control levers back and

forth to vent residual hydraulic pressure.

3 Flow Testing

3.1 Connect a suitable pressure gauge, flow meter and

flow restrictor valve across the flow and return

couplings on the machine, as shown at A. For

reference, items are identified as:

X = Pressure Gauge

Y = Flow Meter

Z = Flow Restrictor Valve

CAUTION: Make sure that the flow restrictor valve Z is fully

OPEN (the adjusting knob screwed fully out) before starting

the engine.

3.2 Start the engine and set the R.P.M. to 1500.

3.3 Enable the HTC circuit, i.e. press the HTC switch B

to the 'ON' position.

3.4 Note the flow meter reading, the valve should be set

at 20 litres/min. If adjustment is required, loosen

locknut C and turn adjusting screw D until the

4 Pressure Testing

4.1 Use the flow restrictor valve to pressurise thecircuit. As the pressure rises watch the flow reading,

it should start to fall when the pressure reaches 138

bar (2000 lb/in2 ).

4.2 If adjustment is required, loosen locknut E and turn

adjusting screw F until the correct pressure is

obtained.

5 Stop the engine, vent residual pressure and remove the

pressure gauge, flow meter and flow restrictor valve.


9803/3260

Section A

1 - 6

Issue 1*




2 - 1

The Extradig dipper wear pads are bolt-on replaceable

items. They support and guide the inner dipper sectionduring extension and retraction. The following procedures

explain how to inspect, and where applicable, adjust the

pads.

There is a front and rear set of pads, each set comprises top

wear pads A and bottom wear pads B.

The top wear pads A are not adjustable and must be

replaced with new pads once they have worn to their limit.

See Inspecting the Top Wear Pads .

The bottom wear pads B are adjustable and take up the

wear on both the top and bottom pads. They must also be

replaced with new pads once they have worn to their limit.

See Ad just ing the Bot tom Wear Pads , page 2 - 2.

New wear pads A and B must be replaced as a set and

fitted by a qualified service engineer.

Inspecting the Top Wear Pads

Park the machine on level ground. Engage the parking brake

and put the transmission in neutral.

Position the boom and dipper as shown at C. Retract the

Extradig dipper D. Make sure that the bucket is clear of the

ground and the dipper is supported.

Stop the engine.

Inspect all the top wear pads, if the pads are worn to the

recess as shown at E then the pads must be replaced with

new ones. If the pads are worn near to their limit then

inspect them more frequently than recommended in the

Service Schedules.


9803/3260

Section A

2 - 1

Issue 1*


S148110

A

B

A

B

E

D

C



2 - 2

Adjust ing the Bottom Wear Pads

Park the machine on level ground. Engage the parking brakeand put the transmission in neutral.

Support the boom and dipper as shown at C.

Stop the engine.

Clean the sliding faces of the inner dipper F with a suitable

solvent.

Start the engine. Retract the Extradig dipper D. Make sure

that the bucket is clear of the ground and the dipper is

supported.

Stop the engine.

With grease, mud etc. removed from the sliding facesvisually check the gap between inner dipper and top wear

pad A, as shown at G. The gap should be no greater than

1.5 mm ( 1 / 16 in).

If the gap is greater than 1 / 16 in (1.5 mm) then adjust as

follows:

a Remove one adjusting bolt H and discard one washer

J.

b Refit and tighten bolt H.

c Repeat the procedure for the remaining 3 adjusting

bolts H on the same side of the dipper.

d Visually re-check the gap is no greater than 1.5 mm

( 1 / 16 in) as shown at G, if necessary repeat steps a to c

for the other 4 bolts H on the opposite side of the

dipper.

e Make sure that the inner dipper seats central to the

sides of the outer dipper.

Note: Remember to alternate sides each time an adjustment

is made.Note: When all the adjusting washers J have been removed

and the clearance is greater than 1.5 mm ( 1 / 16 in), then wear

pads A and B must be replaced as a set and fitted by a

qualified service engineer.

When the adjustments have been completed, apply Waxoyl

to the runners of the inner dipper F.


9803/3260

Section A

2 - 2

Issue 1*


S148120

G G

J

HA A

JF

D

H

C

H



6 - 1


9803/3260

Section A

6 - 1

Issue 1

Auxiliary Valve

S218240

S218210

S218930

S218220

11

12

13

14

15

16

18

20

21

22

23

109

8

30

30A

29

29A

7

6

21

3

4

5

1, 2

17

19

2428

2725

26

X

Y

Z

A



6 - 2

Auxi liary Valve

Following removal of the valve from the machine, plug all

ports and thoroughly clean the outside of the casing.

Dismantling and Assembly

Make sure the working area is clean.

The numerical sequence on the illustration is intended as a

guide to dismantling. For assembly reverse the sequence.

Depending on the nature of the fault, it may only be

necessary to work on individual parts of the assembly as

follows:

1 If there is an oil leak between the units, carry out the

sequence involving items 1 to 7.

2 If a spool is faulty carry out the sequence involving items

8 to 23.

3 If a check valve is faulty, remove tie-rod X and carry out

the sequence involving items 24 to 28.

4 Pressure relief valves 29 and 30 can be individually

removed.

When Dismantling

If removing units 4, place the assembly with its output unit 5

resting on a firm flat surface with tie-rods X, Y and Z vertical.

Remove and discard seals 6 and shims 7 from between the

units. Identify the relative positions of the units.

The exploded view shows valve section 4.

To facilitate removal of shoulder screw 13, prevent spool 19

rotating by inserting a suitable rod (e.g. a screwdriver blade)

in the operating linkage hole at the end of the spool.

In the course of dismantling:

1 Discard wiper seals 20, 23 and 'O' rings 21, 22.

2 Unless damaged, do not remove 'O' ring 27 and back-up

seal 28 from valve guide 24. If damaged remove and

discard.

3 Discard 'O' rings 29A.

4 Discard 'O' rings 30A.

When Assembling

Fit new 'O' rings, back-up seals and shims to replace those

discarded in the dismantling procedures.

Use a suitable rod through the operating linkage hole to

prevent spool 19 rotating while installing shoulder screw 13.

When installing valve guide 24, make sure the hole in the

side aligns with the tie-rod hole in the casing.

When clamping the units together, position the assembly on

the bench with the tie-rods horizontal. Tighten nuts 1 onto

tie-rods in the order X, Y, Z and then X again.

Fit seal retainers 10 and 18 with rounded radius (item A )

nearest the housing.

Relief Valves

Ensure that ARV's 29 and 30 are correctly adjusted and

fitted in their specified positions. Refer to page A/7-1 for

pressure testing procedures.

Torque tighten the ARV's to 20 - 24 Nm (14.75 - 17.7 lbf ft,

2.04 - 2.44 kgf m).

Torque Settings

Item Nm Kgf.m lbf.ft

1 26 - 28 2.65 - 2.85 19.1 - 20.6

8, 11, 13 5 - 8 0.51 - 0.82 3.7 - 5.9


9803/3260

Section A

6 - 2

Issue 1

Auxiliary Valve



7 - 1

Pressure Testing

Auxi liary Relief Valve (A.R.V.)

Make sure that the hydraulic oil is at working temperature,

i.e. 50°C (122°F).

Lower the backhoe bucket and loader shovel to rest on the

ground, lower the stabilisers and stop the engine.

Note: For clarity, the illustration shows some of the hoses

removed.

1 Connect a 0 - 400 bar (0 - 6000 lbf/in2 ) pressure gauge

to pressure test connector A next to the priority valve.

2 Make sure that the area is clear of all personnel.

3 Extending Dipper:

3.1 Set the engine speed to 1000 RPM.

3.2 Raise the boom and dipper. Fully extend the

extradig dipper and hold, the pressure gauge will

indicate the setting of the head side ARV (item B ).

Refer to Technical Data, page E/1-3.

3.3 If the pressure is incorrect, slacken locknut C and

adjust cap D as required. Re-tighten the locknut

after the correct setting has been achieved.

3.4 Raise the boom and dipper. Fully retract the

extradig dipper and hold, the pressure gauge will

indicate the setting of the rod side ARV (item E ). If

the pressure is incorrect, slacken locknut F and

adjust cap G as required. Re-tighten the locknut


4 Knuckle Boom:

4.1 Set the engine speed to 1000 RPM.

4.2 Raise the boom. Swing the knuckle to the left, the

pressure gauge will indicate the setting of the head

side ARV (item B ). Refer to Technical Data, page

E/1-3.

4.3 If the pressure is incorrect, slacken locknut C and

adjust cap D as required. Re-tighten the locknut


4.4 Raise the boom. Swing the knuckle to the right, the

pressure gauge will indicate the setting of the rod

side ARV (item E ). If the pressure is incorrect,

slacken locknut F and adjust cap G as required.

Re-tighten the locknut after the correct setting has

been achieved.


9803/3260

Section A

7 - 1

Issue 1

Auxiliary Valve

A218200

S218190

S147680B

EF

G

DC

B

A



P2A

3B

3A

3M

3L

3N

1A

4V

4E

4M

4W

4F

4N

4P

7

3Q

1A3P

7B

112D

12B

12A12

P

PP

CF

EF

2A

3C

3HP2 P1

S

T

6

6A

4

3

13

26

9 8 0 3 / 3 2 6 0

I s s u e1

Low Flow Attachment Circuit



9 8 0 3 / 3 2 6 0

I s s u e 1

Low Flow Attachment Circuit

Refer also to basic machine circuit on page E/2-2.

Schematic below shows additional items used with ‘Low

Flow’ attachment circuit.

Component Key

P1 Pump, Main SectionP2 Pump, Secondary Section

P2A Pressure Test Point (auxiliary attachments)

S Suction Line

T Tank

1A Neutral Circuit Line2A Neutral Circuit Line


3A Pressure Test Point (M.R.V.)

3B Main Relief Valve

3C Loader Lift Ram Spool

3H Load Hold Check Valve3L Unloader Valve Spool

3M Unloader Pilot Valve

3N Unloader Check Valve3P Pressure Test Point (Unloader)

3Q Hydraulic Speed Control Solenoid

4 Excavator Valve Block4E Dipper Spool

4F Bucket Spool

4M Dipper Ram Head Side A.R.V.

4N Dipper Ram Rod Side A.R.V.

4P Bucket Ram Head Side A.R.V.

4V Load Hold Check Valve4W Load Hold Check Valve

6 In-tank Filter

6A Filter By-pass Valve

7 Priority Valve

7B Connection to Steer Circuit12 Attachment Valve Block12A Attachment Valve Spool

12B Load Hold Check Valve

12C Attachment A.R.V.

12D Attachment A.R.V.

13 Anti-cavitation Check Valve

26 Hydraulic Oil Cooler67 Low Flow Attachment (e.g. Extradig, Jaw

Bucket)



P2A

3B

3A

3M

3L

3N

1A

7

3Q

1A3P

7B

12C12D

12B

12A

12

P

PP

CF

EF

2A

3C

3HP2 P1

S

T

6

6A

4V

4E

4M

4W

4F

4N

4P

4

3

13

26

8

9A

9

4Q

9 8 0 3 / 3 2 6 0

I s s u e1

High Flow Attachment Circuit



9 8 0 3 / 3 2 6 0

I s s u e 1

High Flow Attachment Circuit

Refer also to basic machine circuit on page E/2-2.

Schematic below shows additional items used with ‘High

Flow’ attachment circuit.

Component Key



S Suction Line

T Tank

1A Neutral Circuit Line2A Neutral Circuit Line





3H Load Hold Check Valve3L Unloader Valve Spool


3N Unloader Check Valve3P Pressure Test Point (Unloader)


4 Excavator Valve Block4E Dipper Spool

4F Bucket Spool

4M Dipper Ram Head Side A.R.V.



4Q Bucket Ram Rod Side A.R.V. (see note)4V Load Hold Check Valve

4W Load Hold Check Valve

6 In-tank Filter

6A Filter By-pass Valve

7 Priority Valve7B Connection to Steer Circuit

Note: Au xi li ar y rel ief va lve 4Q is only fitted on

machines equipped with a Powerbreaker circuit.

8 Diverter Valve9 Solenoid Valve

9A Check Valve

12 Attachment Valve Block

12A Attachment Valve Spool

12B Load Hold Check Valve12C Attachment A.R.V.

12D Attachment A.R.V.


21 Sequence Valve

23 Quick Release Coupling

26 Hydraulic Oil Cooler68 High Flow Attachment (e.g. Powerbreaker)



P2A

3B

3A

3M

3L

3N

1A

7

3Q

1A3P

7B

12C12D

12B

12A

12

P

PP

CF

EF

2A

3C

3HP2 P1

S

T

6

6A

4V

4E

4M

4W

4F

4N

4P

4

3

13

26

8

9A

9

4Q

9 8 0 3 / 3 2 6 0

I s s u e1

Extending Dipper fitted with Rockbreaker



ii

Section B Body & Framework

9803/3260

Section B

ii

Issue 1

Contents Page No.

Loader Front End

Loader Arms

- Removal and Replacement 20 - 1

Stabiliser Legs (Sideshift Machines)


Stabiliser Legs Centremount Machines)


Backhoe

Slew Cylinders (Sideshift Machines)

- Dismantling and Assembly 30 - 1

King Post & Carriage (Sideshift Machines)


Boom & Dipper




1 - 1

Engine Side Panels


!WARNING

Raised loader arms can drop suddenly and cause

serious injur y. Before working under raised loader arms,

fit the loader arm safety stru t.GEN 3-2

1 Raise and lock the loader arms.

!WARNING

Do not remove the engine side panels while the engine is

running.2-3-1-5

2 Stop the engine and remove the key.

3 Remove the side panel fixing screw A. Lift the side

panel off.

4 To replace the side panel; slot into position and secure

with fixing screw A.

Engine Cover


1 Remove the side panels.

!WARNING

A hot exhaust w il l burn you. Make sure the exhaust s tack

is cool before removing it.2-3-1-6

2 Loosen clamp F and remove exhaust stack D.

3 Loosen clamp C and remove pre-cleaner B.

4 Remove bolts E, pull cover G forward to release pins H.

5 Lift the engine cover off.

Replacement is a reversal of the removing procedure.


9803/3260

Section B

1 - 1

Issue 1

S146060

S145240



2 - 1

Rivet Nuts

Fitting Procedure

A 'Rivet Nut' is a one piece fastener installed 'blind' from

one side of the machine body/framework. The rivet nut iscompressed so that a section of its shank forms an 'upset'

against the machine body/framework, leaving a durable

thread (see il lustrations).

Rivet nuts are fitted to various parts of the machine body

and framework. They are used in a number of applications,for instance, hose clamp and cab floor plate retention etc.

Various sized rivet nuts are available, see the table below to

determine the size of rivet nut to be used for particular

applications.

If for any reason a new rivet nut requires fitting, then the

correct installation procedure must be followed:

1 Drill a hole in the machine body/framework where the

rivet nut is to be fitted. De-burr hole edges.

2 Screw the rivet nut onto the mandrel of the installation

tool. The bottom of the mandrel should be in line with

the bottom of the rivet nut, shown at A.

3 Wind the body of the installation tool down the

threaded mandrel until it touches the head of the rivet

nut, shown at B.

4 Insert the rivet nut (assembled to the tool) into the hole

drilled in step 1.

5 Hold handle C and at the same time draw the mandrel

into the installation tool by turning nut D. The rivet nut

will contract in length and form an 'upset' (smooth

bulge) seating itself against the body/framework (see

inset E ).

Note: The thread of the rivet nut must not be stripped, take

care when 'upsetting' the rivet nut.

6 Remove the installation tool.

Specifications (all dimensions i n mm)

Rivet Nut Rivet Nut Material Rivet Drill

Thread Outside Thickness Length Hole

Diameter Diameter (Total) Dia.

M5 7 0.25 - 3.00 14.00 7.10

3.00 - 5.50 17.00

M6 9 0.50 - 3.00 16.00 9.10

3.00 - 5.50 19.00

M8 11 0.50 - 3.00 18.00 11.10

3.00 - 5.50 21.00

Note: In an emergency, and if no installation tool isavailable, it is possible to fit a rivet nut by using a nut and

bolt the same thread diameter as the rivet nut beinginstalled. However, this is not the recommended method.


9803/3260

Section B

2 - 1

Issue 1

S150970



10 - 1

Roll Over Protection & Falling Object

Protection (ROPS/FOPS) Structure

Checking

!WARNING

The Machine is fitted with a roll over protection structu re

(ROPS) and a falling object protection structure (FOPS).

You could be killed or seriously injured if you operate

the machine with a faulty or missing ROPS/FOPS.

Modified and incorrectly repaired ROPS/FOPS are

dangerous. If the ROPS/FOPS has been in an accident,

do not use the machine until the structure has been

repaired and inspected by sui tably qualified personnel.INT-2-1-9/1

For assistance, contact your JCB distributor. Failure to take

these precautions could result in death or injury to theoperator.

Check the structure for damage. Check that the mounting

bolts are installed and undamaged. Check the bolt torques.

Tighten them to the correct torque if necessary.

Bolts A 237 Nm (175 lbf ft)

Bolts B 476 Nm (352 lbf ft)

Bolts C 237 Nm (175 lbf ft)


9803/3260

Section B

10 - 1

Issue 1

S144180



12 - 1


9803/3260

Section B

12 - 1

Issue 1*

Air Conditioning

D

E

A

L

K

B

C



Operation

To maintain optimum operator comfort in warm climates or

during seasons of high ambient temperature, the airconditioning system delivers cool, dehumidified air into the

cab. Cooling is provided by passing the warm ambient air,together with recirculated air, over an evaporator coil in the

air conditioning unit.

The air conditioning system is a closed circuit through whichthe refrigerant is circulated, its state changing from gas to

liquid and back to gas again, as it is forced through the

system.

The major components of the system are the compressor A ,

condenser B, receiver drier C, expansion valve D andevaporator coil E.

To operate the air conditioning, the operator turns the air

conditioning switch F clockwise to the ON position and turnsthe blower switch G clockwise to select a suitable blower

running speed for the ambient conditions. Air vents H can beadjusted as at X to vary and direct the airflow. If the air

conditioning system pressure is too low or too high, the

amber light J will illuminate.

Provided that the ambient temperature is above 0°C and the

blower switch is away from the OFF position, the airconditioning will switch on. The compressor's

electromagnetic clutch operates, engaging the compressordrive from the engine pulley system. The compressor A

draws in low pressure refrigerant gas from the suction line

(evaporator to compressor) and increases refrigerant

pressure through compression. Increasing pressure alsoincreases refrigerant temperature.

High pressure refrigerant is forced from the compressor to

the condenser B, mounted below the cab. Ambient air is

drawn across the condenser fins by three integral cooling

fans. In the condenser, the refrigerant changes state to ahigh pressure, high temperature liquid but with a lower heat

content.

The refrigerant passes through the receiver drier C. Thereceiver drier serves as a reservoir for refrigerant and also

contains a desiccant to remove moisture from the system.

12 - 2


9803/3260

Section B

12 - 2

Issue 1*

Air Conditioning

A181590

G



12 - 3

Operation (cont'd)

The high temperature, high pressure refrigerant is forced by

compressor action into the expansion valve D, which meters

the amount of refrigerant entering the evaporator. In the

expansion valve the refrigerant instantaneously expands tobecome a low pressure, low temperature liquid.

The refrigerant is drawn through the evaporator coil E by the

suction of the compressor. The temperature of refrigerant is

now considerably below that of the air being drawn across

the evaporator coil by the blowers. Heat is transferred fromthe ambient and recirculated air to the refrigerant, causing

the low pressure liquid to vaporise and become a low

pressure gas. Moisture in the air condenses on the

evaporator coil and is drained away via condensate drain

tubes through the cab floor.

Cool de-humidified air is emitted through air vents into the

cab.

The low temperature, low pressure, high heat content

refrigerant gas, is now drawn by suction back to thecompressor, where the cycle is completed.

Control

Control of the system is achieved by the cyclic action of the

compressor's electromagnetic clutch. The thermostat switch

senses the evaporator coil temperature by means of a

capillary tube and cycles the compressor clutch on and offto prevent freezing of condensate on the evaporator coil.

The signal from the thermostat switch is sent to the

compressor clutch via two pressure switches. These are

designed to disengage the compressor clutch and protect

the system from damage that would be caused by eitherrefrigerant loss or excessive pressure.

The low pressure switch K is connected to the suction hose

adjacent to the compressor. If the pressure in the suction

hose falls below the low pressure switch setting, it opens,

interrupting the supply from the thermostat to disengage thecompressor clutch. At the same time, lamp J illuminates.

The high pressure switch L is connected to the discharge

hose adjacent to the compressor. If the pressure in thedischarge hose rises above the high pressure switch setting,

it opens, interrupting the supply from the thermostat todisengage the compressor clutch. At the same time, lamp J

illuminates.

Switch Pressures

Low Pressure SwitchCut in = 2.1-2.6 bar (30-38 lbf/ in2 )

Cut out = 0.3-0.6 bar (4-8 lbf/ in2 )

High Pressure Switch

Cut in = 15.5-19 bar (225-275 lbf/ in2 )

Cut out = 23.4-24.8 bar (340-360 lbf/ in2 )

Safety Procedures

The air conditioning system uses refrigerant under pressure

in a closed circuit. Any service procedure which breaks intothe closed circuit and therefore requires discharging of the

system, must only be carried out by an air conditioningengineer. The following guidelines should be adhered to by

all personnel servicing the air conditioning system.

!WARNINGThe air conditioning system is a closed loop system and

contains pressurised refrigerant. No part of the system

must be disconnected except by a qualified refrigeration

engineer.4-3-4-1

1 It is critical that the correct refrigerant is used and that

charging is done only by qualified personnel. It is illegal

to discharge the refrigerant into the atmosphere but as

a precaution in case of accidental leakage, dischargingand charging of the vehicle refrigerant system must be

conducted in a well ventilated area.

2 Containers of refrigerant should be stored in a cool

environment away from direct sunlight.

!WARNINGDo not carry out welding operations close to the air

conditioning refrigerant circuit. A poisonous gas is

produced when refrigerant comes into contact with

naked flames. Do not smoke or allow naked flames close

to the refrigerant circuit.

BF 1- 9

3 Do Not perform welding operations close to refrigeranthoses (maintain a distance of at least 0.5m from hoses).

4 Do Not steam clean refrigerant system components.

5 When charging or discharging the refrigerant system,

no smoking or naked flames should be allowed in theimmediate vicinity. The refrigerant does not give off a

poisonous odour, however, when it comes into contact

with a naked flame, a poisonous gas is produced.

6 When handling refrigerant, rubber gloves and goggles

should be worn. Operators should ensure no refrigerantcomes into contact with the skin. Particular care should

be taken when connecting or disconnecting charging

hoses or pressure switches. When these components

are connected to the system, a short release of

refrigerant occurs. This results in a high velocity, very

cold gas being emitted from the connection point.


9803/3260

Section B

12 - 3

Issue 1*

Air Conditioning



12 - 5

Fault Finding (cont'd)

Harness Wires

Use the illustration below to complete continuity checks on

the air conditioning system harness wires.

Key

1 Fuse, 25A 2 Pressure Switch

3 Pressure Switch

4 Clutch Relay

5 Compressor Clutch

6 Fuse, 25A

7 Blower Relay8 Cooling Fans

9 Fan Relay

10 Blower ON/OFF/Speed Switch

11 Blower12 Warning lIght

13 Warning Light Relay14 Thermostat

15 From Starter Switch

Colour Code

BL Black

Br BrownR Red

Zones

A Engine

B Cab

C Air Conditioning Unit


9803/3260

Section B

12 - 5

Issue 1

Air Conditioning

A209120



12 - 6

Fault Finding (cont'd)

No Air Conditioning

CHECK ACTION

1 Are the controls set correctly, i.e. air conditioning YES: Check 2

selected, thermostat switch set to coldest position NO: Reset controls and retest.

and blower switched on?

2 Is the air conditioning (evaporator) blower working? YES: Check 3.

NO: Check 4.

3 Is the compressor running (visual check of pulley/clutch)? YES: Check11.

NO: Check 7.

4 Is the air conditioning fuse(s) blown? YES: Renew fuse(s) and retest.

NO: Check 5.

5 Is there a 12V supply to the pressure switch harness? YES: Check 6.(See Pressure Switch Testing ) NO: Check 9.

6 Does the compressor clutch engage with both YES: Check 7.pressure switches bypassed? NO: Renew the compressor clutch and retest.

(See Pressure Switch Testing )

7 Does the compressor clutch engage with YES: Renew high pressure switch and retest.

HP switch bypassed? NO: Check 8.


8 Does the compressor clutch engage with YES: Renew low pressure switch and retest.

LP switch bypassed? NO: Charge check required by refrigeration engineer.


9 Does the clutch engage with thermostat switch YES: Renew thermostat switch and retest.

bypassed? NO: Check all electrical connections.

10 Are blower switch and wiring OK? YES: Renew blower motor.

NO: Renew switch or wiring.

11 Is sight glass indication OK? YES: Check 12.

NO: Charge check required by refrigeration engineer.

12 Is condensor air flow blocked? YES: Clean condensor and radiator.

NO: Check 13.

13 Is evaporator air flow blocked? YES: Clean filter and, if necessary the evaporator.

NO: Call in refrigeration engineer.


9803/3260

Section B

12 - 6

Issue 1

Air Conditioning



12 - 7

Checking Refrigerant Charge Level

The pressure in the system, i.e. the refrigerant charge level

can be determined by checking the state of refrigerant at thereceiver drier sight glass. The receiver drier is mounted

beneath the cab, on the left hand main chassis sidemember.

If the level of charge is correct the sight glass will be clear. If

the charge is low bubbles will be seen. Bubbles may also bean indication of inadequate cooling, due to a restriction of air

flow around the condenser coil. Recharging of the system

should be carried out by an air conditioning engineer. Check

refrigerant charge level as follows:

1 Park the machine on firm, level ground. Lower thebackhoe and loader to the ground. Engage the parking

brake.

2 Chock the wheels, to prevent movement.

!WARNINGMake the machine safe before getting beneath it. Lower


brake; remove the starter key, disconnect the battery.

2-3-2-2

3 Start the engine and run at idle. Switch air conditioningON to circulate refrigerant.

4 Check refrigerant charge level at sight glass A . (It will

be necessary to use a mirror and torch to view thesightglass, which is located at the top of the receiver

drier).

Leak Testing

Note: The refrigerant is heavier than air and will leak

downwards from the defective component. Check in stillconditions but in a well ventilated area.

Hose or pipe connections are likely leakage points of any

refrigerant circuit.

To test for leaks in the high pressure side of the system i.e.from the compressor output to the expansion valve, run the

air conditioning for a few minutes then switch off the engine

and test for leakage using an electronic leak detector.

To test for leakage in the low pressure side of the system,

switch off the air conditioning and leave for a few minutesbefore testing.

!WARNINGLeak testing in Air Conditioning systems should be

carried out only in a well ventilated area.BF 1-2

Tightening Leaking Hoses




engineer.4-3-4-1

The refrigerant hoses have crimped ferrule end fittings. The

hose connectors have an 'O' ring seal which compresses

when the connection is tight, creating an air tight seal.

Hoses are used to connect the inlets and outlets of thecompressor, condenser, receiver drier and expansion valve

(the evaporator coil is connected to the expansion valve

within the air conditioning unit using rigid pipes).

If leakage is detected from a hose connector, either by

means of an electronic leak detector or soapy water, tighten

the connector up and repeat the leakage test. If leakage isstill evident, it will be necessary to de-gas the system and

renew the connector 'O' ring seal.


9803/3260

Section B

12 - 7

Issue 1

Air Conditioning



13 - 1

Blower Motor

Removal

Note: Record all electrical connections prior to removal.

1 Disconnect the battery

2 Prepare the shroud assembly 13 for removal as follows:

a Remove and disconnect the radio speakers 1, 2 (to

gain access for steps b - f).

b Disconnect the cab light 3.

c Disconnect warning light 4.

d Disengage the blower switch 7 by pulling off knob 5

and removing nut 6.

e Repeat step d for the air conditioning switch

(thermostat) 10.

f Disconnect and remove any optional switches etc.

which may be mounted on the shroud assembly.

3 Support the shroud and remove screws 11 and 12. Note

that screws 12 are located inside the ventilation louvres

X.

4 Carefully lower the shroud away from the cab roof,

taking care not to snag cables etc. or the thermostat

capillary tube.

5 Disconnect the blower motor connecting wires. Support

the motor assembly 15 and remove screws 14. Carefully

lower the assembly clear.

Replacement is the reverse of the removal procedure.

If necessary, renew the blower mounting flange gasket.

Thermostat

To remove the thermostat, remove the shroud as described

for the blower motor. Disconnect the electrical wires from

thermostat 10 and disengage the sensor end of its capillary

tube from the evaporator fins.

For replacement the sequence should be reversed.

Compressor Clutch Relay

The compressor clutch relay is mounted on the battery

compartment. To remove it, simply disconnect it and remove

its securing screw.


9803/3260

Section B

13 - 1

Issue 1*

S209110

Air Conditioning

1

2

13

4

5

7

8 9

10

1211

11

11

14

15

14

14

14

12

3

6

X

X




!WARNING

Goggles and rubber gloves must be worn when pressure

switches are removed or fitted. A small amount of

refrigerant is released which can be harmful to the skin

and eyes.BF 1-10

Removal

1 Disconnect the electrical connections and unscrew the

pressure switch.

Replacement

Note: The high pressure switch has a red body, the low

pressure switch has a bronze body, both have 1/4 UNF

female threads.

1 Screw the pressure switch into the pressure switch port

and torque tighten sufficiently to form a gas-tight seal.

2 Run the air conditioning and check the pressure

switches for leaks. If any leaks are found, tighten the

pressure switch further until the leaking stops.

13 - 2

Pressure Switches

The 12V supply is fed from the thermostat to the

compressor clutch via the low and high pressure switches

which are wired in series.

The low pressure switch requires a minimum refrigerant

charge level to close its contact. The high pressure switchrequires the charge level to remain below the maximum limit

to keep its contact closed.

Both pressure switch contacts must be closed for the

compressor clutch to operate. If the compressor clutch will

not operate when air conditioning is selected, the fault maybe either electrical or system pressure.

Pressure Switch Testing

1 Switch the engine off so that the air conditioning

system cannot operate.

2 Disconnect the pressure switch harness from the main

vehicle harness and connect an external 12V power

supply to the pressure switch harness connector. If

both pressure switches are working correctly, and the

system is at the correct charge level, the compressorclutch will operate.

If the compressor clutch does not operate with the

external power supply, one of the pressure switches is

faulty or the level of refrigerant charge is insufficient to

close the low pressure switch.

High Pressure Switch Testing

1 Disconnect the air conditioning harness male/female

connectors from the high pressure switch 1.

2 Connect an external 12V power supply to the harness

connectors. If the compressor clutch does not operate,

renew the high pressure switch.

If the clutch operates check the low pressure switch.

Low Pressure Switch Testing

1 If the refrigerant charge level in the system is correct,

but the clutch will still not function, disconnect the air

conditioning harness male/female connectors from the

low pressure switch 2.

2 Connect an external 12V power supply to the harness

connectors. If the compressor clutch does not operate,

renew the low pressure switch.

Note: If both pressure switches operate correctly, check all

electrical connections and the compressor clutch relay.


9803/3260

Section B

13 - 2

Issue 1*

Air Conditioning

S181600

2

1



13 - 3

Condenser Coil

It is likely that over a period of time, because of the

machine's working environment, the airflow around the

condenser coil will become restricted due to a build up of

airborne particles.

If the build up of particles is severe, heat dissipation fromthe refrigerant to the air will be significantly reduced,

resulting in poor air conditioning performance.

In extreme cases, over pressurisation of the system occurs,

causing the high pressure cut out switch to operate and

switch off the system.

High pressure cut out can also be caused by an internal

blockage of the condenser coil.

Condenser Coil Cleaning

Take care not to damage the condenser fins or tubes.

Damaged fins must be straightened out to ensure a good

airflow through the coil.

The condensor is located beneath the cab at the rear of the

machine.

1 Park the machine on firm, level ground. Lower the

backhoe and loader to the ground.

2 Remove the starter key.

3 Chock both wheels

!WARNING

Make the machine safe before getting beneath it. Lower



4 Use compressed air or low pressure water to backflow

through the coil fins. Take care not to damage the fins.

5 Run the air conditioning and check cooling

performance..

Adjust ing the Compressor Drive Belt

!WARNING

Make sure the engine cannot be started. Disconnect the

battery before doing this job.2-3-3-5


backhoe and loader to the ground.

2 Remove the starter key.

3 Remove the left hand side panel.

4 Loosen bolts A, B and C.

5 Position the compressor so that there is 10 mm ( 3

/ 8 in)slack at point X.

6 Tighten bolt A, then bolts B and C.

!WARNING

The air conditioning system is a closed loop system and



engineer.

4-3-4-1


9803/3260

Section B

13 - 3

Issue 1*

Air Conditioning

S181600

A

B

C

X



14 - 1

Technical DataRefrigerant

R134a

System Capacity

1200g (2 lb 10oz)

Switch Pressures

Low Pressure Switch (white)

Cut in = 3.2 bar max. (47 lbf/ in2 max.)

Cut out = 1.6-1.8 bar (23-26 lbf/ in2 )

High Pressure Switch (blue)

Cut in = 15.2-19.3 bar (220-280 lbf/ in2 )

Cut out = 26.2-29 bar (380-420 lbf/ in2 )

Safety Procedures

The air conditioning system uses refrigerant under pressure

in a closed circuit. Any service procedure which breaks into

the closed circuit and therefore requires discharging of the

system, must only be carried out by an air conditioningengineer. The following guidelines should be adhered to by

all personnel servicing the air conditioning system.



should be disconnected until the system has been

discharged by a refrigeration engineer or a suitably

trained person. You can be severely frostbitten or injured

by escaping refrigerant.4-3-4-1/2

1 It is critical that the correct refrigerant is used and that

charging is done only by qualified personnel. It is illegal

to discharge the refrigerant into the atmosphere but as

a precaution in case of accidental leakage, discharging

and charging of the vehicle refrigerant system must be

conducted in a well ventilated area.

2 Containers of refrigerant should be stored in a cool

environment away from direct sunlight.

!WARNINGDo not carry out welding operations close to the air

conditioning refrigerant circuit. A poisonous gas is

produced when refrigerant comes into contact with

naked flames. Do not smoke or allow naked flames close

to the refrigerant circuit.

BF 1- 9

3 Do Not perform welding operations close to refrigeranthoses (maintain a distance of at least 0.5m from hoses).

4 Do Not steam clean refrigerant system components.

5 When charging or discharging the refrigerant system,

no smoking or naked flames should be allowed in theimmediate vicinity. The refrigerant does not give off a

poisonous odour, however, when it comes into contactwith a naked flame, a poisonous gas is produced.

6 When handling refrigerant, rubber gloves and goggles

should be worn. Operators should ensure no refrigerantcomes into contact with the skin. Particular care should

be taken when connecting or disconnecting charging

hoses or pressure switches. When these components

are connected to the system, a short release of

refrigerant occurs. This results in a high velocity, very

cold gas being emitted from the connection point.


9803/3260

Section B

14 - 1

Issue 1

Air Conditioning




14 - 2


9803/3260

Section B

14 - 2

Issue 1

Air Conditioning


S257690

A

B

C

E

S 2

1 0 9 5 1

D

G

F

L

K

Operation



14 - 3

Operation

To maintain optimum operator comfort in warm climates or

during seasons of high ambient temperature, the air

conditioning system delivers cool, dehumidified air into the

cab. Cooling is provided by passing the warm ambient air,together with recirculated air, over an evaporator coil in the

air conditioning unit.

The air conditioning system is a closed circuit through which

the refrigerant is circulated, its state changing from gas to

liquid and back to gas again, as it is forced through thesystem.

The major components of the system are the compressor A ,

condenser B, accumulator C, orifice tube D and evaporator

coil E.

To operate the air conditioning, the operator presses the air

conditioning switch F to the ON position. Control G is

rotated anti-clockwise to decrease the temperature from

ambient to cold. Air vents can be adjusted to vary and direct

the airflow.

The compressor A draws in low pressure refrigerant gas

from the accumulator C. The accumulator contains a

desiccant bag which retains any liquid that may be in the

system. This insures that liquid refrigerant will not enter and

damage the compressor.

The action of the compressor changes the state of the

refrigerant from a low pressure gas to a high pressure gas.

High pressure gas leaves the compressor and enters the

condenser B. Ambient air is drawn across the condenser

fins by the engine driven cooling fan and the gas is cooled .In the condenser, the refrigerant changes state to a high

pressure liquid.

The refrigerant passes from the condenser to the evaporator

E via metering orifice tube D. The orifice tube monitors the

amount of refrigerant entering the evaporator and thereforereduces the pressure of the refrigerant. Air in the cab is

forced through the evaporator coil by a blower fan. Heat is

transferred from the ambient and recirculated air to the

refrigerant, causing the low pressure liquid to vapourise andbecome a low pressure gas. The resulting cool air is

circulated to the interior of the cab through ducts and vents.

The low pressure gas is now drawn by suction back to the

compressor via the accumulator, where the cycle begins

again.

Control

Control of the system is achieved by the cyclic action of the

compressor’s electromagnetic clutch. When current is fed tothe field coil of the compressor’s clutch, a magnetic field

develops between the field coil and the armature which pulls

the field coil, complete with clutch assembly, onto the

compressor rotor. Since the clutch assembly is turned

constantly by the crankshaft pulley drive belt, the

compressor armature turns, starting the refrigeration cycle.

Current is fed to the field coil through three switches in

series; 1) the manual ON/OFF switch F; 2) a low pressure

switch K ; 3) a high pressure switch L.

The (white) low pressure switch K is located in the pipe thatconnects the evaporator E to the accumulator C. If the

pressure falls below the low pressure switch setting, the

switch opens, interrupting the electrical supply to the

compressor clutch. Low pressure leads to a lack of

refrigerant borne lubricant for the compressor which can

suffer severe damage as a result. Possible causes of the lowpressure are low refrigerant charge or low ambient

temperatures.

The (blue) high pressure switch L is located in the pipe that

connects the condenser B to the evaporator E. If the

pressure rises above the high pressure switch setting, theswitch opens, interrupting the electrical supply to the

compressor clutch. Continued high pressure is likely todamage hoses and seals. The most likely reason for

excessively high pressure is debris causing a blockage in

the condenser B or the orifice tube D.


9803/3260

Section B

14 - 3

Issue 1

Air Conditioning




14 - 4

Fault Finding

The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment. It

is recommended that, to locate faults on the system accurately and quickly, an electronic leak detector and a refrigerant

pressure gauge should be used.

General Fault Indications

There are several indications that may help to determine the fault area on a system not working efficiently:

a) Poor Performance Low accumulator pressure- Plugged orifice tube

Repair or replace accumulator

Evacuate & recharge

Condenser coil air flow restricted - Remove debris from around coil using

compressed air or low pressure water.

System overcharged- Evacuate & recharge

b) Blower operates on fan Blower resistor failed - Renew resistor.

speed 3 only Blower motor failed - Renew blower motor.

c) Compressor clutch Condenser coil blockage - Remove debris from around coil/renew condenser.

continually cuts out Overcharging of refrigerant system- Evacuate and recharge system.

Wiring Diagram

Use the illustration below to complete continuity checks on the air conditioning system harness wires. Refer also to the main

machine circuit diagram in Section C.

Key

40 Heater Motor

41 Heater Resistor42 Air Conditioning Compressor

92 Heater Switch

93 Air Conditioning Switch

94 Air Conditioning Pressure Switch



9803/3260

Section B

14 - 4

Issue 1

Air Conditioning


40

41

42

92

93

9594

122

A257780



14 - 5

No Air Conditioning

CHECK ACTION

1 Are the controls set correctly, i.e. air conditioning YES: Check 2selected, thermostat switch set to coldest position NO: Reset controls and retest.

and blower switched on?

2 Is the air conditioning (evaporator) blower working? YES: Check 3.

NO: Check 4.

3 Is the compressor running (visual check of pulley/clutch)? YES: Check11.

NO: Check 7.

4 Is the air conditioning fuse blown? YES: Renew fuse and retest.

NO: Check 5.

5 Is there a 12V supply to the pressure switch harness? YES: Check 6.

(See Pressure Switch Testing ) NO: Check 9.

6 Does the compressor clutch engage with both YES: Check 7.

pressure switches bypassed? NO: Renew the compressor clutch and retest.


7 Does the compressor clutch engage with YES: Renew high pressure switch and retest.HP switch bypassed? NO: Check 8.


8 Does the compressor clutch engage with YES: Renew low pressure switch and retest.

LP switch bypassed? NO: Charge check required by refrigeration engineer.


9 Are blower switch and wiring OK? YES: Renew blower motor.

NO: Renew switch or wiring.

10 Is condensor air flow blocked? YES: Clean condensor and radiator.

NO: Check 11.

11 Is evaporator air flow blocked? YES: Clean filter and, if necessary the evaporator.

NO: Call in refrigeration engineer.


9803/3260

Section B

14 - 5

Issue 1

Air Conditioning




14 - 6

Checking Refrigerant Charge Level

On machines from serial number 430001 there is no

inspection glass to check the charge level. If the air

conditioning system is not performing adequately complete

the fault finding procedures.

Refrigerant Charging & Discharging

Procedures for charging and discharging the system are not

given in this manual as they require special equipment and

training.

Training can be arranged through the JCB InternationalTraining Centre.

The system will not function in very low ambient

temperatures, therefore tests should be carried out in a

warm environment.

The service valves are Schrader type and can be located at

the compressor A , on the suction and discharge ports.

The (white) low pressure switch K is located in the pipe that

connects the evaporator to the accumulator.

The (blue) high pressure switch L is located in the pipe that

connects the condenser to the evaporator.

Leak Testing

!WARNING

Leak testing in Air Conditioning systems should becarried out only in a well ventilated area.BF 1-2

Note: The refrigerant is heavier than air and will leak

downwards from the defective component. Check in still

conditions but in a well ventilated area.

Hose or pipe connections are likely leakage points of any

refrigerant circuit.

To test for leaks in the high pressure side of the system i.e.

from the compressor output to the orifice tube, run the air

conditioning for a few minutes then switch off the engineand test for leakage using an electronic leak detector.

To test for leakage in the low pressure side of the system,

switch off the air conditioning and leave for a few minutes

before testing.

Tightening Leaking Hoses







The refrigerant hoses have crimped ferrule end fittings. The

hose connectors have an 'O' ring seal which compresses

when the connection is tight, creating an air tight seal.

Hoses are used to connect the inlets and outlets of thecompressor, condenser, orifice tube, evaporator coil and

suction accumulator and at bulkhead connectors above and

below the cab floor.

If leakage is detected from a hose connector, tighten the

connector up and repeat the leakage test. If leakage is stillevident, it will be necessary to de-gas the system and renew

the connector 'O' ring seal.


9803/3260

Section B

14 - 6

Issue 1

Air Conditioning


A

L

K

S257700



14 - 21

Blower Motor

Removal

1 Disconnect the battery.

2 Loosen and remove the side console screws A and

remove side console B.

3 Loosen and remove bottom console screws C and

remove the bottom console D.

4 Disconnect the electrical connector to the heater

blower.

5 Loosen and remove M6 flanged bolts E.

6 Carefully remove the heater assembly F from itshousing.

Replacement

Replacement is a reversal of the removal procedure, makesure that the seal located between the housing and heater is

in good condition - replace if necessary.

Note: The heater assembly is of a modular design. This

enables the air conditioning evaporator matrix to be housednext to the standard heater matrix. Complete removal of the

air conditioning unit will require the refrigerant to be drainedfrom the system.


9803/3260

Section B

14 - 21

Issue 1

Air Conditioning


AA

A

A

B

C

C

C

D

E

F

S210341

S257790



14 - 22

Pressure Switches

The 12V supply is fed to the compressor clutch field coil

through three switches in series; 1) the manual ON/OFF

switch F; 2) a low pressure switch K ; 3) a high pressure

switch L.

The low pressure switch requires a minimum refrigerant

charge level to close its contact. The high pressure switch

requires the charge level to remain below the maximum limit

to keep its contact closed.

Both pressure switch contacts must be closed for the

compressor clutch to operate. If the compressor clutch will

not operate when air conditioning is selected, the fault may

be either electrical or system pressure.

High Pressure Switch Testing

1 Switch off the engine and disconnect the electrical

connector to the high pressure switch L.

2 Fit a link wire between the two terminals on the high

pressure switch harness connector.

3 Switch on the engine and the air conditioning system, if

the system operates the high pressure switch is faulty -

replace it with a new one. If the system does not

operate continue to test the Low Pressure Switch.

Low Pressure Switch Testing

1 Switch off the engine and disconnect the electrical

connector to the low pressure switch K .

2 Fit a link wire between the two terminals on the lowpressure switch harness connector.

3 Switch on the engine and the air conditioning system, if

the system operates the low pressure switch is faulty -

replace it with a new one. If the system does not

operate check all electrical connections, fuses etc.


!WARNINGGoggles and rubber gloves must be worn when pressure

switches are removed or fitted. A small amount of

refrigerant is released which can be harmful to the skin

and eyes.BF 1-10

Removal

1 Disconnect the electrical connections and unscrew the

pressure switch.

Replacement

Note: The high pressure switch has a blue body, the low

pressure switch has a white body.

1 Screw the pressure switch into the pressure switch port

and torque tighten sufficiently to form a gas-tight seal.

2 Run the air conditioning and check the pressure

switches for leaks. If any leaks are found, tighten the

pressure switch further until the leaking stops.


9803/3260

Section B

14 - 22

Issue 1

Air Conditioning


A

L

K

S257700

F



14 - 23

Condenser Coil

It is likely that over a period of time, because of the

machine's working environment, the airflow around the

condenser coil B will become restricted due to a build up of

airborne particles.

If the build up of particles is severe, heat dissipation from

the refrigerant to the air will be significantly reduced,

resulting in poor air conditioning performance.

In extreme cases, over pressurisation of the system occurs,causing the high pressure cut out switch to operate and

switch off the system.

High pressure cut out can also be caused by an internal

blockage of the condenser coil.

Condenser Coil Cleaning

Take care not to damage the condenser fins or tubes.

Damaged fins must be straightened out to ensure a good

airflow through the coil.

The condensor is located at the front of the machine, behind

the nose grille A .


backhoe and loader to the ground. Remove the starter

key.

2 Remove the front grille fixing screws. Use compressedair or low pressure water to backflow through the coil

fins. Take care not to damage the fins.

3 Run the air conditioning and check coolingperformance.


9803/3260

Section B

14 - 23

Issue 1

Air Conditioning


S257700

S257800

A

B



14 - 24

Adjusting the Air Conditioning

Compressor Drive Belt







!WARNINGMake sure the engine cannot be started. Disconnect the

battery before doing this job.

2-3-3-5



and block the loader arms. Lower the backhoe to theground and stop the engine.

2 Loosen bolts A , B and C. Position the compressor so

that there is 10 mm (3/8 in) slack at point X .

3 Tighten bolt A , then bolts B and C.


9803/3260

Section B

14 - 24

Issue 1

Air Conditioning


S209392

BA

C

X



15 - 1


9803/3260

Section B

15 - 1

Issue 2

Cab



15 - 3

Direct Glazing (cont'd)

Removing the Broken Glass and Old Sealant (cont'd)

1 Position the machine on level ground and apply the

parking brake. Stop the engine. Put protective covers

over the cab seat and control pedestals.

2 a Laminated glass - leave installed until the old

sealant has been cut away, after which it will be

possible to lift the broken screen away from its frame

housing in one piece.

b Toughened glass - remove as much of the

shattered glass as possible prior to cutting out the oldsealant.

3 Cut out the old sealant, leaving approximately 1 to 2

mm on the cab frame. There are several tools and

techniques for doing this:

a Pneumatic Knife A provides one of the easiest

methods of removing the sealant around laminatedglass. The tool, powered by compressed air,

should be sourced locally.

Note: This tool must not be used on toughened glass (see

WARNING on previous page).

(i) Press the handle to start the knife blade oscillating.

(ii) Insert the knife blade into the sealant.

(ii) Slowly move the knife along the sealant with the

blade positioned as close to the glass as possible.Do not allow the knife blade to overheat or the

sealant will melt.

b Braided Cutting Wire and Handles B. This method

uses a 3-core wire, a wire starter tube and two handles

(see Service Tools, Section 1).

(i) Insert the steel tube C into the old sealant on the

inside of the glass.

(ii) Insert the braided cutting wire D down the centre of

the steel tube. If necessary, from the outside, cut

out local sealant at the point of the tube to gain

access to the wire.

(iii) Using suitable pliers, pull the cutting wire through

the sealant to the outer side of the glass.

(iv) Secure each end of the braided cutting wire in the

special handles E.

(v) Move the cutting wire backwards and forwards in a

sawing motion and at the same time gently push orpull the wire to cut through the old sealant.


9803/3260

Section B

15 - 3

Issue 1

Cab

S186380

S189870

S189880

A

B D

D

E

EDC

C



15 - 4


Removing the Broken Glass and Old Sealant (cont'd)

c Cut-out Knife F. The cut-out knife can be used as a

left handed or right handed tool. For the knife and its

replaceable blades, refer to Service Tools, Section

1.

(i) Insert the knife blade into the sealant.

(ii) Make sure that the blade of the knife is against

the glass as shown at G.

(iii) Use the 'pull-handle' to pull the knife along andcut out the old sealant.

d Craft Knife H. The blades are replaceable.

(i) Insert the knife blade into the sealant.

(ii) Pull the knife along and cut out the old sealant.

Note: There are other tools available to cut out the old

sealant. For example, there is a long handle type craft knife

to give extended reach. Refer to Service Tools, Section 1,

for details of this and any other tools.

4 a Laminated glass - lift out the broken pane using

glass lifters (see Service Tools, Section 1).

b Toughened glass - remove the cut off sealant and all

remaining particles of shattered glass.

5 If necessary, trim off the remaining old sealant to leave

approximately 1 to 2 mm on the upright face of the cab

frame aperture, as shown at J.

6 Apply a coat of 'Black Primer 206J' to the paintwork if:

a Paintwork was damaged or scratched during the

glass/sealant removal procedures.

b The old sealant was inadvertently cut back to the

cab frame during the glass/sealant removalprocedures.

Preparing the Cab Frame Aperture

1 If damp or wet, dry the aperture area using a hot air gun

(sourced locally).

2 Use 'Active Wipe 205' to thoroughly clean and 'prime'

the trimmed sealant. Use a lint free cloth to apply the

'Active Wipe 205', allow 5 minutes flash off (drying)time.

Note: Do not use any other type of cleaning fluids, otherwise


9803/3260

Section B

15 - 4

Issue 1

Cab

S186370

S189890

S189900

F

G

H

J



15 - 5


Preparing the New Glass

! CAUTION

The laminated front screen must be handled with extra

care to prevent breakage. Wherever possible, store and

handle it in a vertical attitude. When placing or lifting the

screen in a hori zontal attitude it must be supported over

its whole area, not just at the edges.BF 1-8

1 Make sure that the new glass correctly fits the frame

aperture K.

a Put two spacer blocks L onto the bottom part of the

frame aperture.

b Install the new glass on the spacer blocks - ALWAYS

USE GLASS LIFTERS M (see Service Tools, Section

1). Check that there is an equal sized gap all roundthe edge of the glass.

Note: The spacer blocks are rectangular in section to give

two common gap widths. If necessary they can be trimmed

to a smaller size to give an equal sized gap around the glass.

IMPORTANT: The glass edges MUST NOT touch the frame,

otherwise movement of the frame will chip and eventually

break the newly installed glass.

2 After checking for size, remove the new glass and place

it on a purpose made glass stand N (see Service

Tools, Section 1).

Small panes of glass will need locating on a 600 x 700 mm x

15 to 19 mm thick plywood board P (sourced locally to fit

the glass stand N ). It is recommended that an access hole is

cut in the board to accommodate the glass lifter, making it

easier and safer to handle small panes of glass. The board

should be covered with felt or carpet to give an anti-scratch

surface. Resting the glass on four spacer blocks will ensureclearance of the cartridge nozzle tip during application of the

polyurethane sealant.

3 Make sure the glass is positioned on the stand the

correct way up (i.e. with the black ceramic ink band

upwards) ready for application of primer etc.

4 a Use 'Active Wipe 205' to thoroughly clean and

'prime' the black ceramic ink band printed on the

glass (see Note 1). Use a lint free cloth to apply the

'Active Wipe 205', allow 5 minutes flash off (drying)

time.

Note 1: Do not touch the glass after cleaning with the 'Active

Wipe 205'.


9803/3260

Section B

15 - 5

Issue 1

Cab

S186291

S186280

S189910

S189920

M

L

K

N

P

R



15 - 6


Preparing the New Glass (cont'd)

5 Install the Ultra Fast Adhesive cartridge (see Sealing

and Retaining Compounds, Section 1 and Note 2

below) into a suitable applicator gun:

a Remove the aluminium disc cover from the base of

the cartridge and discard the 'dessicant capsule'.

b Make sure that the rolled edge of the cartridge is not

damaged - if necessary, the edges should be

pressed flat, otherwise it will be difficult to remove

the cartridge from the applicator gun.

c Pierce the front 'nozzle' end of the cartridge to its

maximum diameter.

d Fit the pre-cut nozzle shown at S.

e Install the cartridge in the applicator gun.

Note 2: Cold material will be very difficult to extrude. The

cartridges must be pre-heated in a special oven (see

Service Tools ) for 1 hour to a temperature of 80°C (176°F).

Pre-heating the cartridges makes the adhesive more

workable and also brings the 'curing' time down to 30

minutes.

6 Apply the pre-heated adhesive to the glass (do not start

in a corner). Keep the nozzle guide T against the edge

of the glass and make sure that the adhesive forms acontinuous 'pyramid' shape.

Note 3: Once the pre-heated adhesive has been applied to

the glass, install the glass in the aperture as soon as

possible. After approximately 10 minutes the sealant will

form a 'skin', this will prevent the glass from bonding.

7 After applying the adhesive, leave a small amount of

sealant protruding from the nozzle. This will prevent any

adhesive left in the cartridge from 'curing'.

Installing the New Glass

1 Make sure the two spacer blocks are in position (see

step 1 of Preparing the New Glass ).

2 Install the glass in the frame aperture:

a ALWAYS use the special lifting tools when moving

the glass. Use a lifting strap to hold large panes of

glass in position as shown W.

b Sit the bottom edge of the glass on the spacer

blocks as shown X.


9803/3260

Section B

15 - 6

Issue 1

Cab

S

T10-15 mm

8-10 mm

A186410

S186440

S189910

S189930

A186410

S

T

T

W

X



15 - 7


Installing the New Glass (cont'd)

3 Make the inside seal smooth:

a Wearing surgical gloves, dip your finger in a soapy

water solution.

b Use your finger to make the inside seal smooth.

4 All exposed edges must be sealed using Black

Polyurethane Sealant (see Sealing and Retaining

Compounds, Section 1).

5 Clean the glass after installation:

IMPORTANT: Use extreme caution when wiping the inside

of the new glass - pushing too hard on the inside of the

glass will affect the integrity of the bonded seal.

a Small amounts of sealant can be cleaned from the

glass using the 'Active Wipe 205'.

b Large amounts of excess sealant should be left to

'cure' (see Note 4) and then cut off with a sharp

knife.

Note 4: On completion of the glass replacement procedures,

the sealant 'curing' time is 30 minutes. This means that themachine can be driven and used after 30 minutes, but it

MUST NOT be used during the curing period of 30 minutes.

c Clean the glass using a purpose made glass

cleaner.

6 On completion of the glass installation procedures tidy

the work area:

a Remove ALL broken glass from the cab area.

b Remove the protective covers from the cab seat and

control pedestals.

c Renew all 'warning' and 'information' decals so that

the new installation conforms with the original cab

installation.


9803/3260

Section B

15 - 7

Issue 1

Cab



20 - 2

Loader Arms


Removal

1 Park the machine on firm level ground. Engage the


2 Remove loader end attachment (such as a shovel) iffitted. If the attachment is hydraulically operated,

disconnect attachment hoses and plug/cap

immediately. Vent residual hydraulic pressure prior to

removing hoses by operating the control levers with the

engine switched off.

!WARNINGDO NOT work under raised loader arms unless they are

adequately supported by stands and/or slings.BF 3-1

3 Remove the engine cover, see page B/1-1.

4 Raise the loader arms to give access to the lift ram

pivot pins A .

5 Sling the loader arms as shown at X . Make sure thatthe slings are taut and therefore holding the weight of

the loader arms.

6 Switch off the engine and vent residual hydraulic

pressure from the loader end by operating the loader

controls back and forth several times.

7 Remove the lift ram pivot pins A (see Note 1).

Note 1: Care must be taken when removing the lift ram pivot

pin, once the pin is removed the ram will drop. Either hold

the ram using a sling or have a second person hold the rambefore removing the pin.

8 Lower the loader arms to the ground using the slings, it

may be necessary to retract the lift rams to enable the

loader arms to rest fully on the ground. Make sure the

lift rams do not foul when retracted.

9 Make sure residual hydraulic pressure has been vented.

Disconnect the shovel ram and auxiliary (if fitted) hoses,

shown at B. Plug and cap the hoses immediately.

10 Disconnect the electrical connections (not shown) tothe loader shovel reset switch (if fitted).

11 Remove pivot pin retaining bolts D, E, F and G (see

Note 2).

Note 2: To gain access to bolts D and F and their retaining

nuts, remove cover C. To gain access to bolts E and G and

their retaining nuts, remove the battery and use access slot

W.

12 Sling the loader arms as shown at Y . Make sure that

the sling is wrapped around the loader arms only andnot the level links.

13 Remove nut and bolt H. Remove retaining ring J and

shim K .

!WARNINGThe loader arm interlevers are potentially dangerous,

when pivoting about their centre they form a 'scissor'

point with the loader arm. Make sure the interlevers are

securely blocked when working in the loader arm area.BF 2-1

14 Secure the interlever lever linkage as shown at Z,

otherwise with level link pivot pin L removed, the

interlever linkage could pivot about its centre and cause

injury and/or damage.

15 Use extractor tool 992/00800 and remove pivot pin L.

16 Repeat steps 13 to 15 for the opposite level link pivot

pin.

17 Remove nut and bolt M. Remove retaining ring N and

shim P.

18 Use extractor tool 992/00800 and remove pivot pin Q.

19 Repeat steps 17 and 18 for the opposite loader arm

pivot pin.

20 When all four pivot pins have been removed, carefully

reverse the machine clear of the loader arms

Replacement


Check operation of loader shovel reset switch (if fitted).

Apply rust inhibiting oil to all static bores and pivot pins

before assembly into rams and mainframe (except for pivot

pins/bores L and Q ).

Apply anti-seize paste to bearing bores of pivot pins L and

Q.

All klipring installations to have a maximum end float of 2

mm (0.078 in).

Fit new liner bearings in the loader arms and/or the level link

using a shouldered mandrel as shown.


9803/3260

Section B

20 - 2

Issue 1



25 - 1


9803/3260

Section B

25 - 1

Issue 1

S216800

D E

G

F

A

B

C



25 - 2

Stabiliser Leg (Sideshift Machines)


The following steps (1 to 11) describe the removal

procedures for the stabiliser inner leg, the stabiliser foot andthe stabiliser ram. However, it is possible to remove these

items as a complete assembly, see step 12.

Removal

1 Park the machine on firm level ground. Engage the


2 Lower the loader shovel to the ground.

3 Make sure that the backhoe assembly is set central to

the mainframe as shown. If necessary 'sideshift' the

backhoe into a central position.

4 Lower the stabiliser legs until the pads are

approximately 1 in. (25mm) off the ground.

5 Remove the bottom locking nut A and bolt B.

6 Drive out the bottom pivot pin C.

Note: Steps 7 to 10 only apply if renewing or repairing thestabiliser ram, however, removing the ram will give more

room when refitting the stabiliser inner leg.

7 Make sure the engine is switched off, vent residual

hydraulic pressure by moving the backhoe and

stabiliser control levers back and forth.

8 Loosen and remove the stabiliser hoses D and E, label

the hoses before removing (as an aid to assembly).

Plug all open orifices to prevent loss of fluid and ingress

of dirt.

9 Loosen and remove the top pivot pin retaining nut and

bolt, as shown at F.

! CAUTIONThe ram is heavy. It is recommended that the ram is

removed with the assistance of a sling and suitablelifting appliance.BF 2-4

10 Remove the stabiliser ram - take the ram out from the

top. Be careful, the ram is heavy.

!WARNINGMake the machine safe, place blocks underneath the

sideshift railsBF 2-5

11 Use the boom and dipper to raise the rear of themachine, as shown at G. Do not raise the machine too

high but allow just enough room for the stabiliser inner

leg to slide clear. Refer to the warning above.

Note: Use the widest backhoe bucket available (if possible,

a 5ft ditching bucket).

12 If required, the stabiliser inner leg, stabiliser foot and

stabiliser ram can be removed as a complete assembly:

12.1 Complete steps 1 to 4.

12.2 Make sure the engine is switched off, vent

residual hydraulic pressure by moving the

backhoe and stabiliser control levers back and

forth.

12.3 Loosen and remove the stabiliser hoses D andE, label the hoses before removing (as an aid

to assembly). Plug all open orifices to prevent

loss of fluid and ingress of dirt.

!WARNINGMake the machine safe, place blocks underneath the

sideshift railsBF 2-5

12.4 Loosen and remove the top pivot pin retaining

nut and bolt, as shown at F.

12.5 Use the widest backhoe bucket available (if

possible, a 5ft ditching bucket), and position

the backhoe as shown at G. Do not raise the

machine too high but allow just enough room

for the stabiliser leg assembly to slide clear.Refer to the warning above.

Inspection

The inner leg should be free from nicks, marks or scores.

Replacement


Use suitable lifting appliances to locate the stabiliser ram.

After replacing or fitt ing the stabi liser leg, connect the

hydraulic pipes, make sure that the ram and leg operatefreely and do not foul.


9803/3260

Section B

25 - 2

Issue 1



26 - 1


9803/3260

Section B

26 - 1

Issue 1

SXXXXXX

S216810

SXXXXXX

A B

CDE

CD

FG



26 - 2

Stabiliser Leg (Centremount Machines)


Removal




stop the engine.

2 Lower the stabiliser legs to the ground.

3 Make sure the engine is switched off, vent residual

hydraulic pressure by moving the backhoe and

stabiliser control levers back and forth.

4 Remove the stabiliser ram:

4.1 Carefully disconnect hydraulic hoses A and B fromthe stabiliser hydraulic ram, label the hoses before

removing (as an aid to assembly). Release theconnections slowly.

4.2 If a stabiliser foot is fitted, remove 'C' washers C

and washers D. Drive out the foot retaining pin E.

! CAUTIONThe ram is heavy. It is recommended that the ram is

removed with the assistance of a sling and suitable

lifting appliance.BF 2-4

4.3 Wrap a suitable sling around the stabiliser ram,make sure that the weight of the ram is supported

by the sling.

4.4 Remove the ram pivot pin retaining nut and bolt,

drive out the ram pivot pin as shown at F.

4.5 Remove the stabiliser ram.

5 Remove the stabiliser leg:

! CAUTIONThis component is heavy. Do not attempt to remove it

unless its weight is held by a sling. Make sure that thesling is attached to a suitable lifting appliance.

HYD 2-3/1

5.1 Wrap a suitable sling around the stabiliser leg,

make sure that the weight of the leg is supported

by the sling.

5.2 Remove the stabiliser leg pivot pin retaining nut

and bolt, drive out the stabiliser leg pivot pin , as

shown at G.

5.3 Remove the stabiliser leg.

Replacement


Use suitable lifting appliances to locate the stabiliser ram

and the stabiliser leg.

After replacing or fitt ing the stabi liser leg, connect thehydraulic pipes, make sure that the ram and leg operate

freely and do not foul.


9803/3260

Section B

26 - 2

Issue 1



30 - 1

Slew Cylinders (Sideshift Machines)


Drain the oil from the slew gearbox.

!WARNING

Slacken but DO NOT remove the cylinder retaining bolts

when using hydraulic pressure to break the seal. Severe

injury can be caused if the cylinder is released suddenly

under pressure.BF 2-2

Slacken bolts A and use hydraulic pressure to break the seal

between cylinder B and the gearbox body. Disconnect and

blank hose C. Remove the bolts and cylinder.

The piston head seals D can be renewed with the piston

head still fitted. To remove the piston head, unscrew bolt E.

Note: If the rack is to be removed, the piston head will not

pass through the rack housing. Prevent rack rotation when

slackening bolt E by leaving the pinion in engagement with

the rack.

Ensure that the new 'O' ring F and spacer G are correctly

located.

Apply JCB Multi-gasket on joint face between cylinders B

and the gearbox body.

Refill gearbox with oil specified on page 3/1-1.

Torque Settings


A 970 99 715

E 405 41 300


9803/3260

Section B

30 - 1

Issue 2*

*

*



31 - 1


9803/3260

Section B

31 - 1

Issue 1

S8365



31 - 2

Kingpost & Carriage - Sideshift Machines


If required, kingpost 9 and carriage 18 can be removed and

replaced without disturbing the slew cylinders; but if therack, or pinion 8B are damaged it is advisable to clean out

the cylinders (see page 30 - 1). If removing the piston heads,

leave driveshaft 8A in position to prevent rack rotation whilst

turning the piston head bolts.

If removing the kingpost with the carriage still fitted, ensure

that there is a clearance of at least 850 mm (34 in) below the

kingpost to allow driveshaft removal. Alternatively, the

kingpost and carriage may be removed as an assembly and

dismantled in a horizontal position.

Before removing the driveshaft, slew the kingpost to dead

centre, drain the gearbox oil (plug 1) and remove the boom

and dipper. Support the kingpost using a hoist and positiona jack under cover plate 4 to support the driveshaft.

Knock back locktabs 2, unscrew bolts 3 and lower the jack

to remove the driveshaft.

When Assembling

Apply JCB High Strength Retainer to the inner and outerfaces of liner ring 19 and to the outer faces of bushes. Fit

liner ring 19 with its internal chamfer at the bottom.

Fit bush 21 with the grooved end at the top and the other

end flush with the bottom of the housing. Ensure that

raincap 20 is clipped onto the bush.

Tighten nut 17 until clearance is 2 - 4 mm (0.08 - 0.16 in)

with the hydra-clamp in the 'ON' position, as shown at A .

Bottom bush 16 must be fitted, with the outside groove at

the bottom, to a depth of 7.5 mm (0.295 in) below the topface of the parent bore. Top bush 15 must be fitted, 'O' ring

groove downwards, to a depth of 6 mm (0.236 in) below the

top face. Ensure that the grease holes in the bush are at

right angles to the grease nipple. Ensure that seals 10 and

13 face in the direction shown.

Apply anti-seize paste to all bearing surfaces and the upper

splined area on the driveshaft.

When fitting the driveshaft, ensure that the kingpost andrack are central.

Ensure that the dowel in cover plate 4 enters the hole in

housing 6.

Ensure that roll pins B and D are fitted and do not protrudeabove the splines. The roll pins should align with master

splines E and C on assembly.

Bleed the Hydraclamps by opening the bleed screw at

clamp 17 and operating the clamps until air-free oil flows

from the screw.

Fill the gearbox with oil (see page 3/1-1).

Grease bushes 15, 16 through their grease nipples.

Note: Do not inject more than 30-50 ml of grease throughthe grease nipple for item 16.

Torque Settings


3 170 17.5 125


9803/3260

Section B

31 - 2

Issue 3*

A204860

2 - 4 MM

S156530

*

A



35 - 1


9803/3260

Section B

35 - 1

Issue 1

159880



35 - 2

Boom & Dipper

Removal & Replacement

Always label hydraulic hoses before disconnecting them,

this will ensure that they are correctly reconnected. Plug andcap all hose open ends to prevent ingress of dirt and loss of

hydraulic fluid.

Removal

1 Remove the backhoe bucket and place the backhoe in

the position shown at A .

2 Lower the stabilisers.

3 Stop the engine and disconnect the battery (to prevent

the engine being started).

4 Operate the backhoe control levers back and forthseveral times to release pressure trapped in the

hydraulic hoses.

5 Remove the dipper from the boom assembly:

5.1 Disconnect hoses 10, 11, 12 and 13.

5.2 Place a suitable support underneath the dipper

ram as shown at L.

5.3 Wrap a sling around the dipper as shown at M.

Make sure the weight of the dipper is held by the

sling before removing pivot pins etc.

5.4 Remove nut N, bolt P and pivot pin Q.

5.5 Remove nut R, bolt S and pivot pin T.

Note: From machine serial number 416130, two thin M12

nuts are used in place of the single nut R. The new

arrangement allows the pivot pin retaining bolt to be secured

without inducing a lateral tension.

5.6 Hoist the dipper clear of the boom.

6 Remove the boom from the kingpost and carriage

assembly:

6.1 Wrap a sling around the boom as shown at B.Make sure the weight of the boom is held by the

sling before removing pivot pins etc.

6.2 Disconnect hoses 1, 2, 3, 4, 5, 6, 7 and 8.

6.3 Make sure that the boom lock is secured in the

raised position. Disconnect the remote boom lockhydraulic hose 9.

6.4 Place a suitable support underneath the boom ram

as shown at D.

6.5 Remove nut E, bolt F and pivot pin G.

6.6 Remove circlip H and shim J (if fitted). Removepivot pin K.

6.7 Hoist the boom clear of the kingpost and carriage

assembly.

Replacement

Replacement is generally a reversal of the installation

procedure.

The boom to dipper pivot pin T must be retained using two

M12 thin nuts (in place of a single nut as shown at R ). Fit the

first thin nut to within 1mm (0.040 in.) of the pivot boss face.Fit the second thin nut and tighten onto the first nut - torque

to 43 Nm (32 lbf ft).

When fitting the dipper to the boom, the maximum

permissible side float is 1.5mm (0.060in). If necessary, fit

shim between the boom nose and dipper, as shown at V .

When fitting the boom and dipper assembly to the kingpost

and carriage, the maximum permissible side float between

kingpost and boom is 3.00mm (0.118in). If necessary, fit

shim, item J, on the right hand side of the machine only (see

notes 1 and 3).

Note 1: With the exception of slewing operations 'Left Hand'

and 'Right Hand' are as viewed from the rear of the machine

facing forwards.

The hoses should have been clearly labelled beforeremoving, however shown below is a key to the hoses and

their final destination:

Hose Destination

1 Auxiliary ram (see note 2)2 Auxiliary ram (see note 2)

3 Boom ram (head side)

4 Boom ram (rod side)

5 Dipper ram (rod side)

6 Dipper ram (head side)

7 Crowd ram (rod side)

8 Crowd ram (head side)

9 Remote boom lock

10 Crowd ram (rod side)

11 Crowd ram (head side)

12 Auxiliary ram (see note 2)13 Auxiliary ram (see note 2)

Note 2: Hoses 1, 2, 12 and 13 feed auxiliary services such

as extending dipper, jaw bucket etc. Hose final destinations,

i.e. auxiliary ram head side or rod side positions, vary

depending on which auxiliary attachment is fitted.

Note 3: Later machines utilise a slightly longer pivot pin and2-off 5 mm thick washers, one at each end. On reassembly

the washers must be positioned adjacent to their circlips.

Shims may still be required between the boom and kingpost

to keep side float within the limit given above. Note that the

maximum permissible clearance between boom and pivot

pin is 1.0 mm (0.039 in). Add shims between the 5 mmspacers and the boom as required.


9803/3260

Section B

35 - 2

Issue 3*

Backhoe

*

*



i

Section C Electrics

9803/3260

Section C

i

Issue 7*

Technical Data

General Electrical Data 1 - 1

Circuit Protection

- to serial number 430000) 1 - 2- from serial number 430001) 1 - 3

Relay Identification - Syncro Shuttle Machines

- to serial number 409434 1 - 4

- from serial number 409435 to 430000 1 - 4

Relay Identification - Powershift Machines

- to serial number 409434 1 - 5

- from serial number 409435 to 430000 1 - 5

Relay Identification - All Models (from serial number 430001) 1 - 6

Test Methods

Use of Multimeter 2 - 1

Measuring DC Voltage 2 - 3Measuring Resistance 2 - 3

Measuring Continuity 2 - 3

How to Test a Diode or Diode Wire 2 - 4

Parking Brake Switch

Adjustment 10 - 1

Circuit Diagrams & Component Lists (to serial number 430000)

Basic Machine 15 - 1

Circuit Options and Variations

- Steer Circuit (AWS Machines Only) 15- 3

- Powershift Transmission 15 - 4

- 2/4 Wheel Drive (up to serial number 409434) 15 - 5

- Transmission Dump Circuit (up to serial number 413772) 15 - 5

- Instrument Lights Test Button (up to serial number 404502) 15 - 6

- Hydraulic Speed Control (HSC) - 2 Relays - (up to serial number 406613) 15 - 6

Circuit Diagrams & Component Lists (from serial number 430001)

Basic Machine (2WS) 18 - 1


- Powershift Transmission & Steer Circuit (AWS Machines Only) 18 - 5

- Powershift Transmission (2WS Machines Only) 18 - 7

- Steer Circuit for 3CX 4x4x4 Machines 18 - 7- 3CXE (214E) Machine Only 18 - 9

Batteries

Safety 20 - 1

Specfic Gravity Test 20 - 2

Battery Testing 20 - 2

Wiring Harness Repair

Harness Repair Introduction 25 - 1

Tools Required 25 - 1

Procedure 25 - 1

Contents Page No.

*

**

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ii

Section C Electrics

9803/3260

Section C

ii

Issue 3*

Contents Page No.

Starter Motor

Starting Circuit Test 38 - 1


Dismantling 38 - 4

Service and Renewal 38 - 4

Assembly 38 - 4

Alternator

Charging Circuit Test 39 - 1

Service Precautions 39 - 3



Dismantling and Assembly (Magneti Marelli Type) 39 - 7

Harness Location

Harness Location - up to serial number 430000 40 - 1

Harness Location - from serial number 430001 40 - 2

Wire Number Identification

Wire/Harness numbers - Explanation of: 41 - 1

Wire numbers (to serial number 430000)

- 000 to 199 41 - 2

- 200 to 599 41 - 4

- 600 to 799 41 - 4

- 800 to 999 41 - 6

Wire numbers (from serial number 430001)

- 000 to 199 42 - 1

- 200 to 599 42 - 3

- 600 to 799 42 - 4

- 800 to 999 42 - 7

*



1 - 1

General Electrical Data

System Type 12 Volt, negative earth

Battery (Heavy Duty)

- Cold crank amps for 1 minute to

1.4 volts per cell at -18 deg C (0 deg F) 550

- Reserve capacity (minutes) for 25 amp load 220

Battery (Temperate)

- Cold crank amps for 1 minute to

1.4 volts per cell at -18 deg C (0 deg F) 410

- Reserve capacity (minutes) for 25 amp load 170

Alternator

2WS Lucas - 65 Amp maximum output

4WS Magnetti Marelli - 72 Amp maximum output4WS (air conditioning or ServoPlus builds) Magneti Marell i - 85 Amp maximum output

Starter Motor Lucas

Light Bulbs

Head lights - main/dip 45/37.5W

Work lights 55W Halogen (front & rear)

Front side lights 5W

Tail/stop lights 5/21W

Fog light 21W

Direction turn indicators 21W (front & rear)

Instruments 1.2W

Warning lights 3W

† Number plate light 2 x 5W

Interior light 10W

† Beacon 70W Halogen

† Note: These items are not apllicable to U.S.A.

Section C Electrics

9803/3260

Section C

1 - 1

Issue 3*

Technical Data

*

*

**



1 - 2

Circuit Protection

The electrical circuits are protected by fuses. The fuses are

located in a fuse box to the right of the steering pedestal. If afuse melts, find out why and rectify the fault before fitting a

new one. The fuses are identified using column letters (A, Band C) and row numbers (1 to 9).

! CAUTIONFuses

Always replace fuses with ones of correct ampere rating

to avoid electrical system damage.8-3-3-5

COLUMN 'A' Fuse

Rating

1 Reverse alarm, brake lights, 2/4WD solenoid†††. 10 Amp

2 Gauges, stabiliser lock relay. 5 Amp

3 Left hand sidelights, dipper light. 5 Amp

4 Gauge illumination, right hand sidelights. 5 Amp

5 Rear wiper. 5 Amp

6 Hazard warning lights. 10 Amp

7 Beacon, Interior light. 10 Amp

8 Radio. 5 Amp

9 Horn, headlight flash, front wiper/washer. 10 Amp

COLUMN 'B'

1 Junction box, remote unload solenoid (HSC). 10 Amp

2 Fuel pump solenoid (engine stop). 5 Amp

3 Dip beam†. 10 Amp

4 Main beam. 10 Amp

5 Front work lights. 10 Amp

6 Direction turn indicators. 5 Amp

7 Dump relay. 5 Amp

8 Heater. 15 Amp

9 Hand dump, buzzer. 5 Amp

COLUMN 'C'

1 Rear work lights. 10 Amp

2 Steering solenoids, proximity switches ††. 5 Amp

3 2/4 WD switch & relay, forward relay andsolenoid, reverse relay and solenoid.

Powershift only - forward high/low relay &

solenoid, reverse high/low relay & solenoid,

drive (mainshaft/layshaft) relay & solenoid,

neutral relay. 10 Amp

4 Fog light †. 10 Amp

5 When applicable - heated seat, clock & cigar

lighter. 15 Amp

† Note: Machines prior to serial number 400077 have the

fog light circuit protected by fuse B3, not C4 as

indicated.

†† Note: Steering solenoids and proximity switches arefitted to AWS machines only.

††† Note: Machines up to serial number 403024 have the

brake lights protected by fuse A1.

Machines from serial number 403025 to 404851 havethe brake lights protected by fuse C3.

Machines from serial number 404852 have the brake

lights, and 2/4WD solenoid protected by fuse A1 (as

indicated in the fuse identification chart).

Section C Electrics

9803/3260

Section C

1 - 2

Issue 3*

Technical Data

S143211

*

*

*

*

*

*

*

*

*



1 - 3

Circuit Protection (from machine serial

number 430001)

The relays and fuses are located in the side console

underneath cover A .

! CAUTIONFuses

Always replace fuses with ones of correct ampere rating

to avoid electrical system damage.

8-3-3-5

Fuse Identification

If a fuse melts, find out why and rectify the fault before fittinga new one. The fuses are identified using column letters (A,

B and C) and row numbers (1 to 9). Note that all the fuses

are shown (including optional equipment fuses). Your

machine may not be equipped with all the fuses shown on

this page.

COLUMN 'A' Fuse Rating

1 Brake lights. 5 Amp

2 Warning lights, buzzer, gauges. 5 Amp

3 Left hand sidelights. 5 Amp

4 Right hand sidelights. 5 Amp

5 Rear wiper/washer. 5 Amp6 Hazard warning lights. 10 Amp

7 Beacon, Interior light. 10 Amp

8 Radio. 5 Amp

9 Horn, headlight flash, front wiper/washer. 15 Amp

COLUMN 'B'

1 Junction box 10 Amp2 Fuel pump solenoid (engine stop). 5 Amp

3 Dip beam. 10 Amp

4 Main beam. 10 Amp

5 Front work lights. 10 Amp

6 Indicators. 5 Amp7 4WD (automatic brake). 5 Amp

8 Heater. 30 Amp

9 Rear horn. 10 Amp

COLUMN 'C'

1 Rear work lights. 10 Amp

2 Steer mode, hydraulic speed control (HSC) 5 Amp

3 Gearbox control, reverse alarm. 10 Amp

4 Fog light. 5 Amp

5 Heated seat, clock & cigar lighter 15 Amp

6 Forward and reverse controls, reverse alarm 3 Amp

Note: Fuse C6 is only fitted on machines from serial number:

3CX (214) - 438636; 4CX (214S) - 437866. Prior to this, the

gear controls were protected by fuse C3.

Section C Electrics

9803/3260

Section C

1 - 3

Issue 4

Technical Data

A

S247030

4W

A254290A



1 - 4

Relay Identification - Syncro Shuttle M/c's

Relays are used in electrical circuits for a variety of reasons. However, the more usual application is to protect components like

switches etc. from being overloaded. A relatively small current (from the switch) energises the relay coil, this coil causesinternal contacts to open (or close) and therefore controls a (larger) current in another circuit. Although relays look similar,

internally they can be different, for example, they can be single contact or double contact; normally closed or normally open.Make sure you fit the correct type of relay, otherwise the machine electrical circuits will not function properly.

All the relays on your machine (except items T & U ) are housed in the front console as shown. Items T & U are secured to the

parking brake mounting bracket, as shown in the inset.

Relay Description Description

(to serial no. 409434) (from 409435 to 430000)

B Neutral Start Neutral Start

C Stabiliser Leg Lock (if fitted) Stabiliser Leg Lock (if fitted)

D Reverse Alarm (if fitted) Reverse Alarm (if fitted)E Buzzer Buzzer

F Road Lights Road Lights

G Parking Brake Parking Brake

H Forward Drive Brake LightsJ Reverse Drive 2WD Select

K Flasher FlasherL Transmission Dump Transmission Dump

R 2/4WD Brake Forward Drive

S 2WD Select Reverse Drive

T Hydraulic Speed Control † Hydraulic Speed Control †

U Hydraulic Speed Control † Hydraulic Speed Control †

V - Parkbrake Dump ††

Note † : From machine serial number 406613 the hydraulic speed control circuit is operated with a single relay, not two relays

as shown.

Note ††: The parkbrake dump relay is only applicable on machines from serial number 413772.

Section C Electrics

9803/3260

Section C

1 - 4

Issue 2

Technical Data

E DCB

F

H

K

J

L

RVS

T

U

G



1 - 5

Relay Identification - Powershift M/c's

Relay Description Description

(to serial no. 409434) (from 409435 to 430000)

A Ignition Ignition

B Neutral Start Neutral StartC Stabiliser Leg Lock (if fitted) Stabiliser Leg Lock (if fitted)

D Reverse Alarm (if fitted) Reverse Alarm (if fitted)

E Buzzer Buzzer

F Road Lights Road LightsG Parking Brake Parking Brake

H Forward Drive Forward High/Low Ratio

J Reverse Drive Reverse High/Low Ratio

K Flasher Flasher

L Transmission Dump Transmission Dump

M Forward High/Low Ratio Forward DriveN Reverse High/Low Ratio Reverse Drive

P Drive (Layshaft/Mainshaft) Drive (Layshaft/Mainshaft)

Q Neutral (Powershift) Neutral (Powershift)

R 2/4WD Brake Brake LightsS 2WD Select 2WD Select

T Hydraulic Speed Control † Hydraulic Speed Control †U Hydraulic Speed Control † Hydraulic Speed Control †

V - Parkbrake Dump ††

Note †: From machine serial number 406613 the hydraulic speed control circuit is operated with a single relay, not two relays

as shown.

Note ††: The parkbrake dump relay is only applicable on machines from serial number 413772.

Section C Electrics

9803/3260

Section C

1 - 5

Issue 1

Technical Data

S215400

E

CB

A

F

R

K

G

S

L

H MP

QV

T

U

D

JN



Note: With the introduction of different machine models,

services and options, the position of the relays may vary

from that shown in the illustration.

If unsure about the position of a realy, check the wire

numbers at the rear of the relay base against the wiredescriptions.

1 - 6

Section C Electrics

9803/3260

Section C

1 - 6

Issue 3*

Technical Data

Relay Identification - All Machine Models (from machine serial number 430001)

The relays and fuses are located in the side console

underneath cover A . Note that all the relays are shown

(including optional equipment relays). Your machine may not

be equipped with all the relays shown on this page.

1 Ignition

2 Neutral Start

3 Indicators

4 Ignition

5 Neutral

6 Transmission Dump

7 Hydraulic Speed Control (HSC)

8 Forward Drive

9 Buzzer

10 Parking Brake

11 Reverse Drive12 Reverse Horn

13 Auxiliary Attachment (Jaw)

14 Heater

15 Lights

16 Worklights (Italian Requirement Only)

17 Hammer Circuit

18 All Wheel Braking

19 Forward High/Low Ratio➀

20 2 Wheel Drive➁

21 2 Wheel Steer➂

22 Reverse High/Low Ratio➀

23 Drive (Layshaft/Mainshaft)➀

24 4 Wheel Steer➂

➀ Powershift Machines Only

➁ All Wheel Steer Machines Only

➂ 3CX 4x4x4 Machines Only

RF

DN F R0

0 0

P

4W

1

2

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24 A254290B

A

*

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*

*

*

S247030



2 - 1

Use of Multimeter

These instructions are intended to cover the use of the recommended multimeters.

1 Make sure that the test leads are plugged into the correct sockets. The black test lead should be plugged into the black

socket (sometimes, this socket is also marked by a " – ", or "E" or marked as "COMMON" or "COM"). The red test lead

should be plugged into the red socket marked with "+", "V" or " ".

2 When making measurements ensure that the test probes have a good clean contact with bare metal, free from grease,

dirt, and corrosion as these can cause a false reading.

3 When measuring voltage:

Make sure that the correct range is selected, that is set the selector to a value equal to or greater than that you are about

to measure.

e.g. If asked to measure 12 Volts, set the selector to the 12V range. If there is no 12V range, set the selector to the nextrange higher, 20V for instance.

If the meter is set to a range that is too low, it may be damaged.

e.g. setting to the 2V range to measure 12V.

Section C Electrics

9803/3260

Section C

2 - 1

Issue 2*

Test Methods

*

A

OFF

V/A

V/A

A

B

A171900

S153070



2 - 2

Section C Electrics

9803/3260

Section C

2 - 2

Issue 1

Test Methods



2 - 3

Measuring DC Voltage

On the FLUKE 85

Turn the switch to position B.

On the AV0 2003Move the right slider switch to position A, and the left hand slider switch to the appropriate range.

On an analogue meter

Turn the dial to the appropriate DC Volts range.

Connect the black probe to the nearest available suitable earth point, usually this will be the starter motor earth, the battery

negative, or the chassis.

Connect the red probe to the wire or contact from which you are measuring the voltage.

Measuring Resistance

Make sure there is no power to the part of the circuit you are about to measure.

Connect one probe at one end of the component or wire to be checked and the other probe at the other end. It does not

matter which way round the two probes are placed.

On the FLUKE 85

Turn the switch to position C and check that the sign at the right hand side of the display window is on. If the F sign is on

instead, press the blue button G to change the reading to .

Touch the meter lead probes together and press the REL ³ key on the meter to eliminate the lead resistance from the meter

reading.

On the AV0 2003

Move the right hand slider switch to position B, and the left hand slider switch to the appropriate Ohms ( ) range.

On an analogue meterMove the dial to the appropriate Ohms ( ) range.

Measuring Continuity

Make sure there is no power to the part of the circuit you are checking for continuity.

Connect one probe to one end of the component or wire to be checked and the other probe to the other end. It does not

matter which way round the two probes are placed.

On the FLUKE 85Turn the switch to position C and check that the beeper symbol appears at the left hand side of the display window. If the F

sign is on instead, press the button labelled F in the meter drawing.

If there is continuity in the circuit, the beeper will sound. If there is no continuity (open circuit), the beeper will not sound.

On the AV0 2003

Move the right hand slider switch to position B, and the left hand slider switch to position C.

If there is continuity (i.e. very low resistance) between two points the buzzer will sound.


Turn the dial to the lowest Ohms ( ) range.

If there is continuity (i.e. very low resistance) between two points the needle will move across fully (or almost fully) to the right

hand side of the scale.

Section C Electrics

9803/3260

Section C

2 - 3

Issue 3

Test Methods



2 - 4

How to Test a Diode or a Diode Wire

A diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end. The diode is

sealed in heatshrink sleeving.

On the FLUKE 85Turn the switch to position D.

Press the HOLD button and check that the H sign appears at the top right hand side of the display window.

Connect the black probe to the end of the diode with a band or to the male connector of the diode wire. Connect the red

probe to the other end of the diode or diode wire. If the beeper does not sound the diode or diode wire is faulty. Connect thered probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be

connected to the other end of the diode or diode wire. If the beeper sounds or the meter does not read O.L., the diode or

diode wire is faulty.

Press the HOLD button and check that the H sign disappears from the right hand side of the display window.

On the AV0 2003Move the right hand slider to position A, and the left hand slider switch to position C.

Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probeshould be connected to the other end of the diode or diode wire. If the Avometer does not buzz the diode is faulty.

Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe

should be connected to the other end of the diode or diode wire. If the Avometer does not read "1" the diode is faulty.


Select the Ohms 1000s (1k) range.Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe

should be connected to the other end of the diode or diode wire. The meter should read 20-400 K , if it reads more than this

the diode is faulty.

Select the Ohms 100s range.

Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probeshould be connected to the other end of the diode or diode wire. The meter should read 300-400 , if it reads less than this the

diode is faulty.

Section C Electrics

9803/3260

Section C

2 - 4

Issue 2

Test Methods



10 - 1

Adjustment

Note: Depending on machine type, the parking brake switch

may be mounted as shown at A or B.

Select the starter switch to the ON position, do not start the

engine.

Select either forward or reverse.

Raise the handbrake to the ON position.

Screw the parking brake switch C in a clockwise direction

until the audible alarm sounds and the visual warning is

illuminated.

Lock switch C in position with lock nuts D.

Release the parking brake and the audible alarm should

cease and the visual alarm extinguish.

For adjustment of the Parking Brake, see Section G,

'Parking Brake Caliper'.

Section C Electrics

9803/3260

Section C

10 - 1

Issue 3

Parking Brake Switch

S218320

A

B

DD

C

C

D

D



15 - 2

Basic Machine Component List (to serial

number 430000)

The 'basic' machine circuit diagram shows the electrical

circuit for a Syncro Shuttle transmission, for Powershift

transmission, refer to page C/15-4.

1 Battery2 Starter Switch

3 Thermostart

4 Starter Solenoid

5 Starter Motor

6 Neutral Start Relay

7 Transmission Dump Relay8 Forward Relay

9 Transmission Foot Dump Switch

9A Transmission Hand Dump Switch

10 Forward Solenoid

11 Park Brake Relay11A Park Brake Dump Relay12 Reverse Relay

13 Reverse Solenoid

14 Park Brake Switch

15 Coolant Temperature Gauge

16 Coolant Temperature Sender

17 Fuel Gauge18 Fuel Gauge Sender

19 Diode Bank

20 Engine Coolant Temperature Switch

21 Transmission Oil Temperature Switch

22 Engine Oil Pressure Switch

23 Transmission Oil Pressure Switch

24 Air Filter Restriction Switch26 Speedometer / Tachometer

27 Alternator

28 Alternator Warning

29 Warning Buzzer

30 Park Brake Indicator Light31 Brake Light Switch➁

32 Brake Lights ➁

34 2/4 Wheel Drive Solenoid➂

35 2/4 Wheel Drive Relay ➂

36 2/4 Wheel Drive Brake Relay ➂

37 2/4 Wheel Drive Select Switch➂

38 Rear Wiper Motor

39 Rear Wiper Switch40 Fuel Pump Solenoid

41 Indicator Flasher Relay42 Hazard Warning Switch

43 Hazard Warning Lamp

44 RH Direction Indicators

45 LH Direction Indicators

46 Direction Indicator Switch

47 Diode48 Heater Motor

49 Heater Switch

50 Beacon

51 Beacon Switch

52 Interior Lamp

53 Interior Light Switch54 Radio

55 Washer Motor

56 Front Washer/Wiper Switch

57 Front Wiper Motor

58 Horn (Front)59 Horn Push (Front)

60 Head Light Flasher Switch

61 Head Light Main Beam Lamps

62 Main Beam Warning

63 Dipped Head Light Lamps

64 Head Light Dip Switch65 Head and Side Lights Switch

67 Front Working Lights

69 Front Working Lights Switch

70 Lighting Relay

71 Rear Working Lights

72 Rear Working Lights Switch75 Gauge Illumination (Tacho, Water, Fuel)

76 Reverse Alarm Relay

77 Reverse Alarm

78 Side Light Left Hand

79 Tail Light Left Hand

80 Socket (Dipper Light)81 LH Number Plate Light (Cab)

82 Number Plate (Chassis)

83 Side Light Right Hand

84 Tail Light Right Hand

85 Hydraulic Speed Control Switch

87 Hydraulic Speed Control Switch88 Hydraulic Speed Control Relay

89 Hydraulic Speed Control Solenoid

90 Socket (Junction Box Feed)

119 Rear Fog Light➀

120 Rear Fog Light Switch ➀

125 Rear Washer Motor

126 Rear Washer Switch

➀ Note: Machines prior to serial number 400077 have the

fog light circuit protected by fuse B3, not C4 as

indicated.

➁ Note: Machines up to serial number 403024 have the

brake lights protected by fuse A1.

Machines from serial number 403025 to 404851 have

the brake lights protected by fuse C3.

Machines from serial number 404852 have the brake

lights and 2/4WD solenoid protected by fuse A1 (as

indicated in the fuse identification chart).

➂ Applicable to 2WS machines only (from serial number

409435). For 2WS machines prior to 409434 and all

4WS machines, refer to page C/15-5.

Fuses

A1 - A9

B1 - B9

C1 - C4

Refer to Technical Data pages at the beginning of Section C

for further fuse details and ratings.

Section C Electrics

9803/3260

Section C

15 - 2

Issue 3

Circuit Diagrams and Component Lists



15 - 5


2/4 Wheel Drive (all machines up to serial

number 409434)

Component List2 Starter Switch31 Brake Light Switch

32 Brake Lights

34 2/4 Wheel Drive Solenoid

35 2/4 Wheel Drive Relay

36 2/4 Wheel Drive Brake Relay

37 2/4 Wheel Drive Select Switch

Section C Electrics

9803/3260

Section C

15 - 5

Issue 3


A216950

600CB

34

600AB 600BR

32

853

600AA

816

35

36

854818

853A

37

108B

877

107D

108

31

A1

C3

2

Transmission Dump Circuit (machines up

to serial number 413772)

Component List2 Starter Switch


7 Transmission Dump Relay

8 Forward Relay9 Transmission Foot Dump Switch

9A Transmission Hand Dump Switch

10 Forward Solenoid

11 Park Brake Relay

12 Reverse Relay

13 Reverse Solenoid14 Park Brake Switch

19 Diode Bank

29 Warning Buzzer

A216960



15 - 6


Instrument Lights Test Button (machines

up to serial number 404502)

Component List2 Starter Switch19 Diode Bank




23 Transmission Oil Pressure Switch24 Air Filter Restriction Switch

25 Warning Lights Test Button

29 Warning Buzzer

Section C Electrics

9803/3260

Section C

15 - 6

Issue 2


A216970

19

29

21 23 25

20 22 24

A2

B9

406

404

403

405

402

600CK

600C 600BU

600CF

600BP

410

2

Hydraulic Speed Control - 2 Relays


Component List2 Starter Switch


86 Hydraulic Speed Control Warning

87 Hydraulic Speed Control Switch88 Hydraulic Speed Control Relay


B1

87

88

88

101A

867A

867

867B

85

89

86

866

866A

2101

101A

101C

A216940



18 - 2

Main Components1 Battery

2 Starter Switch

3 Thermostart

4 Starter Solenoid

5 Starter Motor

6 Forward Solenoid

7 Reverse Solenoid

8 Reverse Alarm


10 Fuel Pump Solenoid

11 Hydraclamp Solenoid


13 Socket (Junction Box Feed)

14 Shovel Reset Solenoid

15 Rear Horn

16 Diode

17 Indicator Flasher Unit

18 Side Instrument Console


20 Fuel Gauge Sender

21 Tachometer


23 Fuel Gauge

24 Hourmeter

25 Front Instrument Console26 Alternator

27 Cigar Lighter

28 Clock

29 Face Level Fan

30 Heated Seat

31 Rear Washer Motor

32 Rear Wiper Motor

33 Washer Motor

34 Front Wiper Motor

35 Horn (Front)

36 Socket (Dipper Light)

37 Beacon38 Tracker

39 Radio

40 Heater Motor

41 Heater Resistor

42 Air Conditioning Compressor

54 Warning Buzzer

Switches60 Transmission Dump Switch (Gear)

61 Transmission Dump Switch (Loader)

62 Forward/Reverse Switch


64 Brake Light Switch

65 Brake/Drive Select Switch

66 Hydraclamp Switch



69 Shovel Reset Switch

70 Rear Horn

71 Hazard Warning Switch






77 Air Filter Restriction Switch

78 Face Level Fan Switch

79 Heated Seat Switch

80 Rear Washer/Wiper Switch

81 Head Light Flasher Switch

82 Front Washer/Wiper Switch

83 Horn Push (Front)

84 Rear Fog Light Switch85 Head and Side Lights Switch

86 Head Light Dip Switch


88 Rear Working Lights Switch

89 Interior Light Switch

90 Interior Light Switch

91 Beacon Switch

92 Heater Switch

93 Air Conditioning Switch



Fuses

A1 - A9

B1 - B9

C1 - C6

Note: Fuse C6 is only fitted on machines from serial number:3CX (214) - 438636; 4CX (214S) - 437866.

Prior to this, the gear controls were protected by fuse C3.



..... continued

Section C Electrics

9803/3260

Section C

18 - 2

Issue 2*


Basic Machine Component List (from serial number 430001)

The basic circuit shows a standard 3CX (214) machine fitted with syncro shuttle transmission and 2 wheel steer. The remaining

pages in section C/18 show machine circuits that differ from the ‘basic’. Note that ONLY the differences are shown.*

*

*



18 - 3

Basic Machine Component List (from

serial number 430001)

Relays


111 Ignition Relay ‘1’

112 Transmission Dump Relay

113 Forward Relay

114 Reverse Relay

115 Park Brake Relay

116 4 Wheel Brake Relay

117 Hydraulic Speed Control Relay

118 Rear Horn Relay


120 Road Lights Relay

121 Italian Worklight Relay

122 Heater Relay

Lights

140 LH Brake Light

141 RH Brake Light

142 LH Front Indicator

143 LH Rear Indicator

144 RH Front Indicator

145 RH Rear Indicator

146 Alternator Warning Indicator Light

147 Park Brake Indicator Light

148 Water Temperature Indicator Light

149 Transmission Temperature Indicator Light

150 Engine Oil Pressure Indicator Light151 Transmission Oil Pressure Indicator Light

152 Air Filter Blocked Indicator Light

153 Hazard Warning Indicator Light

154 Main Beam Warning Indicator Light

155 Gauge Illumination

156 Turn Signal Indicator Light

157 Master Warning Lights

158 Side Lights Indicator Light

159 Rear Work Lights Indicator Light

160 Front Work Lights Indicator Light

161 Rear Fog Light Indicator Light

162 Rear Fog Light163 LH Main Beam Light

164 RH Main Beam Light

165 LH Dip Beam Light

166 RH Dip Beam Light

167 LH Number Plate Light

168 LH Tail Light

169 LH Side Light

170 RH Number Plate Light

171 RH Tail Light

172 RH Side Light

173 Front Working Lights

174 Rear Working Lights


Refer to pages C/42-1 on for full wire number identification

and descriptions.

Section C Electrics

9803/3260

Section C

18 - 3

Issue 1




Electrics

9803/3260 Issue 2*

N o

t e : E x

c e p t f o r t h e t r a n s m i s s i o n a n d s t e e r c

i r c u i t s

( s h o w n

a b o v e ) , t h e A W S e l e c t r i c a l c i r c u i t

i s t h e

s a m e a s

s h o w n o n P a g e C / 1 8 - 1 t o C / 1 8 - 4 .

M a

i n C o

m p o n e n

t s

1

B a t t e r y

2

S t a r t e r S w i t c h

3

T h e

r m o s t a r t

4

S t a r t e r S o l e n o i d

5

S t a r t e r M o t o r

8

R e v

e r s e A l a r m

9

2 / 4

W h e e l D r i v e S o l e n o i d

1 6

D i o d e

4 3

M a i n s h a f t S o l e n o i d

4 4

L a y

s h a f t S o l e n o i d

4 5

F o r w a r d L o w S o l e n o i d

4 6

F o r w a r d H i g h S o l e n o i d

4 7

R e v

e r s e H i g h S o l e n o i d

4 8

R e v

e r s e L o w S o l e n o i d

4 9

C r a

b / 4 W h e e l S t e e r S o l e n o i d

5 0

4 W

h e e l S t e e r S o l e n o i d

5 1

C r a

b S o l e n o i d

5 2

2 W


5 3

S t e e r M o d e P r i n t e d C i r c u i t B o a r d

S w

i t c h e

s

6 1

T r a n s m i s s i o n D u m p S w i t c h ( L o a d e r )

6 2

F o r w a r d / R e v e r s e S w i t c h

6 3

P a r k B r a k e S w i t c h

6 4

B r a k e L i g h t S w i t c h

9 6

4 W

h e e l D r i v e S w i t c h

9 7

P o w

e r s h i f t C o l u m n S w i t c h

9 8

F r o n t P r o x i m i t y S w i t c h

9 9

R e a

r P r o x i m i t y S w i t c h

1 0 0 S t e e r M o d e S e l e c t S w i t c h

1 0 1 4 W

S / C r a b S e l e c t o r ( p a r t o f P C B - i t e m 5 3 )

1 0 2 2 W

S / 4 W S S e l e c t o r ( p a r t o f P C B - i t e m

5 3 )

R e

l a y

1 1 0 N e u t r a l S t a r t R e l a y

1 1 1 I g n i t i o n R e l a y ‘ 1 ’

1 1 2 T r a n s m i s s i o n D u m p R e l a y

1 1 3 F o r w a r d R e l a y

1 1 4 R e v e r s e R e l a y

1 1 5 P a r k B r a k e R e l a y

1 1 6 4 W h e e l B r a k e R e l a

y

1 1 9 I g n i t i o n R e l a y ‘ 2 ’

1 2 3 N e u t r a l R e l a y

1 2 4 A u t o 2 W h e e l D r i v e

R e l a y

1 2 5 D r i v e R e l a y ( L a y s h a

f t & M a i n s h a f t )

1 2 6 F o r w a r d H i g h / L o w

R e l a y

1 2 7 R e v e r s e H i g h / L o w R e a l y

L i g h t s

1 7 5 4 W h e e l S t e e r I n d i c

a t o r L i g h t

1 7 6 C r a b S t e e r I n d i c a t o

r L i g h t


a t o r L i g h t

1 7 8 F r o n t I n s t r u m e n t C o n s o l e I l l u m i n a t i o n

W i r e N u m

b e r

I d e n

t i f i c a

t i o n

R e f e r t o p a g e s C / 4 2 - 1 o n f o r f u l l w i r e n u m b e r

i d e n t i f i c a t i o n a n d d e s c r i p t i o n s .

N o

t e : F u s e C 6 i s o n l y

f i t t e d o n m a c h i n e s f r o m

s e r i a l n u m b e r :

3 C X ( 2 1 4 ) - 4 3 8 6 3 6

; 4 C X ( 2 1 4 S ) - 4 3 7 8 6 6

P r i o r t o t h i s , t h e g e a r c o n t r o l s w e r e p r o t e c t e d b y

f u s e C 3 .

18 - 6 18 - 6Circuit Diagrams and Component Lists

Section C Section C

P o w e r

s h i f t T r a n s m

i s s

i o n

& S t e e r

C i r c u

i t -

A W S M a c

h i n e s O

n l y ( f r o m

S e r i a

l N u m

b e r 4

3 0 0 0 1 )

*



P o w e r

s h i f t T r a n s m i s s i o n - 2 W S M

a c h i n e s O n l y ( f r o m S e r i a l N u m b e r 4 3 0 0 0 1 )

a n d S t

e e r C i r c u i t f o r 3 C X 4 x 4 x 4 M a c h i n e s

Electrics

9803/3260 Issue 3


Section C Section C

A 2 2 8 9 8 1

3

1

5

4

1 1 0

2

1 1 1

1 1 2

1 6

6 1

6 3

1 4 7

1 1

5

1 2 3

1 1 3

1 1 4

6 2

8

9

6 5

6 4

1 1 9

1 1 6

1 4 0

1 4 1

4 3

4 4

4 5

4 6

4 8

4 7

1 2 7

1 6

1 6

1 6

9 7

1 2 5

1 2 6

F U S E

C 6

9 8

9 9

5 2

1 7 7

1 7 8

5 0

1 0 0

1 2 9

1 3 0

F U S E

C 2

F U S E B I

1 0 1

N O C R A B

R E L A Y

1 3 1



Electrics

9803/3260 Issue 3*

N o

t e : E x c e p t f o r t h e t r a n s m i s s i o n c i r c u i t ( s h o w n

a b o v e ) ,

t h e 2 W S e l e c t r i c a l c i r c u i t i s t h e s a

m e a s

s h o w n o

n P a g e C / 1 8 - 1 t o C / 1 8 - 4 .

M a

i n C o

m p o n e n

t s

1

B a t t e r y

2

S t a r t e r S w i t c h

3

T h e

r m o s t a r t

4

S t a r t e r S o l e n o i d

5

S t a r t e r M o t o r

8

R e v

e r s e A l a r m

9

2 / 4

W h e e l D r i v e S o l e n o i d

1 6

D i o d e

4 3

M a i n s h a f t S o l e n o i d

4 4

L a y

s h a f t S o l e n o i d

4 5

F o r w a r d L o w S o l e n o i d

4 6

F o r w a r d H i g h S o l e n o i d

4 7

R e v

e r s e H i g h S o l e n o i d

4 8

R e v

e r s e L o w S o l e n o i d

5 0

4 W


5 2

2 W


S w

i t c h e

s

6 1

T r a n s m i s s i o n D u m p S w i t c h ( L o a d e r )

6 2

F o r w a r d / R e v e r s e S w i t c h

6 3

P a r k B r a k e S w i t c h

6 4

B r a k e L i g h t S w i t c h

6 5

B r a k e / D r i v e S e l e c t S w i t c h

9 7

P o w

e r s h i f t C o l u m n S w i t c h

9 8

F r o n t P r o x i m i t y S w i t c h

9 9

R e a

r P r o x i m i t y S w i t c h

1 0 0 S t e e r M o d e S e l e c t S w i t c h

R e

l a y

1 1 0 N e u t r a l S t a r t R e l a y

1 1 1 I g n i t i o n R e l a y ‘ 1 ’

1 1 2 T r a n s m i s s i o n D u m p R e l a y

1 1 3 F o r w a r d R e l a y

1 1 4 R e v e r s e R e l a y

1 1 5 P a r k B r a k e R e l a y

1 1 6 4 W h e e l B r a k e R e l a

y

1 1 9 I g n i t i o n R e l a y ‘ 2 ’

1 2 3 N e u t r a l R e l a y

1 2 5 D r i v e R e l a y ( L a y s h a

f t & M a i n s h a f t )

1 2 6 F o r w a r d H i g h / L o w

R e l a y

1 2 7 R e v e r s e H i g h / L o w R e l a y

1 2 9 4 W h e e l S t e e r R e l a

y

1 3 0 2 W h e e l S t e e r R e l a

y

1 3 1 R e l a y

L i g h t s

1 4 0 L H B r a k e L i g h t

1 4 1 R H B r a k e L i g h t

1 4 7 P a r k B r a k e I n d i c a t o

r L i g h t


a t o r L i g h t

1 7 8 F r o n t I n s t r u m e n t C o n s o l e I l l u m i n a t i o n

W i r e N u m

b e r

I d e n

t i f i c a

t i o n

R e f e r t o p a g e s C / 4 2 - 1 o n f o r f u l l w i r e n u m b e r

i d e n t i f i c a t i o n a n d d e s c r i p t i o n s .

N o

t e : F u s e C 6 i s o n l y

f i t t e d o n m a c h i n e s f r o m

s e r i a l n u m b e r :

3 C X ( 2 1 4 ) - 4 3 8 6 3 6

; 4 C X ( 2 1 4 S ) - 4 3 7 8 6 6

P r i o r t o t h i s , t h e g e a r c o n t r o l s w e r e p r o t e c t e d b y

f u s e C 3 .


Section C Section C

P o w e r

s h i f t T r a n s m

i s s

i o n -

2 W S M

a c

h i n e s

O n

l y ( f r o m

S e r i a

l N u m

b e r

4 3 0 0 0 1 )

a n

d S t

e e r

C i r c u

i t f o r

3 C X 4 x

4 x 4

M a c

h i n e s *

*



18 - 10

Main Components

1 Battery

2 Starter Switch3 Thermostart

4 Starter Solenoid

5 Starter Motor

6 Forward Solenoid

7 Reverse Solenoid

8 Reverse Alarm


10 Fuel Pump Solenoid

15 Rear Horn

16 Diode

17 Indicator Flasher Unit

18 Side Instrument Console


20 Fuel Gauge Sender

21 Tachometer


23 Fuel Gauge

24 Hourmeter

25 Front Instrument Console

26 Alternator

35 Horn (Front)

37 Beacon

54 Warning Buzzer

55 Hammer Solenoid

Switches

60 Transmission Dump Switch (Gear)

61 Transmission Dump Switch (Loader)

62 Forward/Reverse Switch


64 Brake Light Switch

70 Rear Horn

71 Hazard Warning Switch






77 Air Filter Restriction Switch

83 Horn Push (Front)


88 Rear Working Lights Switch

96 4 Wheel Drive Switch

103 Hammer Isolator Switch

104 Hammer Footswitch

Relays


111 Ignition Relay ‘1’112 Transmission Dump Relay

113 Forward Relay

114 Reverse Relay

115 Park Brake Relay

118 Rear Horn Relay


120 Road Lights Relay

Lights

140 LH Brake Light

141 RH Brake Light

142 LH Front Indicator

143 LH Rear Indicator144 RH Front Indicator

145 RH Rear Indicator

146 Alternator Warning Indicator Light

147 Park Brake Indicator Light

148 Water Temperature Indicator Light

149 Transmission Temperature Indicator Light

150 Engine Oil Pressure Indicator Light

151 Transmission Oil Pressure Indicator Light

152 Air Filter Blocked Indicator Light

155 Gauge Illumination

156 Turn Signal Indicator Light

173 Front Working Lights174 Rear Working Lights


Refer to pages C/42-1 on for full wire number identification

and descriptions.

Fuses

A1 - A9B1 - B9

C1 - C6



Section C Electrics

9803/3260

Section C

18 - 10

Issue 1


3CXE (214E) Machine Only - Component List (from serial number 430001)



20 - 1

Safety

!WARNINGBatteries give off an explosive gas. Do not smoke when

handling or working on the battery. Keep the battery away

from sparks and flames.

Battery electrolyte contains sulphuric acid. It can burn you if

it touches your skin or eyes. Wear goggles. Handle the

battery carefully to prevent spillage. Keep metallic items

(watches, rings, zips etc) away from the battery terminals.

Such items could short the terminals and burn you.

Set all switches in the cab to OFF before disconnecting and

connecting the battery. When disconnecting the battery,

take off the earth (-) lead first.

When reconnecting, fit the positive (+) lead first.

Re-charge the battery away from the machine, in a well

ventilated area. Switch the charging circuit off before

connecting or disconnecting the battery. When you have

installed the battery in the machine, wait five minutes before

connecting it up.

First Aid - Electrolyte

Do the following if electrolyte:

GETS INTO YOUR EYES

Immediately flush with water for 15 minutes, always getmedical help.

IS SWALLOWED

Do not induce vomiting. Drink large quantities of water or

milk. Then drink milk of magnesia, beaten egg or vegetableoil. Get medical help.

GETS ONTO YOUR SKIN

Flush with water, remove affected clothing. Cover burns with

a sterile dressing then get medical help.5-3-4-3/1

Maintenance

To ensure that the battery provides optimum performance

the following steps should be observed:

1 Make sure that the electrical connections are clean and

tight. Smear petroleum jelly on connectors to prevent

corrosion.

2 When applicable - never allow the electrolyte level to

fall below the recommended level - 6 mm (1/4 in) abovethe plates. Use only distilled water for topping up.

3 Keep the battery at least three quarters charged,

otherwise the plates may become sulphated (hardened)

- this condition makes recharging the battery very

difficult.

Extra precautions must be taken when bench charging

maintenance free batteries, they are more prone to damage

by overcharging than the standard type of battery:

- NEVER boost-charge a maintenance free battery.

- NEVER charge a maintenance free battery at a

voltage in excess of 15.8 Volts.

- NEVER continue to charge a maintenance free

battery after it begins to gas.

Section C Electrics

9803/3260

Section C

20 - 1

Issue 3

Batteries



20 - 2

Section C Electrics

9803/3260

Section C

20 - 2

Issue 4

Batteries

Testing - Specific Gravity

The specific gravity of the electrolyte gives an idea of the

state of charge of the battery. Readings should be takenusing a hydrometer, when the electrolyte temperature is 15

°C (60 °F). If the battery has recently been on charge, waitapproximately one hour (or slightly discharge the battery) to

dissipate the surface charge before testing.

Specific Gravity at 15 °C (60 °F)

Battery Testing

This test is to determine the electrical condition of the

battery and to give an indication of the remaining useful

‘life’.

Before testing ensure that the battery is at least 75%

charged (SG of 1.23 to 1.25 for ambient temperature up to27°C).

Ensure that the battery is completely disconnected from the

vehicle.

Connect up the battery tester (part no. 993/85700) asfollows:

1 Set the CHECK/LOAD switch A to OFF.

2 Set rocker switch B to the battery voltage (12V).

3 Connect the red flying lead to the battery positive (+)

terminal and the black flying lead to the battery negative

(-) terminal.

4 Set the CHECK/LOAD switch A to CHECK to read the

battery no-load voltage which should be at least 12.4volts.

Fault Diagnosis

Battery Tester Readings

1 CHECK: 0 - 12.6 Volts

LOAD: less than 6 Volts

2 CHECK: 6 - 12.4 Volts

LOAD: less than 9 Volts and falls steadily but remainsin yellow zone.

3 CHECK: less than 10 Volts

LOAD: less than 3 Volts

4 CHECK: more than 11 VoltsLOAD: 6 - 10 Volts steady

Readings should be as tabulated and should not vary

between cells by more than 0.04. A greater variationindicates an internal fault on that particular cell.

If the electrolyte temperature is other than 15 °C (60 °F) a

'correction factor' must be applied to the reading obtained.

Add 0.07 per 10 °C (18 °F) if the temperature is higher than

15 °C (60 °F) and subtract the same if the temperature islower.

5 Set the CHECK/LOAD switch A to LOAD and hold down

for 5 - 10 seconds until the meter reading stabilises. Thereading should be at least 9 volts.

Note: Do not hold the switch in the LOAD position for more

than 10 seconds.

6 If the foregoing tests are unsatisfactory, consult FaultDiagnosis below.

Remedy

Renew battery

Recharge and re-test. If tests still unsatisfactory renewbattery.

Indicates battery has been over-discharged and unlikely

to recover. Renew battery.

Charge battery which will probably recover.

Fully Charged Half Discharged Fully Discharged

Ambient temperature up to 27 °C (80 °F) 1.270 - 1.290 1.190 - 1.210 1.110 - 1.130

Ambient temperature above 27 °C (80 °F) 1.240 - 1.260 1.170 - 1.190 1.090 - 1.110

239510B

A



25 - 1

Harness Repair Introduction

Instances do occur where it is necessary to incorporate

auxiliary electrical components into existing electricalcircuits and, although unlikely with present wiring harnesses,

repair or replace specific individual wires within a harness.This will also apply to other machines in addition to those of

JCB manufacture.

To ensure that either the inclusion of an auxiliary electricalcomponent or a repair within a harness is completed to an

acceptable standard it is strongly recommended that the

following tools, equipment and procedures are always used.

Note that JCB harnesses have an International Protection

rating of 67 (I.P.67).

The sheath covering of the recommended splice is heat

shrunk onto the original wire insulation. This results in a seal

and corresponding joint to IP 67 specifications.

! CAUTIONWhen installing Auxiliary Electrical Components always

ensure that the additional load rating is suitable for that

particular circuit. It is unacceptable to simply increase

the fuse rating as this can cause overloading and

consequential failure of wiring, along with failure of

integral circuit components, which the fuse is protecting.ELEC 2 - 1

!WARNINGIn addition to the warnings incorporated into the

procedure, extreme care should be taken when handling

the gas heating tool to ensure that the flame does not

damage or set fire to any items in the vicinity of the

repair, i.e. other wires, floor panels, floor mats, sound

proofing, paintwork. etc. This tool should not be used in

any restricted location prohibiting the use of "Naked

Flames' or where risk of explosive gas or similar safety

parameters apply. No other heat source should be used

to attempt a sealed joint .ELEC 2 - 2

! CAUTIONWhen the heater is in use, the reflector and the air

coming out are extremely hot. Keep away to avoid

accidental burns. Do not touch the reflector until it has

had time to cool down after switching off. If flame

reappears at the reflector when the heater is in use, the

catalytic element is damaged or used up. Stop work

immediately and replace the heater.ELEC 2-3

Tools Required

892/00350 Butane Heater assembly 1

892/00349 Crimp tool 1892/00351 Splice 0.5-1.5 mm (Red) 50

892/00352 Splice 1.5-2.5 mm (Blue) 50892/00353 Splice 3.0-6.0 mm (Yellow) 50

Procedure

1 Cut the wire and remove the protective insulation for a

suitable distance dependent upon the size of wire andsplice to be used. For the splices detailed above, the

dimension is 7mm.

2 Using the correct sized splice, attach the new section

of wire required or auxiliary flying lead to the existing

harness and secure using the crimp tool X , part number892/00349.

Note that each of the splices detailed is colour-coded

to make size and range readily visible. They are

secured using the corresponding size and matchingcolour-coded jaws of the crimp tool to ensure joint

security. This tool also incorporates a ratchet closing

mechanism which will not release until the splice is

fully closed to the correct compression size.

3 With the Butane heater assembly, 892/00350, seal theconnection using the procedure on the next page.

....continued

Section C Electrics

9803/3260

Section C

25 - 1

Issue 4

Wiring Harness Repair

S189530

7

X



With the Butane Heater assembly 892/00350, seal theconnection using the following procedure.

3.1Remove the cap

A from the end of the disposable gascartridge B.

3.2 Before assembling the gas cartridge to the reflector

element C, turn the red ring D to the left, (in thedirection of the minus sign marked on the ring).

3.3 Position the tube hanging down from inside the reflector

assembly into the hole at the top of the gas cartridge.

Then press the gas cartridge up into the reflector

assembly as far as possible until the two elements are

clasped firmly together. A click will be heard.

3.4 Turn the small ring E so that the air holes at F are

completely closed.

Procedure (cont'd)

25 - 2

Section C Electrics Section C

25 - 2Wiring Harness Repair

9803/3260 Issue 1

S189490/1

S189490/2

S189490/3

S189490/4

A

B

C

D

F

E



3.5 Turn the red ring D to the right (in the direction of theplus sign) in order to turn on the gas.

IMPORTANT:Before turning the heater on, make sure thatthe cartridge is not hotter than the reflector element. This

may occur if the cartridge is held in the hand for a long time.

The temperature difference between the cartridge and thereflector element may cause long yellow flames to appear on

ignition.

3.6 Hold the heater vertically and, using a match or

cigarette lighter, light the gas as shown.

Note: The fact that the sound of liquid cannot be heard when

the cartridge is shaken does not mean it is empty. No sound

will be heard even when the cartridge is full.

Hold the heater vertically for 1 to 2 minutes until the

catalytic reaction occurs. This is indicated when the

blue flame fades and the ceramic element glows red.

Then turn the small ring E until the air holes at F are

completely open. The tool is ready for use.

The heater can be used in two modes:

3.7 Side wings G down, reflector head completely open. In

this mode the infra-red heat waves are dominant

(recommended for the light coloured plastic splices).

Side wings G up (see fig at step 3.8), reflector head

opening reduced. In this mode the heating is done only

by the hot gas (use for dark coloured plastic splices).

3.8 To switch off the heater, turn the red ring D to the left (in

the direction of the minus sign).

Procedure (cont'd)

25 - 3

Section C Electrics Section C

25 - 3Wiring Harness Repair

9803/3260 Issue 1

S189490/5

S189490/6

S189490/7

S189490/8

D

F

E

G

G

D



38 - 1

Starting Circuit Test

Before carrying out the voltmeter tests, check the battery

condition (see Battery Testing) and ensure that all

connections are clean and tight.

To prevent the engine starting during the tests ensure that

the engine stop fuse is removed, (refer to fuse identificationpage).

Check the readings in the following sequence using a

voltmeter. Unless otherwise stated, the readings must be

taken with the starter switch held in the 'start' position ('HS')

and the transmission forward/reverse selector in neutral.

Note: Do not operate the starter motor for more than 20

seconds at one time. Let the starter motor cool for at least

two minutes between starts.

Test 1Connect the voltmeter across the battery terminals. Reading

in 'start' position: 10.0V approximately. Minimum

permissible reading in 'start' position 9.5V.

A low reading probably indicates a fault in the starter motor.

Test 2

Connect the voltmeter between the starter main terminal A

and the commutator end bracket B. In the 'start' position,

the reading should not be more than 0.5V below the reading

obtained in Test 1. Minimum permissible reading in 'start'position 9.0V.

If the reading is within this limit, continue to Test 3. If the

reading is outside the limit, proceed to Tests 4 and 5.

Test 3

Connect the voltmeter between the solenoid terminal C and

a good earth. Minimum permissible reading in 'start'position: 8.0V.

Test 3a

If the reading is less than specified, connect the voltmeter

between the neutral start relay terminal D and earth. An

increase in reading to 8.0V indicates a fault in the wiring

from the start relay to the solenoid.

Section C Electrics

9803/3260

Section C

38 - 1

Issue 2*

Starter Motor

S151030

S151000

S151010

AB

C

+

-

N

F

R

810C

842 004

600V

A

B

C

D E

H

A215660

*

*



38 - 2

Starting Circuit Test (cont'd)

Test 3b

If the reading between terminal D and earth is below 8.0V,

connect the voltmeter between terminal E and earth. An

increase in the reading to 8.0V indicates either a faulty start

relay or a fault in the feed from the transmission selectorswitch to the relay solenoid. Check also the solenoid earth

connection.

If the reading between E and earth is less than 8.0V, the fault

must be in either the starter switch or in the wiring between

the solenoid, starter switch, and the start relay.

Test 4

Connect the voltmeter between battery negative and starter

earth connection B. The reading in the 'start' position should

be practically zero, maximum permissible reading 0.25V.

If the reading is above 0.25V, a high resistance in the earth

lead or connections is indicated.

Test 5

Connect the voltmeter between battery positive and the

starter main terminal A. With the starter switch 'off', thevoltmeter should indicate battery voltage, but it should fall topractically zero when the switch is turned to the 'on'

position, maximum permissible reading 0.25V.

Test 5a

If the reading is above 0.25V, a high resistance is present in

the insulated lead or in the solenoid. Connect the voltmeter

between the battery positive and solenoid connection H. If

the voltmeter now reads zero with the switch closed, the

fault is in the solenoid.

Finally refit the engine stop fuse.

Section C Electrics

9803/3260

Section C

38 - 2

Issue 2*

Starter Motor

S151050

S151040

B

A

H

*

*



38 - 3

Section C Electrics

9803/3260

Section C

38 - 3

Issue 1

Starter Motor

S02043C



38 - 4


Disconnect cables and remove battery. Remove cables from

main starter terminal and solenoid terminal. Using special

tool 825/00410 (and adapter 825/99833 if required) unscrew

three securing nuts and remove starter motor.

Replace by reversing the removal sequence.

Dismantling

Note: Dismantle only to item 34 unless the field windings are

to be renewed. Test the windings electrically before

removing them from the motor yoke 15.

Using a slotted steel tube, displace ring 23 to permit

withdrawal of ring 22.

Allow brake shoes 28 to remain in the end plate 11 unless

requiring renewal.

Servicing and Renewal

Renew brushes 14 and 14A if their length is less than 8mm

(0.3in.).

Clean the commutator A. If individual copper bars are

burned or eroded the armature has broken windings and

must be renewed. Otherwise polish with fine grade glass

paper (not emery). Renew armature if commutator diameteris 38mm (1.5in.) or less.

Check the field windings for open circuits by connecting a

multimeter set to measure resistance (see page C/2-2)

between the stud terminal B and each positive brush 14A in

turn. A high or infinity reading indicates an open circuit.

Similarly, connect the meter between brushes 14A and the

motor yoke 15. Any reading other than infinity indicates a

short circuit between the coils and the yoke. Renew the coils

as necessary, removing screws 36 with a pole shoe

screwdriver C50 (obtainable from Lucas dealers).

Check bronze bushes 32 and 34 for wear.

Assembly

Align crosspin C with the notches in the brake shoes 28

before assembling brush carrier and back plate to motor

yoke. Ensure that brushes 14A are correctly located in the

insulated brush boxes.

Smear drive shaft splines and operating collar bearingsurface with JCB MPL Grease before assembly. Assemble

operating fork 19 with curved face toward the armature.

Set the movement of drive pinion 24 by connecting a 6v

battery and switch as shown. Operate switch and check

dimension D. Adjust to 0.13-1.14mm (0.005-0.045in.) by

slackening locknut 17 and rotating eccentric pin 18 as

necessary. Re-tighten locknut.

Section C Electrics

9803/3260

Section C

38 - 4

Issue 1

Starter Motor

S02303A

D



39 - 1

Charging Circuit Test

Ensure that all battery and alternator connections are in

place, secure and making good metal - to - metal contact,

especially the 'earth' connections to chassis and engine.

Adjust the alternator drive belt tension if necessary and

make sure that the battery is well charged.

Turn the start switch to the ON position.

'Oil pressure' and 'No charge' warning lights should glow.

If any light fails, proceed to Check 1.

Start the engine; all warning lights should extinguish rapidly.

If the 'No charge' warning light remains ON proceed to

Check 2.

If the oil pressure warning remains on STOP ENGINE

IMMEDIATELY and investigate the engine lubricationsystem.

Check 1

With start switch 'ON' try the heater motor and screen wiper.

If they operate normally, check the warning light bulb for

blown filament.

Simultaneous failure of all items indicates a fault at the start

switch. Check for cable disconnection before condemningthe switch itself.

If the 'No charge' warning bulb is in good order, withdraw

the triple plug from the back of the alternator. Make a

temporary connection between the SMALL terminal in theplug and earth as shown below. If the 'No charge' warning

bulb still fails to light, check the cable for continuity. If the

bulb now lights, check the alternator for a defective regulator

(see Alternator Charging Test).

Check 2

Note: the following checks should be made using an

analogue (moving pointer) type meter.

Stop the engine and turn the starter switch to OFF.

Withdraw the alternator plug and connect the test meter

between the large terminals and 'earth'. With the meter set

to measure 12V DC, the meter should show battery voltage.If the reading is zero, check the cables for continuity,

particularly at the starter terminals.

If the voltage is correct, check the alternator as follows:

Al ternator Charging Test

If the battery is in a fully charged condition, switch on the

working lights for 3 minutes before commencing the test. Alternatively, operate the starter for a few moments withfuse B2 removed.

Install a 100 amp open - type shunt between the battery

positive lead and the battery positive terminal. Connect the

test meter and select DC Amps range.

Start the engine and run at maximum speed (see Page K/1-1). Meter should show maximum alternator output (see

Technical Data).

Note: The meter reading should be taken as soon as

possible after starting the engine, as the charging current

Section C Electrics

9803/3260

Section C

39 - 1

Issue 2*

Alternator

*

*

*



39 - 2

A zero reading indicates failure of the alternator and may be

caused by one of the following conditions. These are listedin the order of probability.

a Defective suppression capacitor.

b Dirty slip rings or worn brushes.

c Defective regulator.

d Defective rectifier.

e Open or short - circuited field (rotor) windings.

f Open or short - circuited power (stator) windings.

To check for fault a, disconnect the capacitor and repeat the

charging test. Renew the capacitor if necessary.

To check for faults b and c, remove the regulator and brush

box assembly. Check the condition of the brushes and, if

necessary, clean the sliprings using extra - fine glasspaper.

The regulator may only be checked by substitution.

Faults d, e, and f may be checked only by removing and

dismantling the alternator for further testing.

Terminal 'W' Output (Tachometer) Test

With the test meter set to 12V DC, measure the output at the'W' terminal as shown. If the reading is less than 7V DC theregulator will need to be replaced. If the output reading at

the 'W' terminal is satisfactory then the problem would lie

with the instrument panel tachometer head.

Section C Electrics

9803/3260

Section C

39 - 2

Issue 3*

Alternator

*

*



39 - 3

Service Precautions

a Ensure that the battery negative terminal is connected

to the earthing cable.

b Never make or break connections to the battery oralternator, or any part of the charging circuit whilst the

engine is running. Disregarding this instruction will

result in damage to the regulator or rectifying diodes.

c Main output cables are 'live' even when the engine is

not running. Take care not to earth connectors in the

moulded plug if it is removed from the alternator.

d During arc welding on the machine, protect the

alternator by removing the moulded plug (or if separate

output cables fitted, remove the cables).

e If slave starting is necessary, connect the second

battery in parallel without disconnecting the vehiclebattery from the charging circuit. The slave battery may

then be safely removed after a start has been obtained.

Take care to connect batteries positive to positive,negative to negative.


Disconnect cables from rear of alternator, remove bolts A, B

and C and withdraw unit from machine.

Replace by reversing the removal sequence. Position the

alternator until belt deflection is approximately 10mm (3/8 in)

before tightening bolts B and C. It may be necessary to

slacken bolt D to allow full movement of alternator. Tighten

bolt A last of all.

Section C Electrics

9803/3260

Section C

39 - 3

Issue 1

Alternator

S099850B

S099850A

A

B

CD



39 - 4

Section C Electrics

9803/3260

Section C

39 - 4

Issue 1

Alternator

S215650



39 - 5


When Dismantling

Remove suppressor 2 (if fitted) by removing nut 1 and

disconnecting lead E from terminal F.

Unscrew bolts 3 and disconnect lead G from terminal H to

remove the brush box and regulator assembly 4. If the brush

length is less than 5mm (0.2 in.), new length 17mm (0.67 in.),

or if spring pressure is less than 1.3N the brush box andregulator assembly must be renewed.

Remove nuts and washers 5, bolts 6 and nuts 7. Remove

slip ring end bracket 8.

Carefully remove rectifier 10 and stator 11 as an assembly.

Unsolder the interconnecting wires at X, Y, and Z only ifrenewing either of these components.

Remove nut and washer 12 using an 8mm Allen key in the

shaft hexagon hole to prevent rotation. If necessary, use a

press to remove rotor 19 from the drive end bracket 17.

Check the rotor poles and the inner faces of the stator for

signs of rubbing, which indicates worn bearings. The drive

end bearing is part of bracket 17 and cannot be removed

separately. If requiring renewal, needle roller bearing 20

should be pressed out in the direction of the arrow.

When AssemblingReverse the dismantling procedure, but note the following:

Ensure that spacers 14,16, and 18 are correctly positioned

as shown.

Ensure that the slip rings J are clean and smooth, using

extra fine glasspaper to rectify slight imperfections.

Ensure that insulation bushes 9 and washers 5 are

positioned as shown.

Take care not to damage the brushes when fitting the brushbox and regulator assembly.

Torque Settings


3 2.7 0.28 2.0

5 4.1 0.41 3.0

6 3.4 0.35 2.5

7 5.4 0.55 4.0

12 60.0 6.10 44.2

Section C Electrics

9803/3260

Section C

39 - 5

Issue 1

Alternator



39 - 6

Section C Electrics

9803/3260

Section C

39 - 6

Issue 1

Alternator

216870

1

23

5

4

5 6

7

8

!

9

0£

B@

A



39 - 7

Dismantling and Assembly - Magneti

Marelli Type

When Dismantling

Remove nuts 1 and cover 2.

Check the protruding length of the brushes A. If this is less

than 10 mm (0.4 in), the brushes must be renewed. This will

involve renewal of the regulator and brush box assembly 6

as the brushes are not available separately.

Un-clip slip-ring shroud 3. Remove screw 4 and nuts 5 to

remove regulator and brush box assembly 6.

Do not separate the rectifier 7 from the slip-ring end bracket

8 as the gasket between them and its jointing paste provide

a special heat conducting path which must not be disturbed.

If further dismantling is required, note the positions of the six

leads B and unsolder them from their locating tags on the

rectifier.

Using special socket 892/00882, remove nut 9, washer 10

and pulley 11. If necessary, press the drive end bearing,

complete with the rotor 12, out of the bracket and stator

assembly 13.

When Assembling

Reverse the dismantling procedure, but note the following:

Ensure that slip ring faces are clean and smooth, using very

fine glasspaper if required. Do not use emery cloth.

Ensure that stator connecting wires will not touch against

the rotor.

Lightly polish side faces of brushes to ensure free movement

in brush box.

Torque Settings

Item Nm Kgf m lbf in

1 3.0-4.0 0.3-0.4 26-36

4 2.0-2.5 0.2-0.25 18-21

5 (M5) 1.7-2.3 0.2-0.23 15-20

5 (M6) 3.6-5.1 0.4-0.5 32-45

Item Nm Kgf m lbf ft

9 70-90 7.2-9.1 52-66

Section C Electrics

9803/3260

Section C

39 - 7

Issue 1

Alternator



40 - 1

Harness Location - Machines upto Serial

Number 430000

ITEM DESCRIPTION

1 Mainframe Harness

2 Panel Harness

3 Cab Harness

4 Cab Roof Harness5 Solenoid Harness

6 Rear Light Extension Harnesses (see note)

Note: The illustration shows a typical machine.

Section C Electrics

9803/3260

Section C

40 - 1

Issue 3

Harness Location

1

2

3

4

6

5

S164091



40 - 2

Harness Location - Machines from Serial

Number 430001

ITEM DESCRIPTION

1 Mainframe Harness

2 Panel Harness

3 Cab Harness

4 Cab Roof Harness5 Solenoid Harness

6 Rear Light Harnesses (see note)

7 Engine Shut Off Harness

Note: The illustration shows a typical machine.

Section C Electrics

9803/3260

Section C

40 - 2

Issue 4

Harness Location

3

2

6

157

4



41 - 1

Wire/Harness Numbers - Explanation of:

Each wire has its own unique identification number, this number is printed on the wire every 50 mm (2 inches). The wire

numbers listed on the next few pages identify the source and final destination of all the wires used on the machine.

Also printed on the wire is the part number of the harness the wire originates from; the harness part number is shortened, sofor instance, if the harness part number is 719/37100, the number printed on the harness wires will be 9/371 (71 and 00 arecommon numbers and therefore deleted).

Although the machine harness wires are all now identified using numbers, there will be instances when electrical components

installed on the machine will have coloured flying leads. To ensure that numbered wires mate with the correct corresponding

coloured flying lead a prefix will be added to the wire number; this prefix identifies the colour(s) of the flying lead that thenumbered wire should mate with. For instance, if wire 819 from harness 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 illustration shows a typical connector and wires. To summarize, the number stamped on the wire in the example shown

identifies the following:

B = The colour of the flying lead that the harness wire should mate with.

819 = The wire's unique identification number.9/371 = The part number of the harness that the wire originates from.

Finally, some more points to notice regarding wire identification:

1 Wires will continue to have the same number even after passing through a bulk head connector into a different harness.

2 Wires in splices are identified by using the original input wire number and then a suffix letter. So for instance wire 000 is

an original input wire, splices from this original wire are identified 000A, 000B and so on.

3 The wire number categories shown in the tables on the following pages are as follows:

3.1 Wire numbers 000 to 199. Wires in this number bracket are allocated to live feeds when the starter switch is at IGN

position, heater start circuits and start circuits.

3.2 Wire numbers 200 to 399. Wires in this number bracket are allocated to battery feeds.

3.3 Wire numbers 400 to 599. Wires in this number bracket are allocated to instruments, (alternator to tacho, fuel gauge

senders to fuel gauges etc.

3.4 Wire numbers 600 to 799. Wires in this number bracket are allocated to earth paths.

3.5 Wire numbers 800 to 999. Wires in this number bracket are allocated to switched supplies to lights, horn etc from

switches and relays.

Section C Electrics

9803/3260

Section C

41 - 1

Issue 3*

Harness and Wire Number Identification

S164110

*

*



41 - 2

000 Starter Switch Fusebox - Fuse B1 4.00 To m/c no. 409434000 Starter Switch Panel Harness Splice (Fusebox) 4.00 From m/c no.

409435000A Fuse B1a Fuse A9a 2.00 To m/c no. 409434

000A Panel Harness Splice (Fusebox) Fuse A9a 2.00

000B Fuse A9a Fuse B8a 2.00 To m/c no. 409434

000B Panel Harness Splice (Fusebox) Fuse B8a 1.40 From m/c no.409435

000C Fuse B8a Fuse B2a 1.00 To m/c no. 409434

000C Panel Harness Splice (Fusebox) Fuse B2a 1.00 From m/c no.

409435

000D Fuse B2a Fuse B7a 1.00 To m/c no. 409434

000D Panel Harness Splice (Fusebox) Fuse B7a 1.00 From m/c no.409435

000E Fuse B7a Fuse B9a 1.00 To m/c no. 409434

000E Panel Harness Splice (Fusebox) Fuse B9a 1.00 From m/c no.

409435000F Panel Harness Splice (Fusebox) Fuse B1a 2.00 From m/c no.

409435001 Starter Switch Panel Harness Feed Splice 4.00

001A Panel Harness Splice 'Ignition' Relay Coil Feed 1.50 Powershift m/c's

001B Panel Harness Splice Fusebox - Fuse C3a 3.00

001C Panel Harness Splice Fusebox - Fuse A1a 1.00 Syncro Shuttle m/c's

001D Panel Harness Splice Fusebox - Fuse A2a 1.00 Syncro Shuttle m/c's

001E Panel Harness Splice Fusebox - Fuse A5a 1.00 Syncro Shuttle m/c's001F Panel Harness Splice Fusebox - Fuse B6a 1.50 Syncro Shuttle m/c's

001H Panel Harness Splice Fusebox - Fuse C5a 1.40 Syncro Shuttle m/c's

001J Panel Harness Splice Fusebox - Fuse C7a 1.00 Syncro Shuttle m/c's

002 Panel Harness Splice 'Ignition' Relay 8.00

002A Panel Harness Splice Fusebox - Fuse A1a 1.00 Powershift m/c's

002B Panel Harness Splice Fusebox - Fuse A2a 1.00 Powershift m/c's002C Panel Harness Splice Fusebox - Fuse A5a 1.00 Powershift m/c's

002D Panel Harness Splice Fuseboc - Fuse B6a 1.50 Powershift m/c's

002E Panel Harness Splice Fusebox - Fuse C2a 1.00 Powershift m/c's

002F Panel Harness Splice Fusebox - Fuse B1a 4.00 Powershift m/c's

002G Panel Harness Splice Fusebox - Fuse A9a 2.00 Powershift m/c's

002H Fuse A9a Fuse B8a 2.00 To m/c no. 409434002H Panel Harness Splice Fusebox - Fuse A9a 1.40 From m/c no.

409435

002J Fuse B8a Fuse B2a 1.00 To m/c no. 409434

002J Panel Harness Splice Fuse B2a 1.00 From m/c no.

409435

002K Fuse B2a Fuse B7a 1.00 To m/c no. 409434002K Panel Harness Splice Fuse B7a 1.00 From m/c no.

409435

002L Fuse B7a Fuse B9a 1.00 To m/c no. 409434

002L Panel Harness Splice Fuse B9a 1.00 From m/c no.

409435

002P Panel Harness Splice Fuse C5a 2.00 From m/c no.409435

002S Panel Harness Splice Fuse C7a 1.00 From m/c no.

409435

003 Starter Switch Thermostart 3.00

004 Starter Switch Neutral Start Relay 3.00

100 Fuse B7 Dump Relay 1.00100A Dump Relay Foot Dump Switch 1.00

101 Fuse B1 Panel Harness Junction Box Splice 2.00

101A Panel Harness Junction Box Splice Junction Box 2.00101B Panel Harness Junction Box Splice Bucket Reset 1.00

101P Junction Box Hydraulic Speed Control Switch 1.00102 Fuse B8 Heater Switch 1.50

102A Heater Switch Heater Switch Warning Light 1.00 From m/c no.

Section C Electrics

9803/3260

Section C

41 - 2

Issue 4


Wire Numbers - 000 to 199 (to serial number 430000)

Wire Wire

No Source Destination Gauge Comment



41 - 3

409435103 Fuse A5 Rear Wiper / Wash 1.50 To m/c no. 409434

103 Fuse A5 Cab Harness Splice 1.00 From m/c no.409435

103A Rear Wiper Switch Rear Wiper Auxillary Feed 1.50 To m/c no. 409434

103A Cab Harness Splice Rear Wiper Switch 1.50 From m/c no.

409435103B Cab Harness Splice Rear Work Light Switch Illumination 1.00 From m/c no.

409435

103C Cab Harness Splice Hydraulic Speed Control Switch Illumination 1.00 From m/c no.

409435

103E Cab Harness Splice Rear Wipe (only) Switch 1.00 From m/c no.

409435103G Cab Harness Splice REar Wash/Wipe Switch Illumination 1.00 From m/c no.

409435

104 Fuse B6 Hazard Switch (Indicators) 1.50 To m/c no. 409434

104 Panel Harness Hazard Splice Hazard Switch 1.40 From m/c no.409435

104A Fuse B6 Panel Harness Hazard Splice 1.40 From m/c no.409435

104B Panel Harness Hazard Splice Beacon Switch Warning Light 1.00 From m/c no.

409435

104C Panel Harness Hazard Splice Main Lights Warning Light 1.00 From m/c no.

409435

105 Fuse B2 Engine Shut-off Solenoid 1.00106 Fuse A2 Fuel Gauge Feed 1.00

106A Fuse A2 Stabiliser Lock Relay 1.00

107 Fuse C3 Panel Harness Splice (Gears) 1.50

107A Panel Harness Splice (Gears) Column Switch 1.00

107B Panel Harness Splice (Gears) Forward Relay 1.00 To m/c no. 413771

107C Panel Harness Splice (Gears) 2WD Relay 1.00 To m/c no. 404851107D Panel Harness Splice (Gears) 2WD Switch 1.00 To m/c no. 409434

107D Panel Harness Splice (Gears) Brake Mode Switch Splice 1.00 From m/c no.

409435

107E Forward Relay Reverse Relay 1.00 To m/c no. 409434

107E Gears Control Feed Splice Reverse Relay 1.00 409435 to 413771

107F Reverse Relay Drive Relay 1.00 To m/c no. 409434107F Panel Harness Splice (Gears) Drive Relay 1.00 From m/c no.

409435

107K Panel Harness Splice (Gears) Brake Mode Switch 1.00 From m/c no.

409435

107L Panel Harness Splice (Gears) Brake Mode Switch 1.00 From m/c no.

409435107M Panel Harness Splice (Gears) Parkbrake Dump Relay 1.00 From m/c no.

413772

107N Panel Harness Splice (Gears) Parkbrake Dump Relay - Coil Feed 1.00 From m/c no.

413772

108 Fuse A1 Foot Brake Switch 1.00 To m/c no. 404851

108 Reverse Alarm Relay Foot Brake Switch 1.00 From m/c 404852108A Fuse A1 Reverse Alarm Relay 1.00 To m/c no. 404851

108A Brake Relay Reverse Alarm Relay 1.00 From m/c 404852

108B Fuse A1 2 Wheel Drive Relay Feed 1.00 From m/c 404852

109 Fuse C2 Solenoid Harness Steer Mode Splice 1.00 AWS m/c's only

109A Solenoid Harness Steer Mode Splice Front Proximity Switch 1.00 AWS m/c's only

109B Solenoid Harness Steer Mode Splice Rear Proximity Switch 1.00 AWS m/c's only109C Solenoid Harness Steer Mode Splice 4 Wheel Steer Solenoid 1.00 AWS m/c's only

109D Solenoid Harness Steer Mode Splice Crab Solenoid 1.00 AWS m/c's only

109E Solenoid Harness Steer Mode Splice Crab/4 Wheel Steer Solenoid 1.00 AWS m/c's only109F Solenoid Harness Steer Mode Splice 2 Wheel Steer Solenoid 1.00 AWS m/c's only

110 Fuse A9 Panel Harness Column Switch Splice 2.00110A Panel Harness Column Switch Splice Flasher 1.00

110B Panel Harness Column Switch Splice Front Wiper/Washer 1.00

Section C Electrics

9803/3260

Section C

41 - 3

Issue 5



Wire Wire




41 - 4

110C Panel Harness Column Switch Splice Horn 1.00111 Fuse B9 Buzzer 1.00

111A Fuse B9 Hand Dump Switch 1.00114 Fuse C5 Deluxe Options

200 Alternator Starter Solenoid 4.50 See Note ➀

200A Alternator Starter Solenoid 4.50 See Note ➀

200B Starter Solenoid Starter Switch 4.00200C Starter Solenoid Starter Relay 4.00

200D Starter Solenoid Starter Relay 3.00

200E Starter Solenoid Road Lights Relay 3.00

200F Starter Solenoid Road Lights Relay 2.50 To m/c no. 409434

200G Starter Solenoid Fusebox - Fuse C1a 4.00

200H Fuse C1a Fuse A7a 2.00200J Fuse A7a Fuse A6a 2.00

200K Fuse A6a Fuse A8a 1.00

300 Fuse A6 Hazard Switch 4.00

302 Fuse C1 Rear Work Lights Switch 2.00

303 Fuse A7 Cab Harness Interior Light Splice 1.50

303A Cab Harness Splice Interior Light 2.00303B Cab Harness Splice Beacon 1.50

303C Cab Harness Splice Front Wiper 1.00

303D Cab Harness Splice Clock 0.60

303F Fuse A7 Beacon Switch 1.40 From m/c no.

409435

304 Fuse A8 Radio 1.00401 Park Brake Relay Warning Light 1.00

402 Air Filter Switch Warning Light 1.00

403 Engine Oil Pressure Switch Warning Light 1.00

404 Transmission Oil Temperature Switch Warning Light 1.00

405 Transmission Oil Pressure Switch Warning Light 1.00

406 Water Temperature Switch Warning Light 1.00407 Alternator Warning Light 1.00 See Note ➀

408 Fuel Gauge Sender 1.00409 Water Temperature Gauge Sensor 1.00

410 Test Button Warning Lights 1.00 To m/c no. 404502

411 Buzzer Instrument Cluster 1.00

Section C Electrics

9803/3260

Section C

41 - 4

Issue 4



Wire Wire




41 - 5

412 Alternator Instrument Cluster 1.00

Note ➀: Terminals 200, 200A and 407 may be either separate terminals or combined in a 'euro plug'.

600 Starter Earth Engine Shut - off Solenoid 1.00600A Starter Earth Mainframe Harness Earth Splice 2.00

600B Mainframe Harness Earth Splice Horn 2.00

600C Mainframe Harness Earth Splice Transmission Oil Temperature Switch 1.00

600D Mainframe Harness Earth Splice Loader Valve 1.00

600E Mainframe Harness Earth Splice Rear Lights 1.00

600F Mainframe Harness Earth Splice Italian Number Plate Light 1.00600G Mainframe Harness Earth Splice L/H Rear Combination Light 1.00

600H Mainframe Harness Earth Splice R/H Rear Combination Light 1.00

600J Starter Earth Panel Harness Earth Splice 4.00

600K Starter Earth Panel Harness Earth Splice 4.00

600L Starter Earth Steer Mode Relay PCB 2.00 AWS m/c's only

600M Panel Harness Earth Splice Cab Earth Splice 4.00

600N Panel Harness Earth Splice Fog Light Switch 1.00600P Fog Light Switch Earth Front Work Lights Switch Earth 1.00 To m/c. no. 409434

600P Panel Harness Earth Splice Front Work Lights Switch Earth 1.00 From m/c no.

409435

600R Front Work Lights Switch Earth Radio 1.00 To m/c. no. 409434

600R Panel Harness Earth Splice Radio 1.00 From m/c no.409435

600S Panel Harness Earth Splice Reverse Alarm Relay 1.00

600T Panel Harness Earth Splice Instrument Cluster 1.00

600U Reverse Alarm Relay Earth Stabilizer Lock Relay 1.00 To m/c. no. 409434

600U Panel Harness Earth Splice Stabilizer Lock Relay 1.00 From m/c no.

409435600V Stabilizer Lock Relay Earth Neutral Start Relay 1.00 To m/c. no. 409434

600V Panel Harness Earth Splice Neutral Start Relay 1.00 From m/c no.

409435600W 2WD Switch Ignition Relay Earth 1.00 To m/c. no. 409434

600W Panel Harness Earth Splice Ignition Relay Earth 1.00 From m/c no.

409435600X Panel Harness Earth Splice Head Light Earth Splice 3.00

Section C Electrics

9803/3260

Section C

41 - 5

Issue 4



Wire Wire




41 - 6

600Y Panel Harness Earth Splice Dump Relay 1.50600Z Panel Harness Earth Splice Solenoids Earth Splice 2.00

600AA Panel Harness Earth Splice 4 Wheel Drive Brake Relay 1.00600AB 4 Wheel Drive Brake Relay Earth 2 Wheel Drive Relay 1.00 To m/c. no. 409434

600AB Panel Harness Earth Splice 2 Wheel Drive Relay 1.00 From m/c no.

409435

600AC Panel Harness Earth Splice Forward Relay 1.00600AD Forward Relay Earth Reverse Relay 1.00 To m/c. no. 409434

600AD Panel Harness Earth Splice Reverse Relay 1.00 From m/c no.

409435

600AE Forward High/Low Relay Earth Reverse Relay 1.00 To m/c. no. 409434

600AE Panel Harness Earth Splice Forward High/Low Relay 1.00 From m/c no.

409435600AF Reverse High/Low Relay Earth Forward High/Low Relay 1.00 To m/c. no. 409434

600AF Panel Harness Earth Splice Reverse High/Low Relay Earth 1.00 From m/c no.

409435

600AG Drive Relay Earth Reverse High/Low Relay 1.00 To m/c. no. 409434600AG Panel Harness Earth Splice Drive Relay Earth 1.00 From m/c no.

409435600AH Neutral Relay Earth Drive Relay 1.00 To m/c. no. 409434

600AH Panel Harness Earth Splice Neutral Relay Earth 1.00 From m/c no.

409435

600AJ Cab Harness Earth Splice Interior Light 1.00

600AK Cab Harness Earth Splice Front Wiper 1.00

600AL Cab Harness Earth Splice Cab Roof Harness Earth Splice 2.00600AM Cab Harness Earth Splice Cab Roof Harness Earth Splice 2.00

600AN Cab Harness Earth Splice Cab Roof Harness Earth Splice 2.00

600AP Cab Roof Harness Earth Splice Beacon 1.00

600AR Cab Roof Harness Earth Splice R/H Front Light 1.00

600AS Cab Roof Harness Earth Splice L/H Front Light 1.00

600AT Cab Roof Harness Earth Splice L/H Rear Combination Light 1.00600AU Cab Roof Harness Earth Splice L/H Number Plate Light 1.00

600AV Cab Roof Harness Earth Splice L/H Rear Work Light 1.00

600AW Cab Roof Harness Earth Splice R/H Rear Combination Light 1.00

600AX Cab Roof Harness Earth Splice R/H Number Plate Light 1.00

600AY Cab Roof Harness Earth Splice R/H Rear Work Light 1.00

600AZ Head Light Earth Splice R/H Head light 1.50600BA Earth Splice Link Earth Splice 1.50

600BB Earth Splice Rear Socket 2.00

600BC Earth Splice L/H Head Light 1.50

600BD Earth Splice Rear Wiper 1.00

600BE Earth Splice Rear Work Light Warning Light 1.00

600BF Earth Splice Hand Brake Switch 1.00600BG Earth Splice Front Washer Motor 1.00

600BH Earth Splice Heater 1.00

600BJ Earth Splice Rear Fog Light 1.00

600BK Earth Splice Rear Washer Motor 1.00

600BL Dump Relay Earth Indicator Relay 1.00 To m/c. no. 409434

600BL Panel Harness Earth Splice Indicator Relay 1.00 From m/c no.409435

600BM Indicator Relay Earth Road Lights Relay 1.00 To m/c. no. 409434

600BM Panel Harness Earth Splice Road Lights Relay 1.00 From m/c no.

409435

600BN R/D Lights Relay Earth Hand Brake Relay 1.00 To m/c. no. 409434

600BN Panel Harness Earth Splice Hand Brake Relay 1.00 From m/c no.409435

600BP Hand Brake Relay Earth Test Button 1.00 To m/c no. 404502

600BR Test Button Earth 2 Wheel Drive Warning Light 1.00 To m/c no. 404502600BR Panel Harness Earth Splice 2 Wheel Drive Warning Light 1.00 To m/c no. 404502

600BS Solenoid Earth Splice Forward Solenoid 1.00600BT Solenoid Earth Splice Reverse Solenoid 1.00

600BU Solenoid Earth Splice Transmission Oil Pressure Switch 1.00

Section C Electrics

9803/3260

Section C

41 - 6

Issue 3



Wire Wire




41 - 7

600BV Solenoid Earth Splice Rear Proximity Switch 1.00 AWS m/c's only600BW Solenoid Earth Splice Front Proximity Switch 1.00 AWS m/c's only

600BX Solenoid Earth Splice Forward Low Solenoid 1.00600BY Solenoid Earth Splice Layshaft Solenoid 1.00

600BZ Solenoid Earth Splice Mainshaft Solenoid 1.00

600CA Solenoid Earth Splice Reverse Low Solenoid 1.00

600CB Solenoid Earth Splice 2 Wheel Drive Solenoid 1.00600CC Junction Box Earth Earth Splice 2.00

600CZ Cab Harness Splice (link) Cab Harness Splice 2.00 From m/c no.

409435

600DF Cab Harness Splice Hydraulic Speed Control Switch Illumination 1.00 From m/c no.

409435

600DJ Panel Harness Earth Splice (link) Panel Harness Earth Splice 1.00 From m/c no.409435

600DN Panel Harness Earth Splice (link) Panel Harness Earth Splice 1.00 From m/c no.

409435

600DP Panel Harness Earth Splice (link) Panel Harness Earth Splice 1.00 From m/c no.409435

600DR Panel Harness Earth Splice (link) Panel Harness Earth Splice 1.00 From m/c no.409435

600DW Panel Harness Earth Splice Main Lights Warning Light Earth 1.00 From m/c no.

409435

600DX Panel Harness Earth Splice Hazard Switch Warning Light Earth 1.00 From m/c no.

409435

600DY Panel Harness Earth Splice Beacon Switch Warning Light Earth 1.00 From m/c no.409435

600EB Cab Harness Splice Heater Switch Illumination 1.00 From m/c no.

409435

600EF Cab Harness Splice Rear Worklight Switch Illumination 1.00 From m/c no.

409435

601 Radio L/H Speaker -ve 1.00602 Radio R/H Speaker -ve 1.00

603 Hydraulic Speed Control Relay Hydraulic Speed Control Switch 1.00 From m/c no.

409435

800 Heater Switch Heater (Low) 1.00 To m/c. no. 409434

800A Heater Switch Heater (Medium) 1.00800B Heater Switch Heater (High) 1.00

802 Hazard Switch Indicator Relay 1.50803 Hazard Switch Indicator Relay 1.50

803A Indicator Relay Column Switch 1.00

Section C Electrics

9803/3260

Section C

41 - 7

Issue 3



Wire Wire




41 - 8

804 Hazard Switch Instrument Warning Light 1.00804A Hazard Switch Diode 1.00

805 Hazard Switch Panel Harness LH Indicator Splice 1.00805A Panel Harness LH Indicator Splice Warning Light (Cluster) 1.00

805B Panel Harness LH Indicator Splice Column Switch 1.00

805C Panel Harness LH Indicator Splice LH Indicator (Chassis) 1.00

805D Panel Harness LH Indicator Splice Cab Harness LH Indicator Splice 1.00805E Panel Harness LH Indicator Splice Front LH Indicator 1.00

805F Panel Harness LH Indicator Splice Rear LH Indicator 1.00

806 Diode Panel Harness RH Indicator Splice 1.00

806A Panel Harness RH Indicator Splice Warning Light (Cluster) 1.00

806B Panel Harness RH Indicator Splice Column Switch 1.00

806C Panel Harness RH Indicator Splice RH Indicator (Chassis) 1.00806D Panel Harness RH Indicator Splice Cab Harness RH Indicator Splice 1.00

806E Panel Harness RH Indicator Splice Front RH Indicator 1.00

806F Panel Harness RH Indicator Splice Rear RH Indicator 1.00

807 Reverse Alarm Relay Reverse Alarm 1.00808 Column Switch Reverse Alarm Relay Coil 1.00

808A Reverse Alarm Relay Reverse Relay 1.00809 Column Switch Forward Relay Coil 1.00

810 Column Switch Panel Harness Neutral Start Splice 1.00 To m/c. no. 409434

810 Panel Harness Splice Powershift Neutral Relay 1.00 From m/c no.

409435

810A Panel Harness Splice Park Brake Relay Coil 1.00

810B Panel Harness Splice Stabiliser Lock Relay Coil 1.00810C Panel Harness Splice Neutral Start Relay Coil 1.00

811 Reverse High/Low Relay Reverse Solenoid 1.00

812 Forward High/Low Relay Forward Solenoid 1.00

813 Powershift Neutral Relay Coil Feed Forward Relay 1.00

814 Column Switch Horn 2.00

815 Park Brake Relay Park Brake Switch 1.00815A Parkbrake Dump Relay Parkbrake Relay 1.00 From m/c no.

413772

816 Panel Harness Splice Brake Relay 1.00

816A Panel Harness Splice Cab Harness Splice 1.00

816B Panel Harness Splice Main Frame Harness Splice 1.00

816C Panel Harness Splice Brake Relay 1.00 See Note ➁

816D Main Frame Harness Splice LH Brake Light 1.00

816E Main Frame Harness Splice RH Brake Light 1.00

817 Powershift Neutral Relay Feed Reverse Relay 1.00

818 2 Wheel Drive Relay Coil Feed 2 Wheel Drive Switch 1.00

818A 2 Wheel Drive Relay Coil Feed 2 Wheel Drive Diode Gate Feed 1.00

819 Front Proximity Switch Steer Switch 1.00 To m/c. no. 409434

819 Front Proximity Switch Panel Harness Splice 1.00 From m/c no.409435

819A Panel Harness Splice Steer Switch 1.00 From m/c no.

409435

819B Panel Harness Splice Steer Switch 1.00 From m/c no.

409435820 Rear Proximity Switch Steer Switch 1.00

821 Steer Switch Steer Mode PCB (Crab) 1.00

822 Steer Switch Steer Mode PCB (2 Wheel Steer) 1.00

823 Steer Switch Steer Mode PCB (4 Wheel Steer) 1.00

Note ➁: Wire 816C is applicable only on machines up to serial number 403024. Also, on machines up to serial number 403024,

wire 816 source is Panel Harness Brake Light Splice and its destination is Foot Brake Switch (refer to Technical InformationBulletin 2/066).

Section C Electrics

9803/3260

Section C

41 - 8

Issue 2



Wire Wire




41 - 9

824 Crab Solenoid Panel Harness Steer Splice 1.00824A Panel Harness Steer Splice Crab Steer Warning Light 1.00

824B Panel Harness Steer Splice Crab Steer Mode PCB 1.00825 2 Wheel Steer Solenoid Panel Harness Steer Splice 1.00

825A Panel Harness Steer Splice 2 Wheel Steer Warning Light 1.00

825B Panel Harness Steer Splice 2 Wheel Steer Mode PCB 1.00

826 4 Wheel Steer Solenoid Panel Harness Steer Splice 1.00826A Panel Harness Steer Splice 4 Wheel Steer Warning Light 1.00

826B Panel Harness Steer Splice 4 Wheel Steer Mode PCB 1.00

827 Side Light Switch Road Light Relay 1.00 To m/c. no. 409434

827A Side Light Switch Head Light Switch 1.00 To m/c. no. 409434

828 Side Light Relay Fusebox - Fuse A3a 2.00 To m/c. no. 409434

828 Fusebox - Fuse A3 Main Lights Switch 2.00 From m/c no.409435

828A Fuse A3a Fuse A4a 2.00

828B Road Light Relay Work Light Switch Flying Lead 2.00 To m/c. no. 409434

828B Road Light Relay Main Lights Switch 2.00 From m/c no.409435

828C Work Light Switch Flying Lead Work Light Switch 2.00829 Fuse A3 Panel Harness LH Side Light Splice 1.00

829A Panel Harness LH Side Light Splice Cab Harness Side Light Splice 1.00

829B Panel Harness LH Side Light Splice Main Frame LH Side Light Splice 1.00

829C Main Frame LH Side Light Splice Italian Number Plate Light 1.00

829D Main Frame LH Side Light Splice LH Rear Tail Light 1.00

829E Cab Harness LH Side Light Splice LH Front Side Light 1.00829F Cab Harness LH Side Light Splice Cab Roof Harness Side Light Splice 1.00

829G Cab Harness LH Side Light Splice LH Number Plate Light 1.00

830 Fuse A4 Panel Harness Splice 1.00

830A Panel Harness Splice Gauge Illumination 1.00

830B Panel Harness Splice RH Rear Combination Lights 1.00

830C Panel Harness Splice Cab Harness RH Side Light Splice 1.00830D Cab Harness RH Side Light Splice RH Side Light 1.00 To m/c. no. 409434

830D Panel Harness Splice Work Light Switch Warning Light 1.00 From m/c no.

409435

830E Cab Harness RH Side Light Splice Rear Socket 1.00 To m/c. no. 409434

830E Panel Harness Splice Hazard Switch Warning Light 1.00 From m/c no.

409435830F Cab Harness RH Side Light Splice Cab Roof Harness RH Side Light Splice 1.00

830G Cab Harness RH Side Light Splice RH Number Plate Light 1.00

830K Cab Harness RH Side Light Splice Deluxe Option Plug 1.00 From m/c no.

409435

831 Front Work Light Switch Fusebox - Fuse B5a 2.00

832 Main Lights Switch RH Column Switch (Dip) 2.00832A Fusebox - Fuse C4a Head Lights Switch 1.00 To m/c. no. 409434

832B Main Lights Switch Work Light Relay Coil 1.00 From m/c no.

409435

833 RH Column Switch (Dip) Fuse B3a 1.50

834 Fuse B3 Cab Harness Dip Head Light Splice 3.00

834A Cab Harness Dip Head Light Splice RH Head Light 1.50834B Cab Harness Dip Head Light Splice LH Head Light 1.50

834C Fuse B3 Fog Light Switch 1.00 To m/c no. 400076

835 Fog Light Switch Fog Light 1.00

835A Fog Light Switch Warning Light 1.00 To m/c no. 400076

836 Main Beam Switch Fuse B4 1.50

837 Fuse B4 Cab Harness Main Beam Head Light Splice 3.00837A Cab Harness Main Beam Splice RH Head Light 2.00

837B Cab Harness Main Beam Splice LH Head Light 2.00

837C Fuse B4 Main Beam Warning Light 1.00838 Foot Dump Switch Dump Relay 1.00

838A Dump Relay Hand Dump Switch 1.00839 Column Switch Front Washer Pump 1.00

840 Column Switch Front Wiper 1.00

Section C Electrics

9803/3260

Section C

41 - 9

Issue 1



Wire Wire




42 - 1

Wire Numbers - 000 to 199 (from Serial Number 430001)

Section C Electrics

9803/3260

Section C

42 - 1

Issue 4*


001 Ignition Switch to Feed Splice 4.00 P

001A Ignition Splice to Ignition Relay 1 0.60 P

001K Ignition Splice to Fuse B8 4.00 P

001L Ignition Splice to Ignition Relay 2 0.60 P

001M Ignition Splice to Lights Relay 0.60 P

002 Ignition Relay 1 to Feed Splice 4.00 P

002D Relay 1 Feed Splice to Fuse B6 1.40 P

002E Relay 1 Feed Splice to Fuse C2 2.00 P

002F Relay 1 Feed Splice to Fuse B1 2.00 P002J Relay 1 Feed Splice to Fuse B2 2.00 P

* 002N Relay 1 Feed Splice to Fuse C6 1.00 P

002R Relay 1 Feed Splice to Fuse C3 1.40 P

003 Ignition Switch to Thermostat 2.00 MF P

003A Ignition Switch Link 2.00 P

004 Ignition Switch to Neutral Start Relay 2.00 P

007 Ignition Relay 2 to Feed Splice 4.00 P

007A Relay 2 Feed Splice to Brake Switch 1.00 P Cab

007B Relay 2 Feed Splice to Fuse A9 2.00 P

007C Relay 2 Feed Splice to Fuse C5 2.00 P

007D Relay 2 Feed Splice to Fuse A2 1.00 P

007E Relay 2 Feed Splice to Fuse B9 1.40 P007F Relay 2 Feed Splice to Fuse A5 1.00 P

009 Lights Relay to Feed Splice 3.00 P

009A Panel Feed Splice to Main Light Switch 1.40 P Cab

009B Lights Splice to Front Work Light Connector 1.40 P

009C Lights Splice to Fuse C1 1.40 P

009D Work Lights Connector to Fuse B5 1.40 P

101 Fuse to Feed Splice 2.00 MF P

101A Splice to Junction Box 2.00 MF P

101AA Feed Splice to Hammer Switch 1.00 Aux

101AB Splice to Rear Horn Switch 1.00 MF

101AG Fuse B1 to Feed Splice 2.00 P

101AH Feed Splice to Hydraclamp Switch 1.00 P

101B Splice to Reset Switch 1.00 MF

* 101D Hammer Connector to Hammer Isolator Switch ➁ 1.00 P

101L Feed Splice to Jaw Change-over (C/O) Relay 1.00 P

101P Feed Splice to Hydraulic Speed Control Switch 1.00 P

101S Feed Splice to Hammer Relay 1.00 P

101Y Mainframe Splice to Aux. Hyd. Feed Splice 1.00 MF Aux

101Z Feed Splice to Jaw Change-over (C/O) Switch 1.00 Aux

102 Heater Fast Relay to Heater Switch 2.00 P

102B Fuse B8 to Heater Fast Relay 4.00 P

102C Heater Switch to Air Con Switch 1.00 P A/C

103 Fuse A5 to Feed Splice 1.00 P

103A Feed Splice to Rear Wash Wipe Switch 1.00 P

103B Feed Splice to Rear Wash Wipe Switch 1.00 P103F Feed Splice to Rear Wiper 1.00 P

104 Fuse B6 to Hazard Switch 1.40 P Cab

105 Fuse B2 to E.S.O.S. 1.00 MF P

Note: The heading 'Harnesses Affected' refers to the harness(es) that house the individual wires, in some instances wires pass

through more than one harness, refer to the illustration on page C/40-2 for harness location.

MF = Mainframe Harness, P = Panel Harness, Cab = Cab Harness, CR = Cab Roof, TR = Transmission, A/C = AirConditioning Harness, Aux = Auxiliary Hydraulics Harness (e.g. Hammer), RL = Rear Lights Harness

Wire Description Wire Harnesses Affected

No Gauge MF P Cab CF TR A/C AUX RL



42 - 2




Section C Electrics

9803/3260

Section C

42 - 2

Issue 3*


* 106 Fuse A2 to Instrument Panel 1.00 P

* 106B Buzzer to Master Warning Light Cluster 1.00 P Cab

106C Fuse A2 to Buzzer 1.00 P

107 Fuse C3 to Feed Splice 1.40 P

107A Feed Splice to LH Column Switch (Powershift) 1.00 Cab

107B Feed Splice to Forward Relay 1.00 P

107D Feed Splice to 4WD Switch 1.00 Cab

107E Feed Splice to Reverse Relay 1.00 P

107F Feed Splice to Drive Shaft Relay 1.00 P

107G Column Switch Feed Forward/Reverse (Syncro) 1.00 Cab

107H Feed Splice to Cab Feed Splice 1.00 P Cab

* 107J Cab Harness Splice to LH Column Switch➁ 1.00 Cab

107L Feed Splice to Brake Mode Switch (2WS Machines) 0.60 P Cab

107L Feed Splice to Steer Mode Switch (AWS Machines) 1.00 P Cab107M Feed Splice to Dump Relay 0.60 P

107N Feed Splice to Dump Relay 0.60 P

107P Feed Splice to 4 Wheel Brake Relay 1.00 P

107R Column Switch Feed Forward/Reverse (Powershift) 1.00 Cab

* 107S Feed Splice to Brake Mode Switch (2WS Machines) ➀ 1.00 P Cab

109 Fuse C2 to Mainframe Feed Splice 2.00 MF P

109A Splice to Front Proximity Switch 1.00 MF

109B Splice to Rear Proximity Switch 1.00 MF

109C Splice to 4WD Solenoid 1.00 MF

109D Splice to Crab Steer Solenoid 1.00 MF

109E Splice to 4WS/Crab Steer Solenoid 1.00 MF

109F Splice to 2WS Steer Solenoid 1.00 MF

110 Fuse A9 to Column Switches 2.00 P Cab

110A Feed Splice to Flash Feed 1.00 Cab

110B Feed Splice to Front Wash/Wipe Feed 1.00 Cab

110H Feed Splice to Column Switch Horn (Powershift) 2.00 Cab

110J Feed Splice to Column Switch Horn (Syncro Shuttle) 2.00 Cab

114 Fuse C5 to Feed Splice 2.00 P

114A Feed Splice to Clock 0.60 Cab

114B Feed Splice to Cigarette Lighter 1.40 Cab

114C Feed Splice to Heated Seat Switch 1.00 P

114E Feed Splice to Face Level Fan 1.40 P

114F Feed Splice to Mainframe Feed Splice 1.40 P Cab

116 Fuse B5 to Front Work Light Switch 1.40 P

117 Fuse C1 to Rear Work Light Switch 1.40 P118 Fuse B9 to Rear Horn Relay 1.40 P

* 125 Fuse C6 to Column Switch (Gears, Forward/Reverse) 1.00 P Cab



42 - 3




Section C Electrics

9803/3260

Section C

42 - 3

Issue 3*


200 Alternator to Starter Solenoid 6.00 MF

200A Alternator to Starter Solenoid 6.00 MF

200B Starter Solenoid to Ignition Switch 4.00 MF P

200C Starter Solenoid to Ignition Switch/Relay 4.00 MF P

200D Starter Solenoid to Ignition Relay 4.00 MF P

200E Starter Solenoid to Road Lights Relay 3.00 MF P

200G Starter Solenoid to Fuse Box 4.00 MF P

200H Feed Splice to Fuse A7 2.00 P

200J Feed Splice to Fuse A6 1.40 P

200K Feed Splice to Fuse A8 1.00 P

200M Starter Solenoid to Ignition Relay 2 4.00 MF P

200N Feed Splice to Main Lights Switch 1.00 P Cab

300 Fuse A6 to Hazard Switch 1.40 P Cab

303 Fuse A7 to Cab Feed Splice 1.40 P Cab303A Feed Splice to Interior Light 1.00 Cab

303B Fuse A7 to Rotating Beacon Switch 1.40 P

* 303B Fuse A7 to Rotating Beacon Socket➁ 1.40 P Cab CR

303C Feed Splice to Front Wiper Aux. Feed 1.00 Cab

303D Feed Splice to Clock 0.60 Cab

303F Feed Splice to Interior Light 1.00 Cab

304 Fuse A8 to on Board Entertainment System 1.00 P

401 Parkbrake Relay to Warning Light 0.60 P

402 Air Cleaner Switch to Warning Lamp 1.00 MF P

403 Engine Oil Pressure Switch to Warning Lamp 1.00 MF P

404 Transmission Oil Temp. Switch to Warning Lamp 1.00 MF P

405 Transmission Oil Pressure Switch to Warning Lamp 1.00 MF P TR

* 405 Trans. Pressure Switch to Warn. Lamp➁ 1.00 MF P TR

406 Water Temperature Switch to Warning Lamp 1.00 MF P

407 Alternator to Warning Lamp 1.00 MF P

408 Fuel Sender to Fuel Gauge 1.00 MF P

409 Water Temperature Sender to Water Temperature Gauge 1.00 MF P

411 Instrument Panel to Warning Buzzer 1.00 P

411A Warning Buzzer to Master Warning Lights 1.00 P Cab

412 Alternator 'W' Terminal to Warning Lamp 1.00 MF P

412A Tachometer Splice to Tachometer 0.60 P

412B Tachometer Splice to German Tachometer 0.60 P Cab



42 - 4




Section C Electrics

9803/3260

Section C

42 - 4

Issue 3*


600 Earth Splice to E.S.O.S. 1.00 MF

600A Starter Earth to Earth Splice 2.50 MF

600AA Panel Earth Splice to 4 Wheel Brake Relay Earth 0.60 P

600AB Panel Earth Splice to 2 Wheel Drive Relay Earth 0.60 P

600AC Panel Earth Splice to Forward Relay Earth 0.60 P

600AD Panel Earth Splice to Reverse Relay Earth 0.60 P

600AE Panel Earth Splice to Forward High/Low Relay Earth 0.60 P

600AF Panel Earth Splice to Reverse High/Low Relay Earth 0.60 P

600AG Panel Earth Splice to Drive Shaft Relay Earth 0.60 P

600AH Panel Earth Splice to Neutral Relay Earth 0.60 P

600AJ Interior Light Earth 1.00 Cab

600AK Front Wiper Earth 1.00 Cab

600AL Panel Earth Splice to Cab Roof Earth Splice 2.00 P Cab CR

600AM Panel Earth Splice to Cab Roof Earth 1.40 P Cab CR600AN Panel Earth Splice to Cab Roof Earth 1.40 P Cab CR

600AP Earth Splice to Beacon Earth 1.00 CR

600AR Earth Splice to RH Work Light 1.00 CR

600AS Earth Splice to LH Work Light 1.00 CR

600AT LH Earth Splice to LH Combination Light 1.00 CR

600AU LH Earth Splice to LH No. Plate Light 1.00 CR

600AV LH Earth Splice to LH Work Light 1.00 CR

600AW RH Earth Splice to RH Combination Light 1.00 CR

600AX RH Earth Splice to RH No. Plate Light 1.00 CR

600AY RH Earth Splice to RH Work Light 1.00 CR

600AZ RH Headlight Earth 1.00 Cab

600B Earth Splice to Front Horn 2.00 MF

600BA Panel Earth Splice to Cab Earth Splice 1.40 P Cab

600BB Dipper Socket Earth Cab

600BC LH Headlight Earth 1.40 Cab

600BC Cab Earth Splice to Earth Splice (Austria) 1.40

600BD Panel Earth Splice to Rear Wiper Earth 1.00 P

600BE Panel Earth Splice to Rear Work Lights Switch 0.60 P

600BF Parkbrake Switch Earth 1.00 Cab

600BG Earth Splice to Front Wash Pump 1.00 MF

600BH Starter Earth to Panel Earth Splice 4.00 MF P

600BJ Rear Fog Light Earth 1.00 Cab

600BK Earth Splice to Rear Wash Pump 1.00 MF

600BL Panel Earth Splice to Indicator Relay Earth 0.60 P

600BN Panel Earth Splice to Park Brake Relay 0.60 P600BR 4WD Switch Light Earth 1.00 Cab

600BS Earth Splice to Forward High Solenoid Earth 1.00 TR

* 600BSEarth Splice to Forward Solenoid Earth ➁ 1.00 MF

600BT Earth Splice to Reverse High Solenoid Earth 1.00 TR

* 600BT Earth Splice to Reverse Solenoid Earth ➁ 1.00 MF

600BU Earth Splice to Transmission Oil Press Switch 1.00 TR

* 600BUEarth Splice to Transmission Oil Press Switch➁ 1.00 MF

600BV Earth Splice to Rear Proximity Switch 1.00 MF

600BW Earth Splice to Front Proximity Switch 1.00 MF

600BX Earth Splice to Forward Low Sol Earth 1.00 TR

600BY Earth Splice to Layshaft Solenoid Earth 1.00 TR

600BZ Earth Splice to Mainshaft Solenoid Earth 1.00 TR600C Earth Splice to Transmission Oil Temperature Switch 1.00 MF

600CA Earth Splice to Reverse Low Sol Earth 1.00 TR

600CB Earth Splice to 4WD Sol Earth 1.00 TR



42 - 5




Section C Electrics

9803/3260

Section C

42 - 5

Issue 2*


* 600CBEarth Splice to 4WD Solenoid Earth➁ 1.00 MF

* 600CCEarth Splice to Junction Box 2.00 MF

* 600CDReverse Alarm Earth 1.00 Cab

* 600CEEarth Splice to Fuel Sender 1.00 MF

600CF Earth Splice to Air Cleaner 1.00 MF

600CH Panel Earth Splice to Aux. Hyd. Switch 0.60 P

600CJ Earth Splice to Hammer Solenoid 1.00 Aux

600CK Earth Splice to Water Temperature Switch 1.00 MF

600CU Panel Earth Splice to Jaw Change-over Relay Earth 0.60 P

600CX Earth Splice to Jaw Change-over Solenoid 1.00 Aux

600D Earth Splice to Loader Valve 1.00 MF

600DA Panel Earth Splice to Heated Seat Switch 0.60 P

600DB Cigarette Lighter Earth 1.40 Cab

600DC Clock Earth 0.60 Cab600DE Earth Splice to Hydraulic Speed Control 1.00 MF

600DF Panel Earth Splice to Hydraulic Speed Control Switch 0.60 P

600DG Earth Splice to Hydraulic Speed Control Switch 1.00 MF

600DH Panel Earth Splice to Heated Seat 1.00 P

600DJ Panel Earth Splice to Earth Splice 0.60 P

600DN Panel Earth Splice to Earth Splice 0.60 P

600DP Panel Earth Splice to Earth Splice 0.60 P

600DW Main Lights Switch Work Light Earth 1.00 Cab

600DX Hazard Lights Switch Work Light Earth 1.00 Cab

600DY Panel Earth Splice to Beacon Switch 0.60 P

* 600DX 4WD Switch to Cab Harness Splice 0.60 Cab

600E Panel Earth to Rear Lights Earth Splice 1.40 P RL

600EA Panel Earth Splice to Hammer Relay Earth 0.60 P

600EF Panel Earth Splice to Rear Wash/Wipe Switch 0.60 P

600EG Face Level Fan Earth 1.40 Cab

600EJ Interior Light Earth 1.00 Cab

600EK Master Warning Lights Earth 1.00 Cab

* 600EL Rear Horn to Cab Harness Earth Splice ➂ 1.40 Cab

* 600EL Rear Horn to Mainframe Harness Earth Splice➂ 1.40 MF

* 600ENMainframe Earth Splice to Aux. Hydraulics Connector 1.00 MF Aux

600EP Earth Splice to Starter Earth 1.00 MF

600ER Earth Splice to Starter Earth 3.00 MF

600ES Earth Splice to Hydra Clamp Valve 1.00 MF

600EZ Earth Splice to Dump Switch 1.00 MF

600F Earth Splice to Number Plate Light 1.00 RL600FA Panel Earth Splice to Italian Work Light Relay 0.60 P

600FB Panel Earth Splice to Air Conditioner Switch 0.60 P A/C

600FC Panel Earth Splice to Hydraclamp Switch 0.60 P

600FF Panel Earth Splice to Ignition 2 Relay Earth 0.60 P

600FG Panel Earth Splice to Rear Horn Relay Earth 0.60 P

600FH Panel Earth Splice to Heater Fast Relay Earth 0.60 P

600FJ Panel Earth Splice to Lights Relay Earth 0.60 P

* 600FK Starter Motor Earth to Panel Harn. Earth Splice 4.00 MF P

600FL Earth Splice to Transmission Dump Switch (Gear Lever) 1.00 TR

* 600FL Earth Splice to Transmission Dump Switch (Gear Lever) ➁ 1.00 MF

600FM Earth Splice to LH Headlight 1.00

600FN Earth Splice to Bucket Lights Earth Splice 1.40600G Earth Splice to LH Rear Lights 1.00 RL

600H Earth Splice to RH Rear Lights 1.00 RL

600J Starter Earth to Panel Earth Splice 4.00 MF P



42 - 6




Section C Electrics

9803/3260

Section C

42 - 6

Issue 2*


* 600K Starter Earth to Panel Earth Splice 4.00 MF P

* 600L Earth Splice to Steer Mode Unit 1.00 P

* 600M Panel Earth Splice to Cab Earth Splice 2.00 P Cab

* 600N Panel Earth Splice to Fog Light Switch 0.60 P

* 600P Panel Earth Splice to Front Work Light Switch 0.60 P

* 600R Panel Earth Splice to on Board Entertainment System 1.00 P

* 600T Panel Earth Splice to Instrument Panel 0.60 P

600V Panel Earth Splice to Neutral Start Relay Earth 0.60 P

600W Panel Earth Splice to Ignition Relay 1 Earth 0.60 P

600X Panel Earth Splice to Cab Earth Splice 1.40 P Cab

600Z Earth Splice to Solenoids Earth Splice 1.40 MF TR

601 Radio to Left Hand Speaker P Cab

602 Radio to Right Hand Speaker 0.60 P Cab

603 Hydraulic Speed Control Switch Earth 1.00 MF P



42 - 7




Section C Electrics

9803/3260

Section C

42 - 7

Issue 2*


* 800 Heater Switch to Heater Resistors 1.40 P

800A Heater Switch to Heater Resistors 2.00 P

800B Heater Fast Relay to Heater Resistor 4.00 P

800C Heater Switch to Heater Fast Relay 0.60 P

802 Indicator Flasher to Hazard Switch 1.40 P Cab

803 Indicator Flasher to Hazard/Column Switch 1.40 P Cab

803A Column Switch Indicator Feed 1.00 Cab

803B Indicator Splice to Hazard Switch 1.40 Cab

804 Hazard Switch to Master Warning Lights 1.00 Cab

804A Hazard Switch to Diode 1.00 Cab

805 Hazard Switch to LH Indicator Splice 1.00 Cab

805B LH Indicator Splice Column Switch Feed 1.00 Cab

805C LH Indicator Cab Splice to LH Rear Indicator 1.00 P Cab RL

* 805C LH Indicator Splice to LH Rear Indicator ➁ 1.00 CR805E LH Cab Indicator Splice to LH Indicator Splice 1.00 Cab

* 805E LH Indicator Splice to LH Front Indicator➁ 1.00 CR

805F Cab Plug to LH Indicator 1.00 Cab CR

* 805F Cab Harn. Splice to Roof Harn. Splice➁ 1.00 Cab CR

805G LH Indicator Master Warning Light Feed 1.00 Cab

805H LH Indicator Splice to LH Indicator 1.00

805J LH Indicator Splice to LH Bucket Indicator 1.00

806 Diode to RH Indicator Splice 1.00 Cab

806B RH Indicator Splice Column Switch Feed 1.00 Cab

806C RH Indicator Cab Splice to RH Rear Indicator 1.00 P Cab RL

* 806C RH Indicator Splice to RH Rear Indicator ➁ 1.00 CR

806E RH Front Indicator Light Feed 1.00 Cab

* 806E RH Indicator Splice to RH Front Indicator➁ 1.00 CR

806F Cab Plug to RH Indicator 1.00 Cab CR

* 806F Cab Harn. Splice to Roof Harn. Splice➁ 1.00 Cab CR

806H RH Indicator Master Warning Light Feed 1.00 Cab

806K RH Indicator Splice to RH Head Light 1.00 Cab

808 Column Switch to Reverse Relay 0.60 P Cab

808B LH Column Switch to Reverse Splice (Powershift) 1.00 Cab

808C LH Column Switch to Reverse Splice (Syncro) 1.00 Cab

809 Column Switch to Forward Relay 0.60 P Cab

809A LH Column Switch to Forward Splice (Powershift) 1.00 Cab

809B LH Column Switch to Forward Splice (Syncro) 1.00 Cab

* 810 LH Column Switch to Neutral Start Splice 0.60 P Cab

810A Neutral Start Splice to Park Brake Relay Coil 0.60 P810C Neutral Start Splice to Neutral Start Relay 0.60 P

811 Reverse Relay to Reverse High Solenoid (Powershift) 1.00 MF P TR

811 Reverse Relay to Reverse Solenoid (Syncro) 1.00 MF P TR

* 811 Reverse Relay to Reverse Solenoid ➁ 1.00 MF P

811A Reverse Relay to Reverse Alarm (Syncro) 1.00 P Cab

812 Forward Relay to Forward High Solenoid (Powershift) 1.00 MF P TR

812 Forward Relay to Forward Solenoid (Syncro) 1.00 MF P TR

* 812 Forward Relay to Forward Solenoid ➁ 1.00 MF P

813 Forward Relay to Neutral Relay Coil 0.60 P

814 Horn Switch to Horn 2.00 MF P Cab

814A LH Column Switch to Horn Splice (Powershift) 2.00 Cab

814B LH Column Switch to Horn Splice (Syncro) 2.00 Cab

815 Park Brake Relay to Park Brake Switch 0.60 P Cab

815A Park Brake Relay to Diode Gate 0.60 P

816 Fuse A1 to Brake Light Splice 1.00 P

816A Cab Plug to Brake Light Splice (USA) 1.00 P Cab



42 - 8




Section C Electrics

9803/3260

Section C

42 - 8

Issue 2*


* 816A Cab Plug to Brake Light Splice 1.00 CR

* 816A Fuse A1 to Cab Harness Brake Light Splice➁ 1.00 P Cab CR

* 816B Panel Brake Splice to Brake Lights Splice 1.00 P RL

* 816D Brake splice to LH Brake Light 1.00 RL

* 816E Brake splice to RH Brake Light 1.00 RL

* 816F Brake Splice to LH Combination Light 1.00 CR

* 816G Brake Splice to RH Combination Light 1.00 CR

* 817 Reverse Relay to Neutral Start Relay 0.60 P

* 818A 2WD Relay to Diode Gate 0.60 P

819 Front Proximity Switch to Steer Switch 1.00 MF P

819A Panel Feed Splice to Steer Mode Switch 0.60 P Cab

819B Panel Feed Splice to Steer Mode Switch 0.60 P Cab

820 Rear Proximity Switch to Steer Switch 1.00 MF P Cab

821 Steer Mode Switch to Steer Mode Unit (Crab) 0.60 P Cab822 Steer Mode Switch to Steer Mode Unit (2WS) 0.60 P Cab

823 Steer Mode Switch to Steer Mode Unit (AWS) 0.60 P Cab

824 Crab Solenoid to Crab Splice 1.00 MF P

824A Crab Splice to Warning Lamp 0.60 P

824B Steer Mode Unit to Crab Splice 1.00 P

825 2WS Solenoid to 2WS Splice 1.00 MF P

825A 2WS Splice to Warning Lamp 0.60 P

825B Steer Mode Unit to 2WS Splice 1.00 P

825C 2WS Splice to Master Warning Light 0.60 P Cab

826 4WS Solenoid to 4WS Splice 1.00 MF

826A 4WS Splice to 4WS Warning Lamp 0.60 P

826B Steer Mode Unit to 4WS Splice 1.00 P

828 Main Lights Switch to Fuse A3 1.00 P Cab

828A Fuse A3 to Fuse A4 1.00 P

828D Side Lights Switch Work Light Feed 1.00 Cab

828E Master Warning Lights Sidelight Feed 1.00 Cab

828F Hazard Switch illumination 0.60 Cab

828G 2/4WD Switch Illumination 0.60 Cab

828H Side Lights Splice Feed 1.00 Cab

829 Fuse A3 to LH Side Lights Splice 1.00 P

829A LH Side Splice to LH Cab Side Splice 1.00 P Cab

829AA Air Conditioning Switch Illumination 0.60 P A/C

829B Panel Splice to LH Side Light Splice 1.00 P RL

829C Side Light Splice to Number Plate Light 1.00 RL

829D Side Light Splice to LH Side Light 1.00 RL829E LH Cab Sidelight Splice to Sidelight Splice 1.00 Cab

829F Cab Plug to LH Tail Light Splice 1.00 Cab CR

829G Cab Plug to LH No. Plate Light 1.00 CR

829H LH Tail Splice to LH No. Plate Light 1.00 CR

829J LH Tail Splice to LH Combination Light 1.00 CR

829K Sidelight Splice to LH Sidelight 1.00

829L Sidelight Splice to RH Bucket Sidelight 1.00

829M Sidelight Splice to LH Bucket Sidelight 1.00

829R Front Work Light Switch Illumination 0.60 P

829S Beacon Switch Illumination 0.60 P

829T Hydraulic Speed Control Switch Illumination 0.60 P

829U Fog Light Switch Illumination 0.60 P829V Rear Work Light Switch Illumination 0.60 P

829W Rear Wash/Wipe Switch Illumination 0.60 P

829X Hydraclamp Switch Illumination 0.60 P



42 - 9




Section C Electrics

9803/3260

Section C

42 - 9

Issue 2*


* 829Y Aux. Hyd. Switch Illumination 0.60 P

* 829Z Heated Seat Switch Illumination 0.60 P

* 830 Fuse A4 to RH Side Lights Splice (Cigarette Lighter) 1.00 P Cab

* 830A RH Side Lights Splice to Gauge Illumination 0.60 P

* 830B RH Side Lights Splice to RH Rear Side Light 1.00 P RL

* 830C RH Side Light Splice to RH Cab Side Splice 1.00 P Cab

* 830D RH Side Lights Splice Feed 1.00 Cab

* 830E Dipper Socket Feed 1.00 Cab

* 830F Cab Plug to RH Tail Light Splice 1.00 Cab CR

830G Cab Plug to RH No. Plate Light 1.00 CR

830H RH Tail Splice to RH Combination Light 1.00 CR RL

830J RH Tail Splice to RH No. Plate Light 1.00 CR

830L RH Side Lights Clock Feed 0.60 Cab

832 Mainlights Switch to Column Switch 1.40 Cab832A Main Lights Switch to Fuse C4 1.00 P Cab

832B Fuse C4 to Italian Worklights Relay 1.00 P

833 Column Switch Dip Feed to Fuse B3 1.40 P Cab

834 Fuse B3 to Dip Headlights Splice 1.40 P Cab

834A RH Dipped Headlight Feed 1.00 Cab

834B LH Dipped Headlight Feed 1.00 Cab

835 Fog Light Switch to Fog Light Cab Splice 1.00 P Cab

835B Fog Light Feed 1.00 Cab

835C Fog Light Master Warning Light Feed 1.00 Cab

836 Column Switch Mainbeam Feed to Fuse B4 1.40 P Cab

837 Fuse B4 to Main Beam Splice 1.40 P Cab

837A RH Headlight Main Beam Feed 1.00 Cab

837B LH Headlight Main Beam Feed 1.00 Cab

837D Master Warning Light Main Beam Feed 1.00 Cab

839 Column Switch to Front Washer Pump 1.00 MF P Cab

840 Front Wiper Motor Feed 1.00 Cab

841 Front Wiper Motor Return 1.00 Cab

842 Neutral Start Relay to Starter Solenoid 2.00 MF P

844 Shovel Reset Switch to Loader Valve 1.00 MF

845 Steer Mode Unit to 4WS/Crab Solenoid 1.00 MF P

846 Forward Relay to Forward High / Low Relay 1.00 P

847 Reverse Relay to Reverse High / Low Relay 1.00 P

847A Reverse Relay to Reverse Alarm (Powershift) 1.00 P Cab

848 Forward High/Low Relay to Forward Low Solenoid 1.00 MF P TR

849 Reverse High/Low Relay to Reverse Low Solenoid 1.00 MF P TR850 Driveshaft Relay to Layshaft Solenoid 1.00 MF P TR

851 Driveshaft Relay to Mainshaft Solenoid 1.00 MF P TR

852 Transmission Dump Relay to Column Switch (For./Rev.) 1.00 P Cab

853 4WD Relay to 4WD Solenoid 1.00 MF P TR

* 853 4WD Switch to 4WD Solenoid➁ 1.00 MF P Cab

853B 4WD Relay to Steer Mode Switch (AWS Machines) 1.00 P

853B Auto 2WD Relay to 4WD Relay (2WS Machines) 1.00 P Cab

* 853C Brake Mode Switch to 4Wheel Brake Relay➀ 1.00 P Cab

855 Cab Plug to Front Work Light Feed Splice 1.40 P Cab CR

855A Feed Splice to RH Front Work Light 1.00 CR

855B Feed Splice to LH Front Work Light 1.00 CR

855C Front Work Light Cab Roof Feed 1.40 Cab855D Master Warning Light Front Work Light Feed 1.00 Cab

* 855E Front Work Light Switch to Panel Harn. Splice➁ 0.60 P

* 855F 4WD Switch to Cab Harness Splice ➁ 0.60 Cab



42 - 10




Section C Electrics

9803/3260

Section C

42 - 10

Issue 2*


* 855G Hazard Switch to Cab Harness Splice➁ 0.60 Cab

* 855H Hammer Isolator Switch to Panel Harn. Splice➁ 0.60 P

* 855J Front Work Light Switch to Panel Harn. Splice➁ 1.40 P

* 855K Panel Harn. Splice to Cab Harn. Splice➁ 1.40 P Cab

* 855L Rear Work Light Switch to Panel Harn. Splice➁ 0.60 P

* 856 Column Switch to 2nd Speed Splice 0.60 P Cab

* 856A 2nd Speed Splice to Diode Gate 0.60 P

* 856B 2nd Speed Splice to Diode Gate 0.60 P

* 857 Column Switch to Diode Gate (3rd Speed) 0.60 P Cab

* 858 Column Switch to 4th Speed Slice 0.60 P Cab

* 858A 4th Speed Splice to Diode Gate 0.60 P

* 858B 4th Speed Splice to Diode Gate 0.60 P

* 858C Column Switch to 4th Speed Splice 1.00 Cab

* 858D Tachometer Feed to Master Warning Light (4th Speed) 1.00 Cab* 859 Radio Cassette to LH Speaker (+VE) 0.60 P Cab

* 860 Radio Cassette to RH Speaker (+VE) 0.60 P Cab

* 861 Cab Plug to Rear Work Light Splice 1.40 P Cab CR

* 861A Rear Work Splice to RH Work Light 1.00 CR

861B Rear Work Splice to LH Work Light 1.00 CR

861C Rear Work Light Cab Roof Feed 1.40 Cab

861D Rear Work Light Master Warning Light Feed 1.00 Cab

862 Rear Wiper Switch to Rear Wiper 1.00 P

863 Rear Wiper Switch to Rear Wash Pump 1.00 MF P

864 Rear Wiper Switch to Return Feed 1.00 P

865 H.S.C. Switch to 'Off' Relay Feed 1.00 P

866 H.S.C. Switch to 'On' Relay Feed 1.00 P

867B Mainframe Solenoid Splice to Relay 'Off' Feed 1.00 MF P868 Fuse C4 to Fog Light Switch 1.00 P

870 Hi-Low Microswitch to Solenoid 1.00 MF P Aux

* 871 Rear Horn Relay to Rear Horn ➂ 1.40 P Cab

* 871 Rear Horn to Harness (Panel) Plug ➂ 1.40 MF

* 871A Rear Horn Relay to Harness (Mainframe)Plug ➂ 1.40 P

872 Jaw Change-over Relay to Aux Hyd. Switch 1.00 P

873 Jaw Change-over Relay to Aux Hyd. Switch 1.00 P

874C Aux Hyd. Switch to Jaw/Ext Dipper Solenoid 1.00 MF P Aux

875 Jaw/Ext Dipper Switch to Jaw Change-over Relay Coil 0.60 MF P Aux

875A Diode Gate to Jaw Change-over Relay Coil 0.60 P

877 Fuse B7 to 4 Wheel Brake Relay Coil 0.60 P

877B Fuse B7 to Brake Mode Switch 0.60 P Cab

883 Column Switch to Drive Shaft Relay Coil 0.60 P Cab

883B Drive Shaft Relay to Diode Gate 0.60 P884 Diode Gate to Forward / Reverse Splice 0.60 P

884A Diode Gate to Forward / Reverse Splice 0.60 P

884B Forward / Reverse Splice to Reverse Relay Coil 0.60 P

884C Forward / Reverse Splice to Reverse Relay Coil 0.60 P

886 Heated Seat Switch to Heated Seat 1.00 P

894 Beacon Switch to Beacon Socket 1.40 P Cab CR

898 Hammer Relay to Aux Hyd. Switch 1.00 P

899 Hammer Switch to Hammer Relay 0.60 MF P Aux

899A Hammer Relay to Diode Gate 0.60 P

902 Air Conditioning Switch to Pressure Switch 1 1.00 A/C

903 Air Conditioning Pressure Switch to Compressor 1.00 MF P A/C

904 Pressure Switch 2 to Pressure Switch 1 1.00 A/C

909A 4 Wheel Brake Relay Coil Feed 0.60 P Cab912 Driveshaft Relay Feed (Powershift) 1.00 P

* 912 Dump Relay to Forward Relay (Syncro) 1.00 P

* 912A Forward Relay to Reverse Relay (Syncro) 1.00 P



42 - 11




Section C Electrics

9803/3260

Section C

42 - 11

Issue 1


920 Hydraclamp Switch to Hydraclamp 1.00 MF P

921 Rear Horn Switch to Rear Horn Relay 0.60 MF P922 2/4WD Switch to Auto 2WD Relay 1.00 P Cab

933 Fuse A1 to Brake Switch 1.00 P Cab

933A Fuse A1 to Fuse B7 0.60 P

934 Dump Relay Coil Earth to Hand Dump Switch 1.00 MF P

934A Dump Splice to Hand Dump Splice 1.00 MF

934B Dump Splice to Transmission Dump Switch (Gear Lever) 1.00 MF TR

934B Dump Splice to Trans. Dump Switch (Gear Lever)➁ 1.00 MF

934C Dump Relay Coil Earth to Diode Gate (P/Brake) 0.60 P

935 Feed Splice to Blower Motor 4.00 P

935A Feed Splice to Heater Resistor 4.00 P

935B Feed Splice to Heater Relay 4.00 P

977 Hammer Isolator Switch to Hammer Connector ➁ 1.00 P

➀ Note: Only applicable to machines fitted with 2/4WD clutches that must be pressurised to give 2WD.

➁ Note: Only applicable on 3CXE (214E) machines.

➂ Note: Machines from serial number, 3CX (214) - 438636; 4CX (214S) - 437866, have the rear horn connection from the

mainframe harness, prior to this the connection was from the cab harness.



i

Section D Controls

9803/3260

Section D

i

Issue 5*

Contents Page No.

Machine Controls

Loader Control Knob- Dismantling and Assembly 1 - 1

Tilt Type Steering Column


Fixed Steering Column


Boom Lock (up to serial number 430000)

Master Cylinder


- Dismantling and Assembly 10 - 1Slave Cylinder



Boom Lock (from serial number 430001 to 433723)

Installation 10 - 3

Boom Lock (from serial number 433724)

Master Cylinder



Slave Cylinder



Transmission Controls

Dump Pedal Microswitch (up to serial no. 430000)


*

*



When Assembling

Apply JCB Lock and Seal to microswitch adapter 5 prior to

assembly.

Note: Microswitch 5 is a non-service item, and must bereplaced as an assembly.

Loader Control Knob

On machines fitted with a hydraulic speed control, the

loader control knob houses two microswitches; one

microswitch energises the transmission dump solenoid and

the other microswitch energises the remote unload valvesolenoid.

For clarity, only one microswitch is shown dismantled. Make

sure that all electrical connections are clearly labelled before

removing the microswitch. Remove and replace

microswitches one at a time.

Note: Machines not fitted with a remote unload valve will

only have one microswitch fitted in the loader control knob.


The numerical sequence shown on the illustration isintended as a guide to dismantling.

For assembly the sequence should be reversed.

When Dismantling

To gain access to the microswitch gently prise off top cover

1. Disconnect wiring harness 2, remove locknut 3 and

shakeproof washer. Microswitch 4, adapter 5, and rubber

cover 6 may now be withdrawn through the knob.

1 - 1

Section D Controls

9803/3260

Section D

1 - 1

Issue 1

Machine Controls

S217040



5 - 1

Section D Controls

9803/3260

Section D

5 - 1

Issue 2

Machine Controls

217080S108000

D

28



5 - 2

Tilt Type Steering Column -

On some machine models the steering column assembly

can be tilted to improve operator reach and comfort levels.

This type of assembly is referred to as a 'tilt column'. Non

tilting columns are referred to as a 'fixed column'.


The numerical sequence shown on the illustration is

intended as a guide to dismantling.


Technical Information Bulletin 2/132 (C34/N.AM) advised of

changes to the method of securing the forward/reverse lever

to the steering column assembly (from serial number

415000). This improvement can be completed on machinesbuilt prior to serial number 415000. Refer to pages D/6-1

and D/6-2 for a description of the new securing method.

Machines from serial number 430001 have the flexible

coupling assembly mounting directly into the steer orbitrol

valve as shown at D. The dismantling and assembly

procedures (including end float settings) remain the same asdescribed.

When Dismantling

Remove the front instrument housing and the steering

column pedestal cover to gain access to the steering

column. Note the electrical connections beforedisconnecting the components mounted on the housing.

It should be noted that the top and bottom bearings 28

housed in the outer column assembly are non serviceable

parts. They may be removed for cleaning and inspection, but

if the bearing(s) have failed, a new outer column assembly

must be used.

To remove the steering column complete, remove bolts 11

and slacken nut 13. Then withdraw the column from the

flexible coupling 22.

When Assembling

To avoid excessive side loading on the steer valve,

assemble the steering column 14, flexible coupling 22,extension shaft 20 and the steer valve with a minimum of

misalignment.

Note: Machines from serial number 430001 have no

extension shaft 20 fitted, instead the coupling assembly

mounts directly into the orbitrol valve as shown at D.

Insert pin 8 into the appropriate groove in spacer 9 to

achieve correct endfloat of inner column 14 in the outer

column 12(correct endfloat is 0.5 to 1.5 mm (0.020 to 0.060

in).

Make sure that the extension shaft 20 (if fitted) is correctly

installed in the flexible coupling 22. The coupling bolt 21

must be engaged with the cut-out in the shaft, shown at B.

Remove all dirt etc from the splined socket of steering valve

A before fitting the column assembly.

Install E-clip 19 as close as possible to the splines on

extension shaft 20. Insert the extension shaft spline into the

splined socket, shown at C (maximum engagement to be no

more than 12 mm). Make sure that there is a 0.5 to 1.5 mm

(0.020 to 0.060 in) gap between the splined shaft and

socket, shown at D. The shaft must not touch the bottom of

the splined socket.

Apply JCB Lock and Seal to the threads of bolts 16 before

fitting them.

Section D Controls

9803/3260

Section D

5 - 2

Issue 2*-

Machine Controls

*

*

*

*

*

*



5 - 3

Section D Controls

9803/3260

Section D

5 - 3

Issue 2

Machine Controls

S217070

S164070

D



5 - 4

Fixed Type Steering Column

On some machine models the steering column assembly

can be tilted to improve operator reach and comfort levels.

This type of assembly is referred to as a 'tilt column'. Non

tilting columns are referred to as a 'fixed column'.




Technical Information Bulletin 2/132 (C34/N.AM) advised ofchanges to the method of securing the forward/reverse lever

to the steering column assembly (from serial number

415000). This improvement can be completed on machines

built prior to serial number 415000. Refer to pages D/6-1

and D/6-2 for a description of the new securing method.

Machines from serial number 430001 have the flexible

coupling assembly mounting directly into the steer orbitrol

valve as shown at D. The dismantling and assembly

procedures (including end float settings) remain the same as

described.

When Dismantling

Remove the front instrument housing and the steering

column pedestal cover to gain access to the steering

column. Note the electrical connections before

disconnecting the components mounted on the housing.

Bend back retaining tabs to permit removal of upper bearing

14. Note that later type column assemblies have a thrust

washer 14A added.

It should be noted that the top and bottom bearings 14 and

15 housed in the outer column assembly are non serviceable

parts. They may be removed for cleaning and inspection, but

if the bearing(s) have failed, a new outer column assemblymust be used.

To remove the steering column complete, remove bolts 11

and slacken nut 16. Then withdraw the column from the

flexible coupling 26.

When Assembling

To avoid excessive side loading on the steer valve,

assemble the steering column 13, flexible coupling 26,extension shaft 24 and the steer valve with a minimum of

misalignment before tightening securing bolts 11, 16 and 25.

Note: Machines from serial number 430001 have no

extension shaft 24 fitted, instead the coupling assembly

mounts directly into the orbitrol valve as shown at D.

Press in bearing 15 until flush with end of outer column, and

bearing 14 until it can be secured by the retaining tabs.

Note: Machines fitted with the later type column assemblieshave an additional thrust washer 14A.

Achieve minimum end-float (maximum permissible 2.0 mm

0.08in.) by selecting groove in spacer 9. Fit additional

spacing washers 19 above set pin 18 if necessary.

Make sure that the extension shaft 24 (if fitted) is correctly

installed in the flexible coupling 26. The coupling bolt 25

must be engaged with the cut-out in the shaft, shown at B.

Remove all dirt etc from the splined socket of steering valve

A before fitting the column assembly.

Install E-clip 23 as close as possible to the splines on

extension shaft 24. Insert the extension shaft spline into the

steer valve splined socket. Make sure that there is a 0.5 to

1.5 mm (0.020 to 0.060 in) gap between the splined shaft

and socket, shown at C. The shaft must not touch the bottom

of the splined socket.

Apply JCB Lock and Seal to the threads of bolts 16 before

fitting them.

Section D Controls

9803/3260

Section D

5 - 4

Issue 2*

Machine Controls

*

*

*

*

*

*

*

*

*

*



6 - 1

Section D Controls

9803/3260

Section D

6 - 1

Issue 1

Machine Controls

SXXXXXX

S214540

SXXXXXX

TILT STEER COLUMN

FIXED STEER COLUMN



6 - 2

Forward/Reverse Lever Retention

Machines from serial number 415000 now have an improved

method of locating the forward/reverse lever to the steeringcolumn. An additional lockplate A is now used, and JCB

Lock & Seal (part number 4101/0202) is applied to thethreads of retaining screws B. If a new lever assembly is

required for machines prior to 415000, it is recommended

the lockplate is fitted, refer to PROCEDURE.

If the lockplate is already fitted, but the steering column

assembly is being dismantled, refer to steps 1, 2, 3, 5, 6 and

7 for the correct removal and replacement procedures.

PROCEDURE



Lower the backhoe and loader end to the ground andstop the engine.

2 Remove the steering wheel and front console.

3 Remove the forward/reverse lever assembly C and then

outer steering column D.

4 Using a suitable saw, cut a slot in the outer steeringcolumn, as shown in the illustrations.

5 Refit the outer column D, insert pin E into the

appropriate groove in spacer F to achieve correct

endfloat of inner column in the outer column (correct

endfloat is 0.5 to 1.5mm (0.020 to 0.060in.)).

6 Fit the forward/reverse lever assembly, make sure

lockplate A is located in the slot. Add JCB Lock & Seal

to the two retaining bolts B, torque bolts to 2.4Nm (1.7

lbf ft).

7 Refit steering wheel and front console, torque tighten

steering wheel retaining nut G to 176Nm (130lbf ft).

Section D Controls

9803/3260

Section D

6 - 2

Issue 1

Machine Controls

SXXXXXX



10 - 1

Boom Lock Master Cylinder

Removal

Slacken the bleed nipple on the slave cylinder and operate

the lever until all fluid is expelled. Uncouple the clevis fromthe lever and disconnect the hydraulic hose. Unscrew the

mounting bolts and remove the cylinder from the machine

complete with reservoir (not illustrated).





Use only JCB Light Hydraulic Fluid for cleaning and

lubrication - DO NOT USE NORMAL BRAKE FLUID.

Fit new seals 6 and 12. Position seal 12 on stem 11 as

shown at A .

Ensure that seal 6 and thimble 7 are fitted as at B.

Replacement

When refitting the master cylinder to the machine, adjust the

position of the clevis so that the pivot pin can be easily fitted

with the master cylinder pushrod fully retracted and thehand lever fully down.

When connecting the hydraulic hose to the slave cylinder,

tighten to 35 - 40 Nm (20 - 30 lbf ft).

See page D/10 - 2 for information on bleeding.

Section D Controls

9803/3260

Section D

10 - 1

Issue 1

Machine Controls

107781



10 - 2

Boom Lock Slave Cylinder

Removal

Disconnect hydraulic hose from cylinder and plug to avoid

excessive fluid loss.

Unscrew mounting bolts and remove cylinder from machine.







Fit a new seal 4.

Replacement

Refit the slave cylinder to the machine by reversing the

removal sequence.

When connecting the hydraulic hose to the cylinder, tightento 35 - 40 Nm (20 - 30 lbf ft).

Bleeding

After refitting, bleed air from the system by means of bleed

nipple 5. Loosen the bleed nipple when the boom lockoperating lever in the cab is fully up. Ensure that the master

cylinder reservoir is kept topped up with JCB Light Hydraulic

Fluid.

Section D Controls

9803/3260

Section D

10 - 2

Issue 1

Machine Controls

107860



A

➀

A

➇

SECTION 'A - A'

➉

➄➂

➅

➈

➃

10 - 3

Boom Lock Installation (from Serial

Number 430001 to 433723)

Note: The boom lock is cable operated on machines from

serial number 430001 to 433723. The boom lock on

machines after serial number 433723 is hydraulicallyoperated (with a cable inter-connect). Refer to pages D/10-4

to 10- 5.

If the boom lock assembly has been dismantled (say to

replace the boom lock cable), use the following procedure to

reset the boom lock. Drawing shows assembly of sideshiftbuilds, the centremount builds are similar except for pivot

pin retention (see step 1b ).

1 Fit boom lock (item 1 ) to boom:

a Sideshift Machines - use pivot pins (item 8 ) andtension pins (item 9 ).

b Centremount Machines - use pivot pins (item 8 ),

M8 bolts and M6 locknuts (not shown).

2 Secure the control cable swivel flange to the cable

retaining bracket on the boom with M6 screws (item 5 )

and M6 nuts (item 3 ).

3 Attach the cable assembly to the ball joint (item 10 ) and

tighten the cable. Tighten the M6 locknut fitted on thecable.

4 Fit the ball joint (item 10 ) to the boom lock (item 1 )

using M8 locknut (item 6 ). Tighten locknut. Make surethat the swivel joint moves freely and is not restricted.

5 Position cable in bracket and tighten M12 nuts fitted on

cable.

6 Attach spring (item 4 ) to boom lock and spring reaction

bracket.

Section D Controls

9803/3260

Section D

10 - 3

Issue 2

Machine Controls

A217001

*



10 - 4

Section D Controls

9803/3260

Section D

10 - 4

Issue 1

Machine Controls

131

X

S235330A

S242170

14

FIG 1

Boom Lock Assembly (from Serial Number

433724)



10 - 5

Section D Controls

9803/3260

Section D

10 - 5

Issue 1

Machine Controls

Boom Lock Assembly (from Serial Number

433724)

Boom Lock Master Cylinder - Removal (FIG 1)

1 Park the machine on firm level ground, engage theparking brake and set the transmission to neutral.


stop the engine.

2 Slacken the bleed nipple on the slave cylinder 31 and

operate the lever 1 until all fluid is expelled.

3 Unscrew banjo bolt 22 and remove hydraulic hose 21.

4 Remove clevis pin 16 and clip 17.

5 Uncouple the clevis 14.

6 Unscrew the mounting bolts 11 and remove thecylinder 10 from its mounting bracket 8.

Boom Lock Master Cylinder - Inspection

The boom lock master cylinder is a non serviceable part.

Check that the push rod moves freely in the cylinder, check

visually for obvious signs of wear, damage or leakage. Ifrequired, replace the full master cylinder assembly.

Boom Lock Master Cylinder - Replacement (FIG 1)

Replacement of the master cylinder is a reversal of the

removal procedures. To adjust and correctly set the boom

lock, note the following:

1 Position lever 1 fully down on last ratchet.

2 Screw clevis 14 on to pushrod to achieve a setting

distance of 131mm (5.157in. - shown in inset X ).

Pushrod must not be pushed in cylinder.

3 Fill the system with JCB Light Hydraulic fluid.

4 Bleed the system using the bleed nipple on the slave

cylinder 31.

5 Make sure that the boom lock 39 fully engages and

disengages.

Boom Lock Slave Cylinder - Removal (FIG 1)


parking brake and set the transmission to neutral.Lower the backhoe and loader end to the ground and

stop the engine.

2 Disconnect the hydraulic hose 28 from cylinder, plugthe hose to avoid excessive fluid loss.

3 Unscrew mounting bolts 37 and remove the cylinder

from the machine.

Boom Lock Slave Cylinder - Dismantling and Assembly

(FIG 2)

The numerical sequence shown on the illustration below is





Boom Lock Slave Cylinder - Replacement (FIG 2)

Replacement of the slave cylinder is a reversal of the

removal procedures. After refitting, bleed air from the system

by means of bleed nipple 5. Loosen the bleed nipple when

the boom lock operating lever is fully up. Ensure that the

master cylinder reservoir is kept topped up with JCB Light

Hydraulic Fluid.

S107860

FIG 2



20 - 1

Dump Pedal Microswitch (machines up to

serial number 430000)

The dump pedal and microswitch is only required on

machines fitted with a Syncro Shuttle transmission.

Because the Powershift transmission is a fully electro-

hydraulic unit, it is not necessary to disconnect the drive

whilst changing gear, therefore the dump pedal and

microswitch are not required on machines equipped with

Powershift transmission.


1 Lift away cab floor mat from base of front control

consoles.

2 Remove bolts A and take off the steering pedestalcover B.

3 Remove the left hand side console. If necessary, label

and disconnect electrical wires to the switches and

radio (if fitted).

4 Disconnect the microswitch lead from the panel

harness, shown at D.

5 Loosen screws C and remove the microswitch.

6 Replacement is a reversal of the removal sequence.

The torque tightening figure for screw C is 0.8 to 1.0

Nm (0.6 to 0.7 lbf ft).

Section D Controls

9803/3260

Section D

20 - 1

Issue 3*

Transmission Controls

S152680B

S152680A

*

A

B

C

*

D



i

Section E Hydraulics

9803/3260

Section E

i

Issue 6*

Contents Page No.

Technical Data

Machine Hydraulics (AWS & 2WS Machines) 1 - 1

Steer Hydraulics (AWS Machines) 1 - 4

* Steer Hydraulics (2WS Machines) 1 - 4

* 3CXE (214E) Machines 1 - 5

Schematics

Basic Machine (2WS & AWS Machines)

- From Serial No. 402174 2 - 1

Circuit Variations 2 - 3

* Steer Hydraulics (AWS Machines) 2 - 5

* Steer Hydraulics (2WS Machines) 2 - 6

* 3CXE (214E) Machines Only 2 - 7

Descriptions

Basic Machine Neutral Circuit 3 - 2

* 3CXE (214E) Machines - Neutral Circuit 3 - 4

Pump Operation 4 - 2

Loader Valve

- Operation 1 5 - 2

- Operation 2 5 - 4

- Operation 3 - Hydraulic Speed Control (H.S.C.) 5 - 4B

Load Hold Check Valve(s)

- Operation 1 5 - 6

- Operation 2 5 - 8

Arms Lower Operation 5 - 10

Float Operation 5 - 12

Main Relief Valve (M.R.V.) Operation 6 - 2

Main Relief Valve (M.R.V.) Operation ('Husco') 6 - 4

Auxiliary Relief Valve (A.R.V.) Operation 7 - 2

Excavator Valve - Neutral Circuit 8 - 2

Excavator Valve

- Operation 1 8 - 4

- Operation 2 8 - 6

Excavator Valve - One Way Restrictor

- Operation 1 8 - 6

- Operation 2 8 - 8

Slew Operation 9 - 2

Slew Auxiliary Relief Valve And

Anti-cavitation Operation 9 - 4

Excavator Valve - Auxiliary Relief Valve (A.R.V.) 10 - 2

Excavator Valve - Auxiliary Relief Valve (A.R.V.)

- Operations 1, 2 and 3 10 - 4

Excavator Valve - Dipper Make-up Check Valve &

Anti-cavitation Operation 10 - 6



ii


9803/3260

Section E

ii

Issue 5*

Contents Page No.

Descriptions (cont'd)

Excavator Valve - Anti-cavitation Operation 10 - 8

Hydraclamp Operation (Sideshift Machines)

- to serial number 430000 11 - 2- from serial number 430001 11 - 4

Ram Operation and End Damping 12 - 2

Twin Ram Slew Operation (Centremount M/c's) 12 - 4

Hose Burst Protection Valve - to Machine

Serial No. 402173

- Operations 1 & 2 13 - 2

- Operations 3 & 4 13 - 4

Hose Burst Protection Valves - from Machine

Serial No. 402174- Operation 1 & 2 13 - 6

- Operation 3 & 4 13 - 8

- Emergency Operation 13 - 8

Stabiliser Check Valve (Sideshift M/c's) 14 - 2

Stabiliser Check Valve with Relief Valve

(Centremount M/c's) 15 - 2

Hydraulic Filter Operation 16 - 2

Steering Priority Valve (AWS Machines)

- Neutral Operation 18 - 2

- Turning Operation 18 - 4

Steering Priority Valve (2WS Machines)

- Neutral Operation 18 - 6

- Turning Operation 18 - 8

Steering (AWS Machines)

- 2 Wheel Steer Select 19 - 2

- 4 Wheel Steer Select 19 - 4

- Crab Steer Select 19 - 6

Hydraulic Steer Unit (AWS Machines)- Operation 1 - Neutral 20 - 2

- Operation 2 - Right Turn 20 - 4

- Operation 3 - Left Turn 20 - 6

- Operation 4 - Left Turn, Unassisted 20 - 8

- Operation 5 - Shock Valve 20 - 10

Hydraulic Steer Unit (2 WS Machines)

- Operation 1 - Neutral 20 - 12

- Operation 2 - Right Turn 20 - 14

- Operation 3 - Left Turn 20 - 16

- Operation 4 - Left Turn, Unassisted 20 - 18

- Operation 5 - Shock Valve 20 - 20

Introduction to Hydraulic Schematic Symbols 24 - 1

Fault Finding 25 - 1

*



iii


9803/3260

Section E

iii

Issue 5*

Contents Page No.

Pumps

Pump Flow Testing 30 - 2

Hydraulic Pump & Drive Assembly (AWS Machines)

- Removal & Replacement 31 - 2

Pump Drive Unit (AWS Machines)

- Dismantling & Assembly 31 - 4

Hydraulic Pump (2WS Machines)

- Removal & Replacement 31 - 6

Hydraulic Pump ('Hamworthy' type)


Hydraulic Pump ('Ultra' type)


Hydraulic Pump - 3CXE (214E) Machines Only

* - Dismantling & Assembly 31 - 13

Valves

Loader Valve


'Hamworthy' Loader Valve - Dismantling & Assembly

- Standard Spool 41 - 3

- Float Spool 41 - 5

- Electric Detent Spool 41 - 7

- M.R.V. 41 - 8- A.R.V. 41 - 9

- Load Hold Check Valves 41 - 10

- Unloader Spool 41 - 12

- Unloader Check Valve 41 - 13

'Husco' Loader Valve - Dismantling & Assembly

- Standard Spool 41 - 21

- Float Spool 41 - 23

- Electric Detent Spool 41 - 25

- M.R.V. 41 - 27

- A.R.V. & L.H.C.V. 41 - 29

- Unloader Valve Assembly 41 - 31

* 'Husco' Loader Valve - 3CXE (214E) Machines Only

* Dismantling & Assembly

* - Standard Spool 41 - 41

* - Float Spool 41 - 43

* - M.R.V. 41 - 45

* - A.R.V. 41 - 45

'Hamworthy' Loader Valve - Pressure Testing

- Main Relief Valve (M.R.V.) 42 - 1

- Unloader Valve 42 - 2

- Hydraulic Speed Control (HSC) 42 - 2

- Loader A.R.V.'s (using hand pump) 42 - 3- Shovel Ram Head Side A.R.V. (In Position) 42 - 4

- Shovel Ram Rod Side A.R.V. (In Position) 42 - 5



v


9803/3260

Section E

v

Issue 1

Contents Page No.

Rams

Typical Ram


Typical Ram (with Dowelled Piston Head)- Dismantling & Assembly 61 - 3

Steer Ram



Gland Seal Fitting Procedure 64 - 1



1 - 2

Machine Hydraulics (AWS and 2WS Machines - excluding 3CXE)

Hydraulic Pumps ('Ultra' type)

Hydraulic Pump - Option 1

Model/Reference Double pump/4071 (2WS), 4075 (AWS)Rotation Clockwise (AWS), Anti-clockwise (2WS)

Mounting:

AWS M/c's Engine Timing Case

2WS M/c's Chassis (driveshaft driven)Machines/Models applicable to: See - Hydraulic Pump Applicability Chart

Flow at 2200 rev/min and system pressure: litres/min UK gal/min

Pump section 1 (mounting flange end) 81.2 17.9

Pump section 2 57.4 12.6

Maximum working pressure See - Relief Valve Operating Pressures


Model/Reference Double pump/4072 (2WS), 4074 (AWS)

Rotation Clockwise (AWS), Anti-clockwise (2WS)

Mounting: AWS M/c's Engine Timing Case

2WS M/c's Chassis (driveshaft driven)Machines/Models applicable to: See - Hydraulic Pump Applicability Chart






Model/Reference Double pump/4070 (2WS)

Rotation Anti-clockwise

Mounting:

2WS M/c's Chassis (driveshaft driven)

Machines/Models applicable to: See - Hydraulic Pump Applicability ChartFlow at 2200 rev/min and system pressure: litres/min UK gal/min





Model/Reference Double pump/4073 (2WS)

Rotation Anti-clockwise

Mounting:

2WS M/c's Chassis (driveshaft driven)

Machines/Models applicable to: See - Hydraulic Pump Applicability Chart




Maximum working pressure see - Relief Valve Operating Pressures

Hydraulic Pump Applicability Chart

Pump Type 2-Wheel Steer Machines All Wheel Steer Machines

3CX S/Master H/Master 4CX 4C 4CN S/Master

4071

4075

4072 - - -

4074

4070 - - - - - - -

4073

Note: The applicability chart is intended as a guide only, make sure that you check the pump data plate (mounted on the

pump) to determine exactly which type of pump is fitted to your machine.


9803/3260

Section E

1 - 2

Issue 5*

Technical Data

*



1 - 3

Machine Hydraulics (AWS and 2WS Machines - excluding 3CXE)

Relief Valve Operating Pressures bar kgf/cm2 lbf/in2

Main Relief Valve (M.R.V.) @ 1500 RPM 228 - 230 233 - 235 3300 - 3335

Unloader Valve 203 - 207 207 - 211 2950 - 3000

Auxiliary Relief Valves (A.R.V.)

† LoaderShovel Ram Head Side 165 - 179 168 - 183 2400 - 2600

Shovel Ram Rod side 303 - 317 309 - 323 4400 - 4600

Backhoe

Boom Ram Head Side 241 - 255 246 - 260 3500 - 3700

Boom Ram Rod Sideto m/c 435209 (Sideshift ), 434984 (C/mount) 303 - 317 309 - 323 4400 - 4600

from m/c 435210 (Sideshift ), 434985 (C/mount) 338 - 352 344 - 358 4900 - 5100

Bucket Ram Head Side

Centremount (17' backhoe - 217 models only) 303 - 317 309 - 323 4400 - 4600Centremount (14' backhoe) 241 - 255 246 - 260 3500 - 3700

Centremount (15' 6" backhoe up to M/C 413521) 241 - 255 246 - 260 3500 - 3700Centremount (15' 6" backhoe from M/C 413522

except knuckle boom) 303 - 317 309 - 323 4400 - 4600

Sideshift 241 - 255 246 - 260 3500 - 3700

Bucket Ram Rod Side (Machines with Powerbreaker only) 241 - 255 246 - 260 3500 - 3700

Dipper Ram Head Side 241 - 255 246 - 260 3500 - 3700

Dipper Ram Rod Side 241 - 255 246 - 260 3500 - 3700Slew Left and Right 255 - 269 260 - 274 3700 - 3900

Attachments bar kgf/cm2 lbf/in2

Extradig Ram Head Side 138 - 145 141 - 148 2000 - 2100

Extradig Ram Rod Side 207 - 214 211 - 218 3000 - 3100

Jaw Bucket Ram Head Side 138 - 145 141 - 148 2000 - 2100Jaw Bucket Ram Rod Side 207 - 214 211 - 218 3000 - 3100

Knuckle Ram Head Side 138 - 145 141 - 148 2000 - 2100

Knuckle Ram Rod Side 207 - 214 211 - 218 3000 - 3100

Hammermaster 207 - 214 211 - 218 3000 - 3100

Roadbreaker 138 - 150 141 - 153 2000 - 2200

Sequence Valve 21 21 300

Hose Burst Protection Valves (optional) bar kgf/cm2 lbf/in2

Machine Serial Numbers - up to 402173

Boom Ram Rod Side 303 - 317 309 - 323 4400 - 4600

Dipper Ram Rod Side 303 - 317 309 - 323 4400 - 4600

Loader Lift Rams Head Side 303 - 317 309 - 323 4400 - 4600

Machine Serial Numbers - from 402174

Boom Ram Rod Side 250 255 3625

Dipper Ram Rod Side 250 255 3625

Loader Lift Rams Head Side 250 255 3625

Stabiliser Check Valve Relief Valve (Centremount M/c's) 303 - 317 309 - 323 4400 - 4600

Return Line Filter bar kgf/cm2 lbf/in2

By-pass pressure 1.5 1.5 22

† When setting 'Hamworthy' Loader Valve A.R.V.'s using a hand pump, set 15 bar (220 lbf/in2 ) below nominal figure shown.

† When setting 'Husco' Loader Valve A.R.V.'s using a hand pump, set to the figure shown above.

Note: Later type loader valves are produced by a different manufacturer (Husco). When appropriate, the loader valve will be

identified using the manufacturer's name, (Hamworthy - earlier type, or Husco - later type). In some instances, there will be noneed to differentiate (e.g., descriptions of operation - the valves operate in the same manner).


9803/3260

Section E

1 - 3

Issue 7*

Technical Data

**

*

*

*

*

**

*



1 - 4

Steer Hydraulics (AWS Machines)

System Type Full Power Hydrostatic

Hydraulic Supply From Main Hydraulic Pump Via Priority ValveControl Unit Type Load Sensing With Integral Relief Valve

Control Unit Relief Valve Operating Pressure(at 1500 revs/min) 120 ± 3.5 bar 122 ± 3.5 kgf/cm2 1740 ± 50 lbf/in2

Control Unit Shock Valve Operating Pressure 175 - 190 bar 178 - 199 kgf/cm2 2538 - 2756 lbf/in2

Front Steer Ram(s) Dimensions

Bore 60 mm (2.362 in)

Rod Diameter 30 mm (1.181 in)

Stroke 210.6 mm (8.290 in)

End Cap Assembly A/F 55 mm (2.165 in)

Piston Head Assembly A/F 41 mm (1.614 in)

Rear Steer Ram(s) Dimensions

Bore 60 mm (2.362 in)


Stroke 210.6 mm (8.290 in)End Cap Assembly A/F 55 mm (2.165 in)


Steer Ram Torque Settings Nm kgf m lbf ft

Piston Head 405 41 300

End Cap 678 69 500

Steer Hydraulics (2WS Machines)

System Type Full Power HydrostaticHydraulic Supply From Main Hydraulic Pump Via Priority Valve

Control Unit Type Load Sensing With Integral Relief Valve

Control Unit Relief Valve Operating Pressure

(at 1500 revs/min) 120 ± 3.5 bar 122 ± 3.5 kgf/cm2 1740 ± 50 lbf/in2

Control Unit Shock Valve Operating Pressure 175 - 190 bar 178 - 199 kgf/cm2 2538 - 2756 lbf/in2

Steer Ram(s) Dimensions

2 Wheel Drive Machines

Location 1 Ram - Front Axle (Right Hand Side)

Bore 70 mm (2.756 in)


Stroke 290 mm (11.417 in)End Cap Assembly A/F 65 mm (2.559 in)


4 Wheel Drive Machines

Location 1 Ram - Front Axle (Left Hand Side)

Bore 70 mm (2.756 in)Rod Diameter 30 mm (1.181 in)

Stroke 290 mm (11.417 in)

End Cap Assembly A/F 65 mm (2.559 in)


Steer Ram Torque Settings Nm kgf m lbf ft

Piston Head 405 41 300End Cap 678 69 500


9803/3260

Section E

1 - 4

Issue 4*

Technical Data

*



1 - 5

3CXE (214E) Machines

Hydraulic Pump

Model/Reference: Single pump/6197Rotation: Anti-clockwise

Mounting: Chassis (driveshaft driven)Machines/Models applicable to: 3CXE (214E) machines only

Flow at 2200 rev/min and system pressure: 99.0 litres/min; 21.9 UK gal/min; 26.3 US gal/min

Maximum working pressure 230 bar; 234.5 kg/cm2; 3335 lbf/in2

Relief Valve Operating Pressures bar kgf/cm2 lbf/in2

Main Relief Valve (M.R.V.) @ 1500 RPM 228 - 230 233 - 235 3300 - 3335

Auxiliary Relief Valves (A.R.V.)

LoaderShovel Ram

Head Side 170 - 174 173 - 177 2465 - 2520

Rod side 308 - 312 314 - 318 4475 - 4525

BackhoeBoom Ram

Head Side 245 - 252 249 - 257 3550 - 3650Rod Side 308 - 312 314 - 318 4475 - 4525

Bucket Ram

Head Side 245 - 252 249 - 257 3550 - 3650

Rod Side 245 - 252 249 - 257 3550 - 3650

Dipper Ram

Head Side 245 - 252 249 - 257 3550 - 3650Rod Side 245 - 252 249 - 257 3550 - 3650

Slew Ram

Left and Right 258 - 266 263 - 271 3750 - 3850

Stabiliser Check Valves

Left and Right 303 - 317 309 - 323 4400 - 4600

Steering 120 - 125 122 - 127 1740 - 1813 Attachments

Hammermaster 170 173 2465

Loader Valve Identification (Fig 1)

1 - Loader Arm Spool

2 - Shovel Spool2A - Rod Side

2B - Head Side

3 - Auxiliary Relief Valve

4 - Inlet Port

5 - Outlet Port

6 - High Pressure Carry Over Port


9803/3260

Section E

1 - 5

Issue 4*

Technical Data

2

1

2A

2B

3

3

4

5

6

A248220

Fig 1

*

*

*

*



2 - 1

Basic Machine (2WS & AWS Machines)

- from Serial No. 402174

Component Key



S Suction Line

T Tank

1A Neutral Circuit Line

1B Neutral Circuit Line2A Neutral Circuit Line





3D Loader Shovel Ram Spool3E Clamshovel Spool

3F Shovel Ram Head Side A.R.V.

3G Shovel Ram Rod Side A.R.V.

3H Load Hold Check Valve

3J Load Hold Check Valve3K Load Hold Check Valve

3L Unloader Valve Spool


3N Unloader Check Valve

3P Pressure Test Point (Unloader)

3Q Hydraulic Speed Control Solenoid4 Excavator Valve Block

4A Slew Spool

4B Boom Spool

4C Stabiliser Spool4D Stabiliser Spool

4E Dipper Spool4F Bucket Spool

4G Hydraclamp Valve

4H Slew A.R.V.

4J Slew A.R.V.

4K Boom Ram Rod Side A.R.V.

4L Boom Ram Head Side A.R.V.4M Dipper Ram Head Side A.R.V.



4R Load Hold Check Valve

4S Load Hold Check Valve

4T Load Hold Check Valve4U Load Hold Check Valve

4V Load Hold Check Valve

4W Load Hold Check Valve

4X Make-up Check Valve

6 In-tank Filter

6A Filter By-pass Valve7 Priority Valve

7B Connection to Steer Circuit (see following pages)


25 Sequence Valve

26 Hydraulic Oil Cooler

31 Shovel Ram R.H.32 Shovel Ram L.H.

33 Lift Ram R.H.34 Lift Ram L.H.

35 Clam Shovel Ram R.H.

36 Clam Shovel Ram L.H.

51 Bucket Ram52 Boom Ram

53 Stabiliser Ram

54 Stabiliser Ram

55 Dipper Ram

56 Left Hand Slew Ram(Centremount Machines Only)

57 Right Hand Slew Ram(Centremount Machines Only)58 One Way Restrictor

59 Stabiliser Check Valve (Standard on Centremount,

Optional on Sideshift Machines)

61 Hose Burst Protection Valve (optional)

62 Hydraclamps (Sideshift Machines Only)

62A Hydra-clamp Exhaust Line64 Slew Cylinders (Sideshift Machines Only)

65 One Way Restrictor (Centremount Machines Only)

66 Hose Burst Protection Valve (optional)

Note: Excavator services shown here are to the JCB controlpattern. If ISO, Case or Ford control pattern is used, the

excavator spools and relief valves will apply to different

services.

Note: The policy of JCB is one of continuous improvement,

therefore as products develop, there may be variations tothe circuits. Page E/2-3 titled 'Circuit Variations' will identify

these differences.


9803/3260

Section E

2 - 1

Issue 4*

Schematics

***

***

**

****

*

**

*



2 - 3

Circuit Variations

The hydraulic schematic diagram shown on page E/2-2 shows the latest machine hydraulic circuit. The purpose of this page is

to identify 'older' circuit variations, where possible the machine serial numbers will be given to help identify the machinerange(s).

Hose Burst Protection Valves (to Serial Number 402173)

The illustration shows the HBPV when fitted to the

boom circuit. This valve is also fitted on the dipperram and the loader arms.

Component Key

4 Excavator Valve Block

4S Load Hold Check Valve4K Boom Ram Rod Side A.R.V.

4L Boom Ram Head Side A.R.V.4B Boom Spool

52 Boom Ram

61 Hose burst Protection Valve (Optional)

'Hamworthy' Type Loader Valve

The illustration shows the 'Hamworthy' type

loader valve, the latest type loader valve

(Husco) has the pilot valve solenoid (used tocontrol the unloader spool) as an integral

part of the valve block, not a separate item

as shown at 3Q.

Component Key

P1 Pump, main Section

P2 Pump, Secondary Section

T Tank

1A Neutral Circuit Line

3 Loader Valve Block3L Unloader Valve Spool


3N Unloader Check Valve

3P Pressure Test Point (Unloader)



9803/3260

Section E

2 - 3

Issue 4

Schematics

61

V1

V2

C1

C2

4S 4B

4K

4L

4

52

P2

P1

3M

3L

3N

1A

3Q

T

3P

3

A196780

A197090



2 - 4

Circuit Variations (cont'd)

Hydraclamp Control Valve (to Serial Number 430000)

The illustration shows the manual type hydraclamp control valve. Machines from serial number 430001 have the hydraclamp

valve operated by a switch (and solenoid).

Component Key

T Tank

1B Neutral Circuit Line

4 Excavator Valve Block4A Slew Spool

4G Hydraclamp Valve

4H Slew A.R.V.

4R Load Hold Check Valve4X Make-up Check Valve

62 Hydraclamps (Sideshift Machines Only)


9803/3260

Section E

2 - 4

Issue 4

Schematics

A217690

4

4G

4X

4H

4A

4R

T

62

1B



T o

h e l p p r e v e n t e x c a v a t o r d i p p e r r a m a n d l o a d e r l i f t

r a m

c a v i t a t i o n , t h e r e i s a c h e c k v a l v e

1 3 f i t t e d t o

t h e

r e t u r n

l i n e .

T h e

c h e c k

v a l v e

r a i s e s

a p p r o x i m a t e l y 5 b a r ( 7 5 l b f / i n 2 ) o f p r e s s u r e i n t h e

l i n e

, w h i c h i m p r o v e s t h e o p e r a t i o n o f t h e r e s p e c t i v e

a n t i - c a v i t a t i o n v a l v e s .

A l s

o , p a r t o f t h e n e u t r a l c i r c u i t i s t h e h

y d r a - c l a m p

e x h

a u s t h o s e 6 2 A . T h e h o s e c o n n e c t s

t h e h y d r a -

c l a

m p s p o o l i n t o t h e e x h a u s t c i r c u i t v i a a d a p t e r B

w h

i c h i s a t t a c h e d t o t h e a n t i - c a v i t a t i o n

c h e c k v a l v e

1 3 . C o n n e c t i n g t h e h y d r a - c l a m p s d i r e c t l y i n t o t h e

e x h

a u s t c i r c u i t p r e v e n t s t h e c l a m p s f r o

m ' l o c k i n g -

u p ' w h e n t h e s i d e s h i f t i n g o p e r a t i o n i s r e

q u i r e d .

T h e h y d r a - c l a m p

e x h a u s t h o s e i s o n

l y f i t t e d

o n

s i d

e s h i f t m a c h i n e s ( t h e r e a r e n o c l a m p s

r e q u i r e d o n

c e n t r e m o u n t m a c h i n e s ) .

Hydraulics

9803/3260 Issue 3*

B a s i c

M a c h i n e N e u t r a l C i r c u i t

O i l i s d r a w n

f r o m t h e h y d r a u l i c t a n k T b

y t h e

h y d r a u l i c p u m p . T h e p u m p

h a s t w o s e c t i o n s ,

P 1

a n d P 2 .

O n 2 - w h

e e l s t e e r m a c h i n e s , t h e h y d r a u l i c p u m p i s

d r i v e n b

y t h e e n g i n e v i a a d r i v e s h a f t , a s s h o w n i n

t h e m a i n

i l l u s t r a t i o n . O n 4 - w h e e l s t e e r m a c

h i n e s ,

t h e p u m

p

i s m o u n t e d

d i r e c t l y t o

t h e e n g i n e a s

s h o w n i n

t h e i n s e t .

O i l f r o m

t h e l a r g e r s e c t i o n P 1 f l o w s d i r e c t

t o t h e

l o a d e r v a l v e 3 . O i l f r o m p u m p s e c t i o n P 2 , f l o w s t o

s t e e r i n g

p r i o r i t y v a l v e 7 , a n d i n n e u t r a l c i r c u i t f l o w s

t h r o u g h

t h e p r i o r i t y v a l v e t o j o i n f l o w

f r o m P

1

a t t h e

l o a d e r v a l v e .

F r o m t h e l o a d e r v a l v e n

e u t r a l g a l l e r y , o i l f l o w s v i a a

h i g h p r e s s u r e c a r r y - o v e

r l i n e t o t h e e x c a v a t o r v a l v e

4 .

S o m e o f t h e e x h a u s t o i l f l o w s d i r e c t l y b a c k t o t h e

t a n k t h r o u g h a n i n - t a n k f i l t e r 6 , a n d

s o m e o f t h e

e x h a u s t o i l r e t u r n s t o

t a n k v i a t h e h y d r a u l i c o i l

c o o l e r A .

3 - 2 3 - 2Descriptions

Section E Section E

* *

* *



T o

h e l p p r e v e n t e x c a v a t o r d i p p e r r a m a

n d l o a d e r l i f t

r a m

c a v i t a t i o n ,

t h e r e i s a c h e c k v a l v e

1 3 f i t t e d t o

t h e

r e t u r n

l i n e .

T h e

c h e c k

v a l v e

r a i s e s

a p p r o x i m a t e l y 5 b a r ( 7 5 l b f / i n 2 ) o f p r e s s u r e i n t h e

l i n e

, w h i c h i m p r o v e s t h e o p e r a t i o n o f t h e r e s p e c t i v e

a n t i - c a v i t a t i o n v a l v e s .

Hydraulics

9803/3260 Issue 1

3 C X E

( 2 1 4 E ) M a c h i n e s - N e u t r a l

C i r c u i t

O i l i s d r a

w n f r o m t h

e h y d r a u l i c t a n k T b y t h e

s i n g l e

s t a g e h y

d r a u l i c p u m p P .

T h e p u m p i s m o u n t e d o n

t h e c h a s

s i s a n d i s e n g i n e d r i v e n v i a a d r i v e s h a f t .

P r e s s u r i s e d

o i l f r o m

t h e p u m p

f l o w s t o s t

e e r i n g

p r i o r i t y v

a l v e 7 , a n d i n n e u t r a l c i r c u i t f l o w s t h

r o u g h

t h e p r i o r i t y v a l v e t o t h e l o a d e r v a l v e 3 .

F r o m t h

e l o a d e r v a l v e n

e u t r a l g a l l e r y , o i l f l o w s v i a a

h i g h p r e s s u r e c a r r y - o v e r l i n e 1 B

t o t h e e x c a v a t o r

v a l v e 4 .

S o m e o f t h e e x h a u s t o i l f l o w s d i r e c t l y b a c k t o t h e

t a n k t h r o u g h a n i n - t a n k f i l t e r 6 , a n d

s o m e o f t h e

e x h a u s t o i l r e t u r n s t o

t a n k v i a t h e h y d r a u l i c o i l

c o o l e r A .


Section E Section E



Hydraulics

9803/3260 Issue 1

P u m p

O p e r a t i o n

A l l m a c h

i n e s i n t h e r a n g e a r e f i t t e d w i t h a d

o u b l e -

s e c t i o n p u m p a s s h o w n .

B o t h s e c t i o n s P 1 a

n d P 2

o p e r a t e a s d e s c r i b e d b e l o w .

T h e b a s

i c p r i n c i p l e o f t h e g e a r p u m p

d e p e n

d s o n

t h e m e s h i n g o f t w o s p u r g e a r s A , o n e o f w h i c h i s

e n g i n e -

d r i v e n w h i l e t h e o t h e r i s a n i d l e r .

O i l i s p i c k e d

u p

b y t h e g e a r t e e t h o n t h e s

u c t i o n

s i d e o f t h e p u m p a n d c a r r i e d a r o u n d

b e t w e

e n t h e

t e e t h a n

d t h e p u m p b o d y .

A s t h e g e a r s c o m

e i n t o

m e s h , t h

e s p a c e c a r r y i n g t h e o i l i s f i l l e d b y

a g e a r

t o o t h o n

t h e m a t i n g g e a r , f o r c i n g t h e o i l o u t

o f t h e

s p a c e a n

d t h r o u g h t h e p u m p o u t l e t .

T h e w e a r p l a t e s B

a r e l o a d e d t o w a r d s t h e g e a r s b y

p r e s s u r i s e d

o i l w h i c h

i s f e d

t o

t h e b a c k s o f t h e

w e a r p l a t e s v i a c h a n n e

l s C .

T h i s e n s u r e s t h a t t h e

c l e a r a n c e b e t w e e n t h e

w e a r p l a t e s a n d

g e a r s i s

p r e v e n t e d

f r o m

b e c o m i n g

e x c e s s i v e

a s o u t l e t

p r e s s u r e r i s e s .

T h e s i d e o f e a c h w e a r

p l a t e t h a t f a c e s t h e g e a r s

h a s t w o r e c e s s e s D .

T h e r e c e s s o n t h e i n l e t s i d e o f

t h e

p u m p

a s s i s t s t h e

f l o w

o f o i l i n t o

t h e

g e a r

s p a c e s ,

t h u s r a i s i n g t h e

c a v i t a t i o n t h r e s h o l d o f t h e

p u m p .

T h e

r e c e s s o n

t h e

o u t l e t s i d e

v e n t s o i l

t r a p p e d

b e t w e e n m e s h i n g

g e a r t e e t h

t o

p r e v e n t

c o m p r e s s i o n l o a d s o n t h e b e a r i n g s .


Section E Section E



P r e

s s u r e i n t h e i n l e t g a l l e r y C

i s s e n s

e d

b y p i l o t

v a l v e 3 M v

i a t h e b o r e o f s p o o l 3 L .

A t p r e s s u r e

b e l o w

t h e s e t t i n g o f t h e u n l o a d e r v a l v e

, b o t h p i l o t

v a l

v e 3 M a

n d s p o o l 3 L r e m a i n c l o s e d .

T h e e x h a u s t g a l l e r y i s c o n n e c t e d t o t h e

t a n k r e t u r n

l i n e

v i a p o r t T .

C o

m p o n e n t K e y

3

L o a d e r v a l v e b l o c k

3 B

M a i n R e l i e f V a l v e

3 C

L i f t R a m S

p o o l

3 D

S h o v e l R a m S

p o o l

3 E

C l a m S

h o v e l S p o o l

3 L

U n l o a d e r V a l v e S p o o l

3 M

U n l o a d e r P i l o t V a l v e

3 N

C h e c k V a l v e

3 Q

S o l e n o i d V a l v e

N o

t e : L a t e r d e s i g n v a l v e b l o c k s ( H u s c

o ) h a v e t h e

p i l o t v a l v e

s o l e n o i d

a s s e m b l y 3 Q f i t t e d

a s a n

i n t e g r a l p a r t o f t h e l o a d e r v a l v e - n o t

a s e p a r a t e

s o l e n o i d v a l v e a s s h o w n a t 3 Q .

A l s

o ,

t h e

H u s c o

v a l v e

b l o c k

m a y

d i f f e r

i n

a p p e a r a n c e s l i g h t l y f r o m

t h e v a l v e b l o c k s h o w n i n

t h e

f o l l o w i n g i l l u s t r a t i o n s ,

h o w e v e r , t h e d e s c r i p t i o n s

o f o p e r a t i o n e t c . a r e s t i l l a p p l i c a b l e .

Hydraulics

9803/3260 Issue 2*

L o a d e

r V a l v e

O p e r a t i o n 1

U n l o a d e

r s p o o l o p e r a t i o n p r o t e c t s t h e e n g i n e f r o m

b e i n g o

v e r l o a d e d

i f a

s e r v i c e

i s b e i n g w

o r k e d

p a r t i c u l

a r l y h a r d ,

f o r e x a m p l e

w h e n

u s i n

g

t h e

e x c a v a t o

r t o t e a r o u t . I t d o e s t h i s b y d u m p i

n g t h e

o i l f r o m

p u m p

s e c t i o n P 2 t o t a n k , a l l o w i n g e n g i n e

p o w e r t o

b e a p p l i e d f u l l y t o t h e m a i n p u m p s

e c t i o n

P 1 .

I n n e u t r a l c i r c u i t h y d r a u l i c o i l f r o m p

u m p s e c t i o n P 2

e n t e r s t h e l o a d e r v a l v e

a t 1 C

v i a a s t e e r i n g p r i o r i t y

v a l v e .

O n e n t e r i n g t h e v

a l v e b l o c k , o i l f l o w s a r o u n d

t h e w a i s t e d s e c t i o n o f t h e u n l o a d e r v a l v e 3 L , p a s t

c h e c k v a l v e 3 N a n d j o i n s f l o w

f r o m p

u m p P 1 .

O i l f r o m p

u m p s e c t i o n P

1 e n t e r s t h e l o a d e r v a l v e a t

1 A .

C o m b i n e d o i l f l o w

f r o m P

1 a n d P 2 p a s s e s t h e m a i n

r e l i e f v a l v e 3 B

( M . R . V . )

a n d

f i l l s t h e p a r a l l e l g a l l e r y

B .

F r o m t h

e p a r a l l e l g a l l e r y t h e o i l f l o w s a r o u n d t h e

w a i s t e d

c e n t r a l p o r t i o n s o f s p o o l s 3 C ,

3 D

a n d

3 E

( a l l i n n e u t r a l p o s i t i o n ) a n d

f l o w s o n t o

f e e d

t h e

e x c a v a t o r v a l v e v i a h i g

h p r e s s u r e c a r r y o v e r l i n e

1 B .


Section E Section E

*



W h

e n p r e s s u r e i n t h e i n l e t g a l l e r y C

f a l l s ,

f o r

e x a

m p l e i f t h e e x c a v a t o r h a s s t o p p e d

t e a r i n g o u t ,

p i l o

t v a l v e 3 M w

i l l c l o s e .

T h i s m e a n s o i l i n s p r i n g

c a v i t y 3 P

w i l l b e a t t h e s a m e p r e s s u

r e a s o i l i n

g a l l e r y C , s p r i n g p r e s s u r e w i l l m o v e s p o o l 3 L b a c k

o n t o i t s s e a t , c l o s i n g p u m p P 2 c o n n e c t i o n t o t a n k .

Hydraulics

9803/3260 Issue 1

L o a d e

r V a l v e

O p e r a t i o n 2

I f t h e p r e s s u r e i n t h e i n l e t g a l l e r y C

r i s e s

t o t h e

s e t t i n g

o f p i l o t v a l v e 3 M ,

t h i s v a l v e w i l l

o p e n ,

a l l o w i n g

o i l i n s p r i n g c a v i t y 3 P

t o e s c a p e

m o r e

q u i c k l y

t h a n i t c a n b e r e p l a c e d b y o i l e n

t e r i n g

t h r o u g h t h e s m a l l d r i l l i n g D .

T h i s c r e

a t e s a p r e s s u r e d i f f e r e n t i a l b e t w e e n t h e

s p r i n g c a v i t y 3 P

a n d g a l l e r y C .

H i g h e r p r e s s u r e i n

g a l l e r y C

a c t s o n t h e f a c e o f s p o o l 3 L c a u s i n g t h e

s p o o l t o

b e m o v e d o f f i t s s e a t .

O i l e n t e r i n g t h e v a l v e

b l o c k f r o m

p u m p P 2 n o w

f l o w s d i r e c t l y t o t a n k ( T ) .

H i g h p r e s s u r e i n g a l l e r y C a l s o h o l d s c h e c k v a l v e

3 N f i r m l y c l o s e d , p r e v e n

t i n g o i l f r o m

p u m p P 1 f r o m

a l s o b e i n g d u m p e d .


Section E Section E



Hydraulics

9803/3260 Issue 1

L o a d H o l d C h e c k V a l v e ( s )

O p e r a t i o n 1

T h e i l l u s

t r a t i o n s h o w s ' a r m s r a i s e ' b e i n g s e

l e c t e d

b y t h e l i f

t r a m s

p o o l .

T h e w e i g h t o f t h e l o a d e d

s h o v e l , a s i n d i c a t e d

b y

t h e a r r o w s , p r o d u c e s a h i g h e r p r e s s u r e i n s

e r v i c e

l i n e

D t

h a n i n t h e p a r a l l e l g a l l e r y B .

T h i s p r e s s u r e

d i f f e r e n t i a l c a u s e s l o a d

h o l d

c h e c k v a l v e

3 J

t o

c l o s e , t

h u s p r e v e n t i n g t h e l o a d f r o m d

r o p p i n g .


Section E Section E



Hydraulics

9803/3260 Issue 1

L o a d H o l d C h e c k V a l v e ( s )

O p e r a t i o n 2

A s t h e n e u t r a l c i r c u i t h a s b e e n

b l o c k e d

b y t h e

c e n t r a l l a n d o f t h e s e l e c t e d s p o o l 3 C ,

t h e p r e s s u r e

i n p a r a l l e l g a l l e r y B

i n c r e a s e s u n t i l i t i s g r e a t e

r t h a n

t h a t i n s e r v i c e l i n e D .

A t t h i s p o i n t , l o a d

h o l d

c h e c k v a l v e 3 J o

p e n s ,

a l l o w i n g

o i l t o f l o w

f r o m t h

e p a r a l l e l g a l l e r y i n

t o t h e

s e r v i c e l i n e a n d o p e r a t e t h e l i f t r a m s 3 3 a n d 3

4 .


Section E Section E



Hydraulics

9803/3260 Issue 1

A r m s L o w e r O p e r a t i o n

W h e n a

s p o o l i s s e l e c t e d a s s h o w n a t 3 C ,

t h e

c e n t r a l

l a n d o f t h e s p o o l C

b l o c k s t h e n

e u t r a l

c i r c u i t .

O i l f r o m t h

e p u m p , e n t e r i n g a t 1 A ,

i s

d i v e r t e d

i n t o t h e p a r a l l e l g a l l e r y B , o p e n s t h

e l o a d

h o l d c h e

c k v a l v e 3 J , a n d f l o w s a r o u n d t h e w

a i s t e d

s e c t i o n o f t h e s p o o l D a n d o u t t o t h e r o d s i d e o f l i f t

r a m s 3 3

a n d 3 4 .

T h e l o w e r l a n d o f t h e s e l e c t e d s p o o l E b l o c

k s t h e

f l o w

f r o m

t h e p a r a l l e l g a l l e r y t o t h e h e a d s i d

e p o r t

a n d o i l r

e t u r n i n g f r o m

t h e r a m s i s d i v e r t e d i n

t o t h e

e x h a u s t

g a l l e r y .


Section E Section E



Hydraulics

9803/3260 Issue 1

F l o a t O p e r a t i o n

T h e f l o a

t f a c i l i t y i s p r o v i d e d

t o

a l l o w

t h e a r m s t o

m o v e u p

a n d

d o w n s o

t h a t t h e s h o v e l c a n

f o l l o w

t h e s u r f a

c e c o n t o u r s a s t h e m a c h i n e i s d r i v e

n o v e r

u n e v e n g r o u n d .

T h i s i s a

c h i e v e d b y m o v i n g t h e l i f t s p o o l 3 C

d o w n

b e y o n d

' a r m s l o w e r ' i n t o

t h e ' f l o a t ' d e t e n t , w h e n

t h e f e e d

f r o m

t h e p a r a l l e l g a l l e r y t o

t h e s

e r v i c e

p o r t s i s

b l o c k e d

a n d

t h e

n e u t r a l c i r c u i t

i s r e -

o p e n e d

. B o t h

s e r v i c e

p o r t s a r e

c o n n e c t e d

t o

e x h a u s t

v i a t h e s p o o l w a i s t s A .

O i l c a n t

h e n b e d i s p l a c e d f r o m e

i t h e r e n d o f

t h e l i f t

r a m s 3 3

a n d

3 4

i n t o

t h e e x h a u s t g a l l e r y , a l

l o w i n g

t h e r a m s

t o o p e n a n d c l o s e a s r e q u i r e d .


Section E Section E



3

V a

l v e

M o v e s o

f f i t s S e a

t

I n v i e w

3 , p u m p p r e s s u r e a t 1 A

h a s r i s e n t o t h e s e t -

t i n g o f t h e m a i n r e l i e f v a l v e b u t p r e s s u r e

i n c h a m b e r

D

h a s n o t r i s e n b e c a u s e t h e s e a t o r i f i c e o f p i l o t

v a l v e

F

i s l a r g e r t h a n

s m a l l d r i l l i n g E

a n d

o i l i s

u n a b l e t o f i l l t h e c h a m b e r a s q u i c k l y a s i t i s b e i n g

e x h a u s t e d .

P r e

s s u r e a c t i n g o n t h e u p p e r f a c e s o f m

a i n p l u n g e r

A

i s t h e r e f o r e g r e a t e r t h a n t h e c o m b i n

e d

f o r c e o f

s p r i n g

C

a n d

t h e

p r e s s u r e

i n

c h a m

b e r

D .

T h e

p l u

n g e r t h e n m o v e s o f f i t s s e a t , a l l o w i n g p r e s s u r e

t o b e r e l e a s e d i n t o t h e e x h a u s t g a l l e r y .

A s

t h e p u m p p r e s s u r e d e c r e a s e s ,

t h e p

i l o t v a l v e i s

a b l e t o r e s e a t a n d

p r e s s u r e i n c h a m b e r

D

a s s i s t s

s p r i n g

C

t o f o r c e t h e m a i n p l u n g e r

A b

a c k o n t o i t s

s e a

t .

Hydraulics

9803/3260 Issue 1

M a i n R

e l i e f V a l v e ( M . R . V . )

O p e r a t i o n

1

V a l

v e a

t R e s

t

T h e m a i n r e l i e f v a l v e ( M . R . V . )

3 B , s i t u a t e d

i n t h e

l o a d e r v a l v e b l o c k , p r o v i d e s c o n t r o l o f b o t h

l o a d e r

a n d e x c a v a t o r p r e s s u r e s .

I l l u s t r a t i o n 1 s h o w s a l o a d e r s e r v i c e s e l e c t e d

b y

s p o o l 3 D

c a u s i n g p r e s s u r e t o r i s e i n t h e s e r v i c e l i n e

a n d b a c k t h r o u g h t h e l o a d e r v a l v e t o t h e p u m p v i a

l i n e

1 A .

T h e s e r v i c e i s o p e r a t i n g u n d e r l i g h

t l o a d

a n d

t h e

p r e s s u r e i s n o t s u f f i c i e n t t o

c a u s

e a n y

r e s p o n s e i n t h e M . R . V .

T h e m a i n p l u n g e r

A

i s h e l d

o n i t s s e a t B

b y t h e

c o m b i n e

d e f f e c t o f s p r i n g

C

a n d t h e p u m p p r e s s u r e

w h i c h e n t e r s c h a m b e r

D

t h r o u g h t h e s m a l l d r i l l i n g

E .

P u m p

p r e s s u r e o u t s i d e t h e c h a m b e r i s n o

t h i g h

e n o u g h t o l i f t t h e p l u n g e r o f f i t s s e a t .

2

P i l o t V a

l v e

O p e n s

I f , a s s h o w n i n v i e w

2 , p u m p

p r e s s u r e r i s e s h i g h

e n o u g h

t o

f o r c e t h e p

i l o t v a l v e

F

f r o m

i t s s e a t

( a g a i n s t s p r i n g

G ) , t h e

p r e s s u r e i n c h a m b e r

D

i s

v e n t e d i n t o t h e e x h a u s t

g a l l e r y

H .

U n l e s s t h e p r e s s u r e c o

n t i n u e s t o r i s e , p l u n g e r

A

w i l l r e m a i n o n i t s s e a t .


Section E Section E



3

M a i n P o p p e t O p e n s

A s

s e r v i c e p r e s s u r e c o n t i n u e s t o r

i s e a n d o i l

e s c a p e s f r o m

c a v i t y L ,

t h e p r e s s u r e

d i f f e r e n t i a l

b e t w e e n t h e u p p e r a n d l o w e r s u r f a c e s

o f p i s t o n C

c a u s e s t h i s p i s t o n t o r i s e a n d s e a t o n

t h e p o i n t o f

p i l o

t p o p p e t E .

O i l c o n t i n u e s t o e s c a p e f r o m

c a v i t y

L

b u t t h e

i n c

o m i n g f l o w

t o t h e c a v i t y h a s b e e n c u t o f f . T h i s

p r o

d u c e s a p r e s s u r e d r o p a b o v e p o p p e

t B , c a u s i n g

t h e

p o p p e t t o l i f t a n d r e l e a s e s e r v i c e p

r e s s u r e i n t o

e x h

a u s t g a l l e r y K .

Hydraulics

9803/3260 Issue 1

M a i n R

e l i e f V a l v e O p e r a t i o n

( H u s c o L o a d e r V a l v e )

1

V a l

v e a t R e s t

W h e n t h

e s e r v i c e i s i n n e u t r a l a n d t h e r e a r e n o

e x c e s s i v

e f o r c e s a c t i n g o n t h e e q u i p m e n t , s

e r v i c e

p r e s s u r e

a t A

w i l l b e a c t i n g o n t h e l o w e r f a c e o f

p o p p e t B

a n d w i l l a l s o b e f e l t i n s i d e t h e v a l v e v i a

h o l l o w p

i s t o n C .

T h e f o r c

e o f s p r i n g s D

a n d F , c o m b i n e d w i t h t h e

s e r v i c e p

r e s s u r e a c t i n g o n t h e u p p e r f a c e s o

f p o p -

p e t B a n

d p i s t o n C ,

k e e p s p o p p e t s B

a n d E

t i g h t l y

s e a t e d .

T h e f o r c

e o f s p r i n g F

i s a d j u s t a b l e t o s u i t t h e r e l e -

v a n t s e r v i c e b y m e a n s o f c a p - n u t G

( s e e n o t e

) .

N o t e : T h

e M R V f i t t e d t o t h e l o a d e r v a l v e i s s l i g h t l y

d i f f e r e n t

i n a p p e a r a n c e t o t h e v a l v e s h o w n

i n t h e

d e s c r i p t i o n s ,

b u t t h e p r i n c i p l e o f o p e r a t i o n i s

e x a c t -

l y t h e s a m e .

2

P i l o t V a l v e O p e n s

A s s e r v i c e p r e s s u r e r e a c h e s t h e p i l o t s e t t i n g o f t h e

v a l v e , p i l o t p o p p e t E l i f t s , a l l o w i n g o i l t o e s c a p e

i n t o c a v i t y H

a n d p a s s

d o w n t h e s i d e s o f s l e e v e J

i n t o t h e e x h a u s t g a l l e r y K .


Section E Section E



* N

o t e : O n t h e H u s c o

t y p e l o a d e r v a l v e t h e A R V

o p e r a t i o n i s t h e s a m e a s f o r t h o s e i n t h

e e x c a v a t o r

v a l v e .

Hydraulics

9803/3260 Issue 2*

A u x i l i a r y R e l i e f V a l v e ( A R V )

O p e r a

t i o n

U n d e r n o r m a l o p e r a t i n g c o n d i t i o n s , w i t h t h e

s h o v e l

i n t h e ' c a r r y ' p o s i t i o n , t h e m e c h a n i c a l l i n k a g e

k e e p s

t h e s h o v

e l l e v e l a s t h e a r m s a r e r a i s e d , t o p

r e v e n t

s p i l l a g e o f t h e l o a d .

I f , a s i l l u

s t r a t e d , t h e s h o v e l i s f u l l y t i p p e d w h

e n t h e

a r m s a r e b e i n g r a i s e d , t h e s h o v e l i s u n a b l e

t o t i p

f u r t h e r , p

r o d u c i n g b a c k p r e s s u r e i n t h e h e a d s i d e o f

t h e s h o v

e l r a m s 3 1 a n d 3 2 a n d c a v i t a t i o n i n t

h e r o d

s i d e .

A s t h e a r m s c o n t i n u e

t o

r i s e , t h e b a c k p r e s s u r e

i n c r e a s e s u n t i l i t r e a c h e s t h e s e t t i n g o f A . R . V .

3 F .

T h i s A . R . V . t h e n o p e n s

, a l l o w i n g t h e e x c e s s b a c k

p r e s s u r e t o b e d u m p e d

t o e x h a u s t a n d p r e v e n t t h e

r a m s a n d l i n k a g e f r o m b

e i n g d a m a g e d .

T h e r o d s i d e A . R . V .

3 G

s e n s e s a h i g h e r p r e s s u r e i n

t h e e x h a u s t g a l l e r y t h a n i n t h e s e r v i c e p o r t a n d

t h e r e f o r e o p e n s t o a l l o

w

e x h a u s t o i l t o

o v e r c o m e

t h e c a v i t a t i o n .


Section E Section E



Hydraulics

9803/3260 Issue 1

E x c a v

a t o r V a l v e - N e u t r a l C i r c u i t

O i l f r o m

t h e l o a d e r v a l v e e n t e r s t h e e x c a v a t o

r v a l v e

a t A

a n d

f l o w s t h r o u g h t h e n e u t r a l g a l l e r y a

r o u n d

t h e w a i s t s o f t h e s o l i d s p o o l s , a s s h o w n b y t h

e f l o w

a r r o w s . I t a l s o f i l l s t h e p a r a l l e l g a l l e r y B

b u t i s

n o t a t

a h i g h

e n o u g h

p r e s s u r e

t o

o p e n

t h e l o a d

h o l d

c h e c k v a

l v e s C .

C o m p o n

e n t K e y ( J C B

C o n t r o l P a t t e r n )

4 A

S l e w

S p o o l

4 B

B o o

m S

p o o l

4 C

S t a b i l i s e r S p o o l

4 D

S t a b i l i s e r S p o o l

4 E

D i p p e r S p o o l

4 F

B u c

k e t S p o o l

N o t e : M

a c h i n e s w i t h I S O

c o n t r o l p a t t e r n h a

v e t h e

b o o m a n

d d i p p e r s p o o l s i n t e r c h a n g e d .


Section E Section E



Hydraulics

9803/3260 Issue 1

E x c a v

a t o r V a l v e

O p e r a t i o

n 1

F l o w

t o

t h e s e r v i c e v i a a t y p i c a l s o l i d

s p o o l 4 B

i s

c o n t r o l l e

d b y t h e l o a d h o l d c h e c k v a l v e 4 S w

h i c h i s

a s p r i n g

- l o a d e d

n o n - r e t u r n v a l v e o p e r a t i n g

a c r o s s

t h e p r e s

s u r e f e e d

f r o m

t h e p a r a l l e l g a l l e r y B .

T h e

v a l v e p r e v e n t s r e v e r s e f l o w

f r o m t h

e r a m s i n

t o t h e

p r e s s u r e f e e d

l i n e , s o

m a i n t a i n i n g

r a m

p r e s s u r e

u n t i l e x c

e e d e d b y s y s t e m p

r e s s u r e .

T h e i l l u s

t r a t i o n

s h o w s a

s e r v i c e

s e l e c t e d

b u t b a c k p r e s s

u r e

D

e x c e e d s

s y s t e m

p r e s s u r e w h i c h

c l o s e s t h e l o a d

h o l d c h e

c k v a l v e 4 S .


Section E Section E



Hydraulics

9803/3260 Issue 1

E x c a v

a t o r V a l v e -

O n e W

a y R e s t r i c t o r

O p e r a t i o

n 2

W h e n t h e b o o m

i s b e i n g l o w e r e d ,

t h e o i l f l o w

t h r o u g h

t h e o n e w a y r e s t r i c t o r E r e - s e a

t s t h e

p o p p e t ,

t h e r e f o r e t h e f l o w

o f o i l i s r e s t

r i c t e d

t h r o u g h

t h e s m a l l d r i l l i n g i n t h e b a s e o f t h e p

o p p e t .

T h i s s l o w

s t h e b o o m d o w n t o a c o n t r o l l a b l e s p e e d .


Section E Section E



Hydraulics

9803/3260 Issue 1

S l e w O

p e r a t i o n ( S i d e s h i f t )

T h e i l l u s t r a t i o n s h o w s r i g h t h a n d s l e w

s e l e c t e

d . T h e

l o w e r p o

r t C

h a s b e e n p r e s s u r i s e d b y t h e s p o

o l . O i l

f l o w s f r o

m t

h e p a r a l l e l g a l l e r y B , o u t p a s t A . R

. V .

4 H

t o t h e r i g h t h a n d s i d e o f t h e s l e w

a c t u a t o r . H e r e i t

p u s h e s

o n

t h e

p i s t o n

a n d

r a c k , c a u s i n

g

t h e

e x c a v a t o r e n d

t o

s l e w

t o

t h e r i g h t . D i s p l a c

e d

o i l

f r o m

t h e

l e f t h a n d

s i d e o f t h e s l e w

a c t u a t o r f l o w s

b a c k t h r

o u g h t h e u p p e r s e r v i c e p o r t D

a n d b

a c k t o

t a n k .

T h e l o w e r i l l u s t r a t i o n s h o w s t h e a c t u a t o r r e a c h i n g

t h e e n d

o f i t s t r a v e l a n d

t h e r e s t r i c t o r c o

l l a r E

c o n t a c t

i n g

t h e

e n d

w a l l o f t h e

s l e w c y l

i n d e r ,

p a r t i a l l y

c l o s i n g o f f t h e e x h a u s t p o r t . E n d d a

m p i n g

i s a c h i e v e d

b y t w o

r a d i a l s l o t s a c r o s s t h e

o u t e r

r i d g e o f

t h e c o l l a r w h i c h a l l o w

r e s t r i c t e d f l o w

t o

e x h a u s t .


Section E Section E



Hydraulics

9803/3260 Issue 1

S l e w A

u x i l i a r y R e l i e f V a l v e

a n d A n t i - c a v i t a t i o n O p e r a t i o n

T h e s p o o l 4 A

i s i n n e u t r a l b u t t h e m o m e n t u m

o f t h e

s l e w i n g e x c a v a t o r e n d c r e a t e s b a c k p r e s s u r e

i n t h e

l e f t h a n d

s l e w

c y l i n d e r . T h i s o p e n s

A . R . V . 4

J

a n d

d u m p s o i l t o e x h a u s t . A t t h i s p o i n t t h e r i g h t h a n d

s l e w

c y l i n d e r c a v i t a t e s a n d

e x h a u s t o i l p r e s s u r e

c a u s e s

A . R . V .

4 H

t o

o p e n , a l l o w i n g

o i l f r o

m t h e

e x h a u s t

g a l l e r y t o f i l l t h e r i g h t h a n d c y l i n d e r .


Section E Section E



Hydraulics

9803/3260 Issue 1

H y d r a u l i c S t e e r U n i t ( 2 W h e e l S t e e r

M a c h i n e s )

O p e r a t i o

n 5 - S h o c k V a l v e

I n n o r m a l o p e r a t i o n o i l f l o w

f r o m

t h e p u m p

e n t e r s

t h e s t e e r i n g u n i t v i a t h e r i g h t h a n d p o r t , o p e

n i n g a

s p r i n g - l o a d e d

n o n - r e t u r n

v a l v e

H .

T h e f

l o w

i s

d i r e c t e d

b y t h e s t e e r i n g u n i t t o a c h i e v e t h e d

e s i r e d

t u r n ( r i g h t h a n d s h o w n ) . I n t h e e v e n t o f a p r e s s u r e

s h o c k w

a v e b e i n g g e n e r a t e d

i n t h e s y s t e m

b y a n

o u t s i d e f o r c e , s h o c k v a l v e G 1 v e n t s t h i s p r e s s u r e t o

e x h a u s t

p r e v e n t i n g d a m a g e t o t h e s t e e r i n g u n

i t .

N o n - r e t u r n

v a l v e J 1 i

s h e l d

o n

i t s s e a t b y t h e

g e n e r a t e d p r e s s u r e a n d

n o n - r e t u r n v a l v e H c l o s e s

t o p r e v e n t t h e s h o c k w

a v e b e i n g f e d

b a c k t o t h e

p u m p .

S o m e o f t h e e x

c e s s f l o w s v i a n o n - r e t u r n

v a l v e J 2

t o t h e o p p o s i t e s i d e o f t h e r a m t o

p r e v e n t

c a v i t a t i o n o c c u r i n g .


Section E Section E



24 - 1

Introduction to Hydraulic Schematic

Symbols

Complex hydraulic components and circuits can be

described to the engineer by using graphical symbols. The

following pages illustrate and give a brief description forsome of the more common symbols used.

There are many symbols in use and it would be impossible

to include them all here. However it should be noted that

most are only variations or refinements on the basic

principles explained here. If more detailed information isrequired you are recommended to obtain a copy of BS2917

or IS01219.

Once familiar with the symbols, the engineer can use

hydraulic circuit diagrams as an aid to fault finding. It will be

possible to see the complete hydraulic circuit and decipherthe relationship between hydraulic components.

General (Basic & Functional Symbols)

Rams

Pumps & Motors


9803/3260

Section E

24 - 1

Issue 1

A189680

A189660

A189670

Spring

Flow restrictionaffected by viscosity

Direction of flow

Indication of rotation

Indication of directionand paths of flow

Variable control

Single acting

Double acting

Double ended

Double acting withdamping at rod area end

Fixed capacity pumpone direction of flow

Fixed capacity pumptwo directions of flow

Variable capacity pumpone direction of flow

Variable capacity pumptwo directions of flow

Fixed capacity motorone direction of flow

Fixed capacity motortwo directions of flow

Variable capacity motorone direction of flow

Variable capacity motortwo directions of flow



24 - 2


Symbols (cont'd)

Control Valves


9803/3260

Section E

24 - 2

Issue 1

A189700 A189690

Used to enclose severalvalves indicating that theyare supplied as one unit

3-Position, 4-Portspring centred pilotoperated valve

3-Position, 6-Portspring centred handoperated valve

3-Position, 4-Portspring centred solenoid & pilot pressure operated valve

3-Position, 4-Portspring centred detenthand operated valve

Non - return valve

Non - return valve withback pressure spring

Pilot operated

non - return valve

One way restrictor

High pressure selector(shuttle valve)

Throttling orifice -normally closed

Throttling orifice -normally open

Relief valve

Variable restrictor



24 - 3


Symbols (cont'd)

Energy Transmissions and Conditioning


9803/3260

Section E

24 - 3

Issue 1

A189720 A189710

Pilot control

Drain lines

Flexible pipe

Line junction

Crossing lines

Air bleed

Line plugged, alsopressure test point

Line plugged withtake off line

Quick releasecouplings - connected

Quick releasecouplings - disconnected

Working line, return or feed Reservoir - return lineabove fluid level

Reservoir - return linebelow fluid level

Header tank

Pressure sealed tank

Accumulator

Filter or strainer

Water trap

Cooler - with noindication of coolant flow

Cooler - indicatingdirection of coolant flow

Heater



24 - 4


Symbols (cont'd)

Control Mechanisms


9803/3260

Section E

24 - 4

Issue 1

S189740S189730

Rotating shaft-one direction

Rotating shaft-two directions

Detent

Locking device

Over centre device

Simple linkage

General control

Push button operated

Lever operated

Pedal operated

Stem operated

Spring operated

Roller operated

Roller trip operated(one directional)

M

Solenoid one winding

Solenoid two winding

Electric motor operated

Internal pressurepilot operated

External pressurepilot operated

Pressure operatedspring release

Pilot operated by solenoidpilot valve

Pilot operated by a solenoidor separate pilot valve

Pressure gauge

Pressure switch



24 - 5


Symbols (cont'd)

Control Valves

Control valves are usually represented by one or moresquare boxes.

Fig. 1 shows a control valve represented by three boxes.

The number of boxes indicates the number of possible valve

operating positions, (4 boxes - 4 positions etc).

Fig. 2 - In circuit diagrams the pipework is usually shown

connected to the box which represents the unoperated

condition. (Hydraulic circuit diagrams are usually shown in

the unoperated condition).

Fig. 3 shows a valve described as a 3- position, 4-portcontrol valve. Port describes the openings to and from the

valve by which the hydraulic fluid enters or leaves. In the fig

shown, Position 2 indicates that in an unoperated condition

all 4 ports are blocked.

If the valve spool was moved to Position 1, movement of the

spool would connect Port 1 to Port 2, and Port 3 to Port 4.

If the valve spool was moved to Position 3, movement of the

spool would connect Port 1 to Port 4, and Port 3 to Port 2.

It must be noted that not all spools are of the same type.

Their operating designs can be seen by following the path

the flow arrows take in their respective operating squares.

Three typical JCB style spools are known as 'D' spools, 'F'

spools and 'N' spools.

The 'D' spools generally control rams because when in the

neutral position the outlet ports are blocked, preventing ram

movement. Fig 3 shows a 'D' type spool.

Fig 4 - 'F' spools are often shown as four position spoolswith the three normal positions for neutral and service

control; and the forth position, which has a detent, connects

both sides of the ram together to allow the service to 'float'.

Fig 5 - 'N' spools are sometimes used to control hydraulic

motors, and it can be seen from the flow arrows, that inneutral position both service ports are connected to the

exhaust oil port


9803/3260

Section E

24 - 5

Issue 1

A189760

Position 1 Position 2 Position 3

FIG 2

FIG 1

FIG 3

FIG 4

FIG 5

Port 1

Port 4

Port 3

Port 2



24 - 6


Symbols (cont'd)

Example of Schematic Circuit

Some of the symbols described on the preceding pageshave been arranged into a simple schematic circuit shown

below.

Hydraulic tank A is a pressurised tank with an internally

mounted strainer B on the suction line to the fixed

displacement pump C. System pressure is limited to thesetting of relief valve D.

Valve spool E is an open-centre spool that is in neutral

position; flow from the pump passes through the spool and

returns to the hydraulic tank.

If the lever operated spool is moved away from neutral

position hydraulic fluid is directed to either head side or rod

side of hydraulic ram G. Notice that the fluid must first open

one way valve F before flowing to the ram.

Example Circuit Key

A Hydraulic Tank

B Strainer

C Fixed Displacement Pump

D Relief Valve

E SpoolF One Way Valve

G Double Acting Hydraulic Ram


9803/3260

Section E

24 - 6

Issue 1

A189770

A

B

C

D

E

F

G



25 - 1

Fault Finding Contents

Page No.

Introduction 25 - 1

Lack of power in all hydraulic functions 25 - 1

All hydraulic rams slow to operate 25 - 2

One hydraulic service fails to operate or is

slow to operate 25 - 2

The engine tends to stall when the

hydraulics are under load 25 - 2

A spool is sticking 25 - 3

Leaking Oil Seal (Control Valves) 25 - 3

Ram creep 25 - 3

Hydraulic oil becomes too hot 25 - 4

Steering fails to operate or

is stiff to operate 25 - 4

Steering fails to respond to

selected mode 25 - 4


9803/3260

Section E

25 - 1

Issue 2

Fault Finding

Fault Probable Cause Action

1 Lack of power in all hydraulic functions. Insufficient hydraulic fluid. Check for leaks and top up as required.

Hydraulic leaks in system. Check hoses, replace as required.

Engine performance. Check engine performance, see

transmission section for stall speedtest procedures.

Main relief valve (MRV) Check and adjust as required.setting incorrect.

Low pump flow. Check pump flow, if required service orreplace pump.

Hydraulic tank breather Clean or replace the breather

Tank filter by-pass valve Check condition of hydraulic filter

Unloader valve pressure Check pressure setting of the

setting too high unloader valve.

..... continued

Introduction

The purpose of this section is to help you trace hydraulic

faults to a faulty unit (valve, actuator, ram etc). Once you

have traced the faulty unit, refer to the appropriate

dismantling, inspecting and test instructions given elsewherein the hydraulics section.

To help identify circuits, valves, rams etc mentioned in the

fault finding procedures, refer to the hydraulic schematic

diagrams (near the beginning of the Hydraulics Section).

1 Before you begin fault finding, read the Safetyinformation at the beginning of this manual.

2 Make simple checks before say, stripping a major

component.

3 Make sure that the hydraulic fluid is at correct working

temperature (50 °C, 122 °F).

4 What ever the fault, check the condition of the hydraulic

fluid. Drain and replace if necessary.

5 Make any relevant electrical checks before moving on

to the hydraulics.

6 Be sure to remove ALL contamination and if possible

identify its origin. It may be part of a component from

elsewhere in the circuit.

7 Replace any seals such as 'O' rings before re-

assembling hydraulic components.



25 - 2


2 All hydraulic rams slow to operate. Neutral circuit or low pressure Check pipe lines and replace as required.lines leaking, damaged, trapped

or kinked.

Low pump flow. Check pump flow, if required service or

replace pump.

Priority valve operating Check if the priority valve is sticking,

rectify as required.

Main relief valve (MRV) Check and adjust as required.

setting incorrect.

Unloader valve Check if unloader valve is sticking, i.e.

dumping flow from pump section P2.

Tank filter by-pass valve Check condition of hydraulic filter

Hydraulic tank breather Clean or replace the breather

3 One hydraulic service fails to Associated service pipe lines , Check hoses, replace as required.

operate or is slow to operate. leaking damaged, trapped

or kinked.

Associated ram leaking. Complete ram leakage check, replaceseals as required.

Auxiliary relief valve (ARV) Check and adjust as required.

setting incorrect.

Associated valve block section Check for leaks, rectify as required.

leaking or not operating. Also, see fault 6 'Leaking Oil Seal (Control Valves)'.

Make sure that the associated load hold

check valve is operating.

Check that the control lever and

associated linkages is operating

the spool, rectify as required. Also, see

fault 5, 'A spool is Sticking'.

Check valve malfunctioning Test check valve, rectify as required.

(if fitted, e.g. stabiliser circuit)

Hose burst protection valve Test HBPV, service as required.(if fitted) malfunctioning.

Piston rod is bent Replace piston rod, check pressure

settings of MRV and ARV.

Check that associated pivot pins are

adequately greased

4 The engine tends to stall when M.R.V setting incorrect. Check and adjust as required.

hydraulics are under load.

Poor engine performance. Check engine performance, seetransmission section for stall speed

test procedures.

Unloader valve pressure Check pressure setting of the

setting too high unloader valve.


9803/3260

Section E

25 - 2

Issue 2

Fault Finding



25 - 3


5 A spool is sticking. Oil temperature abnormally high. Check for correct flu id, see Lubricantsand

Capacities. Check oil cooler and grille for

blockage.

The hydraulic fluid is dirty. Clean the tank strainer. If strainer badly

clogged, drain and flush hydraulic systemFill with clean hydraulic fluid.

The service pipe connection Check tightening torque.

is over tightened.

The valve housing was twisted Loosen retaining bolts and tighten toduring installation. correct torque figures.

Pressure too high. Check system pressure.

A control linkage is bent Di sc on nec t th e l in ka ge . Rep ai r th elinkage if possible, or fit a newone

A spool is bent Dismantle the control valve. Renew spool

as necessary.

A return spring is broken. Renew as necessary.

A return spring or cap is out of Remove the cap, check that the spring is

alignment. in the correct position. Refit cap and

torque tighten bolts

Temperature distribution within Warm the entire system up before

control valve not uniform. using service.

6 Leaking Oil Seal (Control Valves) Paint or dirt on the seal face. Remove the seal and clean.

The back pressure in the valve Check circuit pressures. Adjust ifpossible. circuit is excessively high. Otherwise investigate thoroughly.

Spool damaged. Dismantle. Inspect all parts. Renovate or

renew as necessary.

The seal is not secured. Clean the seal and tighten the retainingbolts to the correct torque.

The seal is cut or damaged. Fit a new seal.

7 Ram creep. Associated ram or pipe lines from Check and rectify as required.ram leaking.

Check valve malfunctioning Test check valve, rectify as required.

(if fitted, e.g. stabiliser circuit)

Associated valve section spools Rectify, check for contamination.leaking.

Associated ARV leaking Rectify, check for contamination .

..... continued


9803/3260

Section E

25 - 3

Issue 2

Fault Finding



25 - 4


8 Hydraulic oil becomes too hot Oil cooler obstructed Remove debris from cooler fins

Restriction in neutral circuit Check hoses, replace as necessary

lines

Hydraulic filter clogged and Change hydraulic filter

by-pass valve not working

9 Steering fails to operate or Tyres not inflated to Inflate tyres to correct pressure

is stiff to operate correct pressure

Insufficient hydraulic fluid. Check for leaks and top up as required.

Low pump flow. Check pump flow, if

required service or replace pump.

Leaks in the relevant hoses or Check hoses and connections for leaks

component connections

Steer relief valve set Check pressure setting of steer unit relief

incorrectly valve, adjust as required.

Priority valve not operating Check if the priority valve is sticking,

correctly rectify as required.

Check the load sense line from the steer

unit to the priority valve for signs of

leaking or poor connection.

Steer mode valve not operating Check if spools sticking, rectify as

correctly required

Check if solenoids operating, replace

solenoids as required

Mechanical failure Check for damaged axle components,such as rams, trackrods, linkages etc.

Check for damaged steer unit

components.

Steering column and associatedcomponents not set correctly.

10 Steering fails to respond to Selector switch faulty Check selector switch, replace a required

selected modeProximity switches not operating Check setting of proximity switches, reset

correctly or replace switches as required.

Steer mode valve not operating Check if spools sticking, rectify as

correctly required

Check if solenoids operating, replace

solenoids as required.

Leaks in the relevant hoses or Check hoses and connections for leaks

component connections

Electrical failure Check relevant electrical connectors, if

problem still persists, do a wiring

continuity check on relevant circuits.


9803/3260

Section E

25 - 4

Issue 2

Fault Finding



30 - 1


9803/3260

Section E

30 - 1

Issue 1

Pumps

S193200

S193210



30 - 2

Pump Flow Testing

FIG X = All Wheel Steer Machines

FIG Y = 2 Wheel Steer Machines

Before removing the pump it is necessary to determine thesource of any problem by measuring the output flow at

system pressure from both of the pump outlet ports.

To check flow it is necessary to fit flow meter A into theoutput line of each pump section in turn. If available, load

valve B (JCB Part No. 892/00270) should also be installed

(see Note 1 ). Make sure the flow meter is installed with its

arrow pointing away from the pump and, if applicable,

located between the pump and the load valve.

Note 1: If no load valve is available, ignore the references to

the load valve in Fitting/Removing a Flow Meter and Load

Valve below. An alternative method of determining flow is

included in the Checking Flow procedures following.

Fitting/Removing a Flow Meter and Load

Valve

Before fitting/removing a flow meter and load valve, switchoff the machine and operate the loader/excavator controls a

few times to vent system pressure.

!WARNINGHydraulic fluid at system pressure can injure you. Before

disconnecting or connecting hydraulic hoses, stop the

engine and operate the controls to release pressure

trapped in the hoses. Make sure the engine cannot be

started while the hoses are open.INT-3-1-11/1

!WARNINGTake care when disconnecting hydraulic hoses and

fittings as the oil will be HOT.TRANS 1-2

Fitting

1 AWS machines

a Pump section 1 - disconnect hose C from the

pump. Fit the flow meter and load valve (see Note

2 ) between hose C and the pump.

b Pump section 2 - due to the limited access at the

rear of the pump, disconnect hose D from priorityvalve E. Fit the flow meter and load valve (see Note

2 ) between hose D and the priority valve.

2 2WS machines

Connect the flow meter and load valve (see Note 2 )

between the pump port and the disconnected machinehose. Hose F connects to pump section 1 and hose G

to pump section 2.

Note 2: Make sure the load valve is in the open position, i.e.

with the adjusting knob screwed fully out, before carryingout the Checking Flow procedure.

Removing

Removing is the reverse of fitting.

Checking Flow

1 Check the setting of the Main Relief Valve (MRV) as

described in Loader Valve, Pressure Testing. Adjust if

necessary.

2 a Using a load valve - fit a flow meter and load valve,as described in Fitting, to each pump outlet in turn.

Fit a 0-400 bar (0-6000 lbf/in2) pressure gauge to

the load valve pressure test connector.

b If no load valve is available - fit a flow meter, as

described in Fitting, to each pump output in turn.

3 Start the engine and bring the hydraulics up to normal

operating temperature. Set the engine speed to 2200

rpm.

4 a Using a load valve - adjust the load valve so thatthe pressure gauge reading is just below the MRV

setting.

b If no load valve is available - raise or lower the

loader arms until the rams are fully open or closed.

Continue to operate the raise/lower control so thatsystem pressure builds up. Watch the flow meter

and note its reading at the moment the MRV

operates.

5 The flow reading should be as listed in Technical Data,

Machine Hydraulics (AWS and 2WS Machines),

Hydraulic Pumps.


9803/3260

Section E

30 - 2

Issue 1

Pumps



41 - 1

Loader Valve


!WARNING

Make the machine safe before working underneath it.Park the machine on level ground, lower the arms. Apply




started while you are beneath the machine.GEN-1-2

Note: The illustration shows a 'Hamworthy' type valve fitted.

The 'Husco' type valve is similiarly mounted. The maindifference being the hose routing from pump sections P1

and P2. Make sure all hoses are clearly labelled before

removing them.

Removal

1 Operate the valve block levers back and forth to vent

residual pressure.

2 Remove clevis pins A to disconnect the control levers

from the the valve block spools.

3 Disconnect all hydraulic hoses from the valve block and

plug all orifices to prevent ingress of dirt. Label each

hose before disconnecting, this will ensure correct

position when refitting.

4 Loosen and remove nuts B, the loader valve andspacing washers C.

Replacement


!WARNINGFine jets of hydraulic fluid at high pressure can penetrate

the skin. Do not use your fingers to check for hydraulic

fluid leaks. Do not put your face close to suspected

leaks. Hold a piece of cardboard close to suspected

leaks and then inspect the cardboard for signs of

hydraulic fluid. If hydraulic fluid penetrates your skin, get

medical help immediately.INT-3-1-10/1

After replacement check the main relief valve (M.R.V.) and

auxiliary relief valve (A.R.V.) pressure settings.

Note: All hydraulic adapters that are installed together with a

bonded sealing washer must also have sealant (Loctite 577)

applied to the threads of the adapter.

For dismantling and assembling the loader valve see pages

E/41-2 to E/41-13 (Hamworthy type valve) and pages E/41-20 to E/41-31 (Husco type valve).


9803/3260

Section E

41 - 1

Issue 2*

Valves

S144460

*

*

A

C

B

B

C

B

C



41 - 2


9803/3260

Section E

41 - 2

Issue 1

Valves



41 - 3

'Hamworthy' Loader Valve - Standard

Spool




When Dismantling

Hold the spool in clamp 992/10100, unscrew bolt 11 and

remove spring 13 with cups 12 and 14.

When Assembling

Renew seal 3 and 'O' rings 8 and 9.

When fitting bolt 11 or eye end 15, clean the threads

thoroughly using Super Clean Safety Solvent, leave it for 10

minutes then apply a small quantity of JCB Lock and Seal to

the threads.

Do not overtighten eye end 15.

Torque Settings

Item Nm kgf m lbf ft1 6.5 0.7 5

5 6.5 0.7 5

11 14 1.4 10

15 15 1.5 11


9803/3260

Section E

41 - 3

Issue 2*

Valves

*



41 - 4


9803/3260

Section E

41 - 4

Issue 1

Valves



41 - 5

'Hamworthy' Loader Valve - Float Spool





When Dismantling

Carefully remove collar 14 and collect detent balls 15.

Remove spacer 16 and lift off spring housing 17.

Using tool 992/10100 to hold the spool, unscrew bolt 18 and

remove ball cage 19, spacer 20, spring 21 and cups 22 and23.

When Assembling

Renew seal 3 and 'O' rings 6, 8 and 9.

When fitting bolt 18 or eye end 24, clean the threads

thoroughly using Super Clean Safety Solvent, leave it for 10

minutes then apply a small quantity of JCB Lock and Seal to

the threads.

Apply grease liberally to cage 19 to hold balls 15 in positionduring assembly and to provide lubrication.


Torque Settings


1 6.5 0.7 5

7 6.5 0.7 5

18 14 1.4 10

24 15 1.5 11


9803/3260

Section E

41 - 5

Issue 2*

Valves

*



41 - 6


9803/3260

Section E

41 - 6

Issue 1

Valves



41 - 7

'Hamworthy' Loader Valve - Electric

Detent Spool




When Dismantling

Using tool 992/10100 to hold the spool, remove capscrew

11, washer 12 and housing 13. Unscrew bolt 14 and remove

spring 15 with cups 16 and 17.

When Assembling

Renew seal 3 and 'O' rings 7 and 8.

When fitting capscrew 11, bolt 14 or eye end 18, clean the

threads thoroughly using Super Clean Safety Solvent, leave

it for 10 minutes then apply a small quantity of JCB Lockand Seal to the threads.


Apply JCB Mult i-Gasket to the threads of solenoid 10.

Tighten to 20 Nm (15 lbf ft).

Check the operation of the solenoid after assembly by

connecting a 12V supply . The spool should be held when it

is pushed into the detent position and returned when thesupply is disconnected.

Torque Settings


1 6.5 0.7 5

5 6.5 0.7 5

14 14 1.4 1018 15 1.5 11


9803/3260

Section E

41 - 7

Issue 2*

Valves

*



41 - 8

'Hamworthy' Loader Valve - Main Relief

Valve (M.R.V.)




When Assembling

Renew all 'O' rings.

Lubricate parts with JCB Hydraulic Fluid before assembling.

Ensure that the small drilling A in the main plunger 11 is

clear.

Adjust pressure setting as required (see page E/42 - 1).

Torque Settings


1 28 2.9 215 20 2.0 15


9803/3260

Section E

41 - 8

Issue 2*

Valves

S143150

*



41 - 9

'Hamworthy' Loader Valve - Auxiliary

Relief Valve (A.R.V.)




When Assembling


Hold valve 5 in clamp 992/10100 when removing and

replacing the adjusting screw. If any parts are worn, renew

valve complete.


Adjust pressure setting as required (see page E/42 - 3).


9803/3260

Section E

41 - 9

Issue 3*

Valves

S143160

*



41 - 10

'Hamworthy' Loader Valve - Load Hold

Check Valves




When Assembling

Renew 'O' rings.


Tighten item 1 to 75-81Nm (55-60lbf ft).


9803/3260

Section E

41 - 10

Issue 2*

Valves

S143170

*



41 - 11


9803/3260

Section E

41 - 11

Issue 2

Valves

S143180



41 - 12

'Hamworthy' Loader Valve - Unloader

Valve Spool




When Dismantling

Use a nylon rod to push out spool assembly item 15, DO

NOT damage spool bore.

When Assembling

Renew all 'O' rings and seals.


Apply JCB Lock and Seal to all threads except the pressure

adjusting screw 6.

Ensure that the small drillings through the centre of items 1,

15 and 16 are clear.

Check pressure setting after refitting (see page E/42 - 2).

Torque Settings


1 28 2.9 215 20 2.0 15

11 28 2.9 21


9803/3260

Section E

41 - 12

Issue 2*

Valves

*



41 - 13

'Hamworthy' Loader Valve - Unloader

Check Valve




When Assembling



Apply JCB Lock and Seal to threads of item 1.

Torque Settings


1 41 - 47 4.2 - 4.8 30 - 35


9803/3260

Section E

41 - 13

Issue 2*

Valves

S143190

*



41 - 20


9803/3260

Section E

41 - 20

Issue 1

Valves

S197440

1

2

3

4

15

14

13

12

11

10

7

9

5

8

6



41 - 21

'Husco' Loader Valve - Standard Spool





The following points MUST be avoided when dismantlingand assembling the valve:

CONTAMINATION• DAMAGE TO SPOOL• DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible

problems with the valve.

When Dismantling

Remove the lever linkage from the tang (lever) end of the

spool.

When removing 'O' rings and seals, use an appropriately

rounded tool that WILL NOT cause any damage to the spoolor seal grooves, for instance, item 3, which is a wiper seal

and is a press fit in the counterbore.

Care must be taken to ensure that the spool 8 is not

damaged when removing it from the valve block.

Hold the spool in clamp 992/10100, unscrew bolt 9 and

remove spring 12, spacer 10 and cups 11 and 13.

Check for surface contamination on the under side of the

seal plates 2 and 14. Clean if necessary. Check for the

flatness of the seal plate. If found to be bent - replace withnew (any work previously carried out on this valve may have

resulted in the bending of the seal plate).

When Assembling

Renew seal 3 and 'O' rings 4 and 15. Make sure the 'O' rings

and wiper seals are not trapped or damaged.

When fitting bolt 9, clean the threads thoroughly using Super

Clean Safety Solvent, leave it for 10 minutes then apply a

small quantity of JCB Lock and Seal to the threads of thespool.

Make sure that all the parts move freely, check that item 10

does not interfere with item 13.

Re-connect the lever mechanism to the tang (lever) end ofthe spool.

Run the engine and inspect the valve for external leaks.

Torque Settings


1 5.4 0.6 4

5 9.5 0.96 7

9 9.5 0.96 7


9803/3260

Section E

41 - 21

Issue 1

Valves



41 - 22


9803/3260

Section E

41 - 22

Issue 1

Valves

S197460

1

34

5

6

7

8

9

11

10

12

13

14

15

16

17

1819

20

21

22

23

24

25

2



41 - 23

'Husco' Loader Valve - Float Spool





The following points MUST be avoided when dismantlingand assembling the valve:

• CONTAMINATION• DAMAGE TO SPOOL• DAMAGE TO SEAL GROOVES



When Dismantling


spool.


rounded tool that WILL NOT cause any damage to the spoolor seal grooves, for instance, item 3, which is a wiper seal

and is a press fit in the counterbore.



Carefully remove collar 11 and collect detent balls 12.

Using tool 992/10100 to hold the spool, remove circlip 18,

plug 19, ball 20 and spring 21. Unscrew detent pin 22 and

remove spring 24 and cups 23 and 24.


seal plates 2 and 16. Clean if necessary. Check for the

flatness of the seal plate. If found to be bent - replace with

new (any work previously carried out on this valve may have


When Assembling

Renew seal 3 and 'O' rings 4, 6 and 17. Make sure the 'O'

rings and wiper seals are not trapped or damaged.

When fitting detent pin 22, clean the threads thoroughly

using Super Clean Safety Solvent, leave it for 10 minutes

then apply a small quantity of JCB Lock and Seal to thethreads of the spool.

Apply grease liberally balls 12, this will help to hold the balls

in position whilst assembling.

Re-connect the lever mechanism to the tang (lever) end ofthe spool.


Torque Settings


1 9.5 0.96 7

8 9.5 0.96 7

22 9.5 0.96 7


9803/3260

Section E

41 - 23

Issue 1

Valves



41 - 24


9803/3260

Section E

41 - 24

Issue 1

Valves

S197450

1 2

3

4

5

6

7

8

9

10

11

12

1314

15

16

17

18



41 - 25

'Husco' Loader Valve - Electric Detent

Spool




The following points MUST be avoided when dismantling

and assembling the valve:




When Dismantling


spool.


rounded tool that WILL NOT cause any damage to the spool

or seal grooves, for instance, item 3, which is a wiper sealand is a press fit in the counterbore.



Use tool 992/10100 to hold the spool, remove circlip 13 and'clapper' 14. Unscrew spool end 15 and remove spring 17

with cups 16 and 18.


seal plates 2, 8 and 10. Clean if necessary. Check for theflatness of the seal plate. If found to be bent - replace with



When Assembling

Renew seal 3 and 'O' rings 4 and 11. Make sure the 'O' ringsand wiper seals are not trapped or damaged.

When fitting spool end 15, clean the threads thoroughly

using Super Clean Safety Solvent, leave it for 10 minutes

then apply a small quantity of JCB Lock and Seal to the

threads of the spool.

Make sure that the chamfer on item 14 faces away from the

solenoid, item 6.

Check the operation of the solenoid 6 after assembly by

connecting a 12V supply . The spool should be held when itis pushed into the detent position and returned when the

supply is disconnected.

Re-connect the lever mechanism to the tang (lever) end of

the spool.


Torque Settings


1 5.4 0.6 4

5 9.5 0.96 7

15 9.5 0.96 7


9803/3260

Section E

41 - 25

Issue 1

Valves



41 - 26


9803/3260

Section E

41 - 26

Issue 1

Valves

S197410

1

2

34

5

6

7

8

9

1011

12

13

14

1516

17

18

19



41 - 27

'Husco' Loader Valve - Main Relief Valve

(M.R.V.)









When Dismantling


rounded tool that WILL NOT cause any damage to the seal

grooves.

Discard ALL 'O' rings and back up rings. DO NOT use worn

or damaged items.

Inspect the valve components for scratches, nicks or any

other type of damage, replace with new if required.

When Assembling

Renew all 'O' rings and back-up rings.


Make sure that all the parts move freely.

Make sure that the 'O' rings and back-up rings are fitted the

correct way, items 15, 16 and 11, 12.

Fit chamfered end of spring 6 against head of pilot poppet

item 7.

Adjust pressure setting as required (see page E/42-10).

Torque Settings


3 5.4 0.6 4

8 45 4.6 3318 45 4.6 33


9803/3260

Section E

41 - 27

Issue 1

Valves



41 - 28


9803/3260

Section E

41 - 28

Issue 1

Valves

S197420

1

2

3

4

5

6

7

8

9

1011

12

14

15

16

17

18

A

B 13



41 - 29

'Husco' Loader Valve -

Auxiliary Relief Valves (ARV) and

Load Hold Check Valves (LHCV)









The ARV's are identical in design but have different pressure

settings (see Technical Data).

The LHCV's are identical.

When Dismantling

When removing 'O' rings and seals, use an an appropriatelyrounded tool that WILL NOT cause any damage to the seal

grooves.


or damaged items.

Dismantle sub-assembly 14 from item 1 using a special tool

(see Service Tools, Section 1). The special spanner locates

in cross holes B.

Make sure that small drilling A is not blocked.

Ensure good condition of seating faces on poppet 18 and on

the mating face of the valve block.



When Assembling




Fit back-up ring 13 on the upper side of 'O' ring 12.

Fit flat face of sleeve 9 against shoulder of poppet 10.

Torque tighten item 14 using the special tool (see Service

Tools, Section 1), until its shoulder seats firmly against item

1.

Pressure test the relief valves using the procedure described

on page E/45-1.

Torque Settings


1 65 6.6 48

3 24 2.5 18

15 81 8.3 60


9803/3260

Section E

41 - 29

Issue 1

Valves

S143160



41 - 30


9803/3260

Section E

41 - 30

Issue 1

Valves

S197430

12

4

56

7

8

9

10

11

12

13

15

16

17

18

19

21

22

23

2425

26

27

14

3



41 - 31

'Husco' Loader Valve - Unloader Valve

Assembly









When Dismantling

When removing 'O' rings and seals, use an an appropriately


grooves.


or damaged items.

Use a nylon rod to push out spool assembly item 23, DO

NOT damage spool bore.



When Assembling




Ensure that the small drilling through the centre of items 23,

is clear.

Shims 21 are intended to limit the maximum pressure

setting, the specified pressure setting is achieved by

adjusting capnut 15. If the specified pressure cannot be

achieved under test, it is permissible to add shims as

required. There MUST be at least one hardened shim next tothe spring item 22.

Do not over-tighten the solenoid assembly, it may effect the

operation of the solenoid, use the spanner flats and torque

tighten to figure indicated in the table below (items 1 and 5 ).

Fit chamfered end of spring 22 against head of pilot poppet

item 23.

Check pressure setting after refitting, see page E/42-11.

Check the operation of the hydraulic speed control, see

page E/42-11.

Torque Settings

Item Nm kgf m lbf ft1 6.7 0.7 5

5 27 2.8 20

8 81 8.3 60

12 81 8.3 60

16 45 4.6 33

19 34 3.5 25


9803/3260

Section E

41 - 31

Issue 1

Valves



41 - 40


9803/3260

Section E

41 - 40

Issue 1

Valves

A248450

S248430



41 - 41

'Husco' Loader Valve - Standard Spool

(3CXE (214E) Machines Only)






CONTAMINATION• DAMAGE TO SPOOL• DAMAGE TO SEAL GROOVES



When Dismantling


spool.






Check for surface contamination on the under side of theseal plates 4 and 13. Clean if necessary. Check for the




When Assembling

Renew wiper seals 5 and 14 and ‘O’ rings 6, 15 and 18.

When fitting bolt 9, clean the threads thoroughly using JCB

Cleaner & Degreaser, leave it for 10 minutes then apply a

small quantity of JCB Lock and Seal to the threads of the

spool.


the spool.


Torque Settings


7 6.1 - 7.5 0.62 - 0.76 4.5 - 5.5

9 9.5 - 10.9 0.97 - 1.11 7 - 8


9803/3260

Section E

41 - 41

Issue 1

Valves



41 - 42


9803/3260

Section E

41 - 42

Issue 1

Valves

A248460

S248440



41 - 43

'Husco' Loader Valve - Float Spool










When Dismantling


spool.






Remove retainer 7 and spacer 8. Using a suitable tool onball 12, compress spring 13 and allow detent balls 11 to roll

into their holes in the detent pin 14. Carefully remove the

spool cap 10 and collect detent balls 11.

Check for surface contamination on the under side of theseal plate 4 and spacer 19. Clean if necessary. Check for the




When Assembling

Renew wiper 5 and 'O' rings 6, 20, 21 and 24.

Apply grease liberally to detent pin 14 to hold detent balls 11

in position during assembly and to provide lubrication.

When fitting detent pin 14, clean the threads thoroughly

using JCB Cleaner & Degreaser, leave it for 10 minutes thenapply a small quantity of JCB Lock and Seal to the threads

of the spool.


the spool.


Torque Settings


9 6.1 - 7.5 0.62 - 0.76 4.5 - 5.5

14 9.5 - 10.9 0.97 - 1.11 7 - 8


9803/3260

Section E

41 - 43

Issue 1

Valves



41 - 44


9803/3260

Section E

41 - 44

Issue 1

Valves

A248460

S248440



41 - 45

'Husco' Loader Valve - M.R.V & A. R. V’s



Note: The M.R.V. and loader valve A.R.V.'s are identical indesign.









When Dismantling



grooves.


or damaged items.



When Assembling




Make sure that the 'O' rings and back-up rings are fitted the

correct way, items 12, 13 and 18, 19.

Adjust pressure setting as required.

Torque Settings


1 5.4 - 8.2 0.55 - 0.83 4 - 6

3 41 - 68 4.15 - 6.9 30 - 50

5 5.4 - 8.2 0.55 - 0.83 4 - 6

10 41 - 68 4.15 - 6.9 30 - 50


9803/3260

Section E

41 - 45

Issue 1

Valves



42 - 1

'Hamworthy' Loader Valve - Pressure

Testing

Main Relief Valve (M.R.V.)

Make sure that the hydraulic oil is at working temperature,i.e. 50°C (122°F).

Lower the excavator bucket and loader shovel to rest on the

ground; stop the engine; operate the control levers to vent

residual hydraulic pressure.


to pressure test connector A on the loader valve, (see

Service Tools, Section 1).

2 With the engine running at 1500 revs/min, check M.R.V.

pressure by raising or lowering the loader arms until therams are fully open or closed and noting the maximum

gauge reading. CAUTION: Do not select 'float'. The

maximum pressure should be as stated in Technical

Data.

Note: The rams must be 'held' open or closed when reading

gauge.

3 If the pressure is incorrect, slacken locknut B and

adjust screw C. Turn it clockwise to increase pressure

and anti-clockwise to decrease the pressure. When thepressure is correct, tighten the locknut.

Hydraulics

9803/3260

42 - 1

Issue 2*

Valves

Section E Section E

*

S144440

BC

A

*

*



42 - 2


Testing

Unloader Valve

Make sure that the hydraulic oil is at working temperature,i.e. 50°C (122°F).

Lower the excavator bucket and loader shovel to rest on the



Make sure that the 'hydraulic speed control' facility is NOT

switched on, otherwise the correct unloader valve pressure

cannot be obtained.

If the machine has a front- mounted roadbreaker, ensure

that the roadbreaker control valve lever is in the 'off' position(lever down), otherwise the roadbreaker relief valve will

operate and prevent unloader valve pressure from being

reached.

1 Connect a 0 - 400 bar (0 - 6000 lbf/in2 ) pressure gaugeto pressure test connector D on the loader valve, (see


2 With the engine running at 1500 revs/min, slowly

operate arms raise or lower.

Note: The arms raise or lower service is specified because it

has no auxiliary relief valve (A.R.V.). Selecting this service

ensures that the pressure vents through the unloader and

not an A.R.V.

3 When the service reaches full travel, the gauge readingshould rise slowly to unloading pressure then fall back

to zero. The maximum reading should be as specified

in Technical Data.

4 If the pressure is incorrect, slacken locknut E and

adjust screw F. Turn it clockwise to increase pressureand anti-clockwise to decrease the pressure. When the

pressure is correct, tighten the locknut.

Hydraulic Speed Control (HSC)

The following procedure can be used to establish if thehydraulic speed control facility is working correctly.

1 Connect a 0 - 400 bar (0 - 6000 lbf/in2 ) pressure gauge to

pressure test connector D.

2 With the engine running at maximum speed, slowlyoperate arms raise, raise the pressure to approximately

137 bar (2000 lbf/in2 ).

3 Make sure that the HSC rocker switch (mounted on the

console) is in the OFF position.

4 Press the HSC control button (mounted on the loader

control knob). The pressure gauge reading should drop

to zero (or near zero).

5 Repeat the above procedure but this time press the HSCrocker switch on (instead of the button on the loader



6 If there is no pressure drop at steps 4 and 5, then check

the HSC hydraulic and electrical circuits for any faults.


9803/3260

Section E

42 - 2

Issue 2*

Valves

S143200

*

*

*

D

E

F

*



42 - 3


Testing

Loader A.R.V.'s (Using Hand Pump)

Auxiliary relief valves (A.R.V's.) are set 15 bar (220 lbf/in2 )below the nominal figure stated on the Technical Data page

when using a hand pump. For example:

Shovel ram rod ARV = 303 to 317 bar (4400 to 4600 lbf/in2 )

Nominal figure = 310 bar (4500 lbf/in2 )

Hand pump setting = 310 - 15 = 295 bar (4280 lbf/in2 )

Insert the A.R.V. B into test block A , part number 992/10200.

Connect hand pump 892/00223 and a 0-400 bar(0-6000

lbf/in2 ) pressure gauge.

Pressurise until oil begins to escape at C when the gauge

will indicate the A.R.V. setting. Remember to set the A.R.V.

15 bar (220 lbf/in2 ) below the nominal figure shown on the

Technical Data page.

If required, adjust the pressure by holding the valve in clamp

992/10100 and turning the adjusting screw using an allen

key as shown.


9803/3260

Section E

42 - 3

Issue 2*

Valves

S159130

S159120

A

B

C

*



42 - 4


Testing

Shovel Ram Head Side A.R.V. (In Position)

Testing of A.R.V's on the machine should be avoided (usehand pump method as described on page E/42 - 3). However,

the procedure described below is a secondary checking

method which can be used if no hand pump is available.

When checking the shovel ram head side A.R.V. on the

machine using main pump flow, the following tolerances mustapply:

Pump Type Engine Revs Temperature Pressure

P2AJ190705 1000 r.p.m. 50 - 80 °C 170 - 192 bar

(122-176°F) (2465-2785 lbf/in2 )

P2AJ190606 1000 r.p.m. 50 - 80 °C 170 - 195 bar

(122-176°F) (2465-2830 lbf/in2 )

P2AJ190706 1000 r.p.m. 50 - 80 °C 170 - 200 bar(122-176°F) (2465-2900 lbf/in2 )

P2AJ190906 1000 r.p.m. 50 - 80 °C 170 - 205 bar

(122-176°F) (2465-2970 lbf/in2 )

Procedure

Make sure that the hydraulic oil is at working temperature, i.e.

50°C (122°F).

Connect a 0 - 400 bar (0 - 6000 lbf/in2 ) pressure gauge to test

connector A on the loader valve. (See Service Tools, Section1.)

Run the engine at 1000 revs/min, hold the shovel ram fully

open and check the maximum gauge reading, which should

equal the operating pressure shown in Technical Data. If

necessary, adjust as detailed below

A.R.V. Adjustment

Remove the A.R.V. from the control valve and hold in clamp

992/10100 as shown. Turn the adjusting screw using an allen

key. Adjust clockwise to increase the setting and anti-clockwise to decrease the setting.


9803/3260

Section E

42 - 4

Issue 2*

Valves

S143200

S159130

A

*

*



42 - 5


Testing

Shovel Ram Rod Side A.R.V.

Testing of A.R.V's on the machine should be avoided (usehand pump method as described on page E/42 - 3).

However, the procedure described below is a secondary

checking method which can be used if no hand pump is

available.

The shovel ram rod side A.R.V. is set at a higher pressurethan the M.R.V. (maximum system pressure). To raise the

pressure in the shovel ram rod side service line above

system pressure it is necessary to disconnect/connect

hoses (as shown in the following procedures) so that oil

displaced from the LIFT ram (rod side) is fed through the

A.R.V.


i.e. 50°C (122°F).

Rest the shovel on the ground, stop the engine and vent allservices.

Disconnect hoses B and C from metal pipes B1 and C1

respectively, shown at X .

Screw a tee piece fitted with a 0-400 bar (0-6000 lbf/in2 )pressure gauge to metal pipe B1, shown at Y.

Pull the hose C down from behind the loader arm and fit to

the other side of the tee piece as shown at Y.

Fit a cap to metal pipe C1 and fit a plug to hose B.

Note: For reference, C is the service hose for the shovel

ram, rod side. B is the service hose for the lift ram, rod side.

With the engine running at 1000 revs/min, select and

operate slowly the loader arms lift service until the ramcreeps, keep raising the arms slowly until a reading on the

pressure gauge is obtained.

The highest pressure value shown on the gauge will be the

setting of the shovel ram rod side A.R.V. (see Technical

Data). If necessary, adjust as detailed below.

A.R.V . Adjustment

Remove the A.R.V. from the control valve and hold in clamp

992/10100 as shown. Turn the adjusting screw using an

allen key. Adjust clockwise to increase the setting and anti-clockwise to decrease the setting.


9803/3260

Section E

42 - 5

Issue 2*

Valves

S132890

S132870

S159130

*

*

X

Y



42 - 10

'Husco' Loader Valve - Pressure Testing

Main Relief Valve (M.R.V.)


i.e. 50°C (122°F).





to pressure test connector A on the loader valve, (see


2 With the engine running at 1500 revs/min, check M.R.V.pressure by raising or lowering the loader arms until the

rams are fully open or closed and noting the maximum

gauge reading. CAUTION: Do not select 'float'. The

maximum pressure should be as stated in TechnicalData.

Note: The rams must be 'held' open or closed when reading

gauge.

3 If the pressure is incorrect, remove cap D and its O-

ring, slacken locknut B and adjust screw C. Turn it

clockwise to increase pressure and anti-clockwise todecrease the pressure. When the pressure is correct,

tighten the locknut and refit the cap with its O-ring..

Hydraulics

9803/3260

42 - 10

Issue 1

Valves

Section E Section E

S197660

A

D

CB



42 - 11


Unloader Valve


i.e. 50°C (122°F).




Make sure that the 'hydraulic speed control' facility is NOT

switched on, otherwise the correct unloader valve pressure

cannot be obtained.

If the machine has a front- mounted roadbreaker, ensurethat the roadbreaker control valve lever is in the 'off' position

(lever down), otherwise the roadbreaker relief valve will

operate and prevent unloader valve pressure from being

reached.

1 Connect a 0 - 400 bar (0 - 6000 lbf/in2 ) pressure gaugeto pressure test connector D on the loader valve, (see


2 With the engine running at 1500 revs/min, slowly

operate arms raise or lower.

Note 1: The arms raise or lower service is specified because

it has no auxiliary relief valve (A.R.V.). Selecting this service

ensures that the pressure vents through the unloader and

not an A.R.V.

3 When the service reaches full travel, the gauge readingshould rise slowly to unloading pressure then fall back

to zero. The maximum reading should be as specified

in Technical Data.

4 If the pressure is incorrect, slacken locknut E and

adjust cap F. Turn it clockwise to increase pressure andanti-clockwise to decrease the pressure. When the

pressure is correct, tighten the locknut.

If the correct pressure cannot be achieved, add or

subtract shims as required, see page E/41-30 and

E/41-31 for shim description and location.

Note 2: The illustration shows the unloader pressure test

connector D fitted to the loader valve block. On some

machines, there is a plug fitted at point D. The pressure test

point in this instance is located next to the steering priority

valve, it is the same test point that is used to check thesteering circuit pressures.

Hydraulic Speed Control (HSC)

The following procedure can be used to establish if the

hydraulic speed control facility is working correctly.


to pressure test connector D (see note 2 opposite).

2 With the engine running at maximum speed, slowly

operate arms raise, raise the pressure to approximately

137 bar (2000 lbf/in2 ).

3 Make sure that the HSC rocker switch (mounted on the

console) is in the OFF position.

4 Press the HSC control button (mounted on the loader



5 Repeat the above procedure but this time press theHSC rocker switch on (instead of the button on the

loader control knob). The pressure gauge reading

should drop to zero (or near zero).

6 If there is no pressure drop at steps 4 and 5, then

check the HSC hydraulic and electrical circuits for anyfaults.


9803/3260

Section E

42 - 11

Issue 1

Valves

S197670

D

F

E



42 - 12


Shovel Ram Head Side A.R.V. (In Position)

Testing of A.R.V's on the machine should be avoided (use

hand pump method as described on page E/45-1). However,the procedure described below is a secondary checking


Procedure


i.e. 50°C (122°F).

Connect a 0 - 400 bar (0 - 6000 lbf/in2 ) pressure gauge to

test connector A on the loader valve. (See Service Tools,Section 1.)

Run the engine at 1000 revs/min, hold the shovel ram fully

open and check the maximum gauge reading, which shouldequal the operating pressure shown in Technical Data. If

necessary, adjust as detailed below

A.R.V. Adjustment

If the pressure is incorrect, the A.R.V. must be adjusted

using the procedure described on pages E/45-1 to E/45-4.


9803/3260

Section E

42 - 12

Issue 1

Valves

S197670

A



42 - 13


Shovel Ram Rod Side A.R.V.


hand pump method as described on page E/45-1). However,the procedure described below is a secondary checking


The shovel ram rod side A.R.V. is set at a higher pressurethan the M.R.V. (maximum system pressure). To raise the

pressure in the shovel ram rod side service line above

system pressure it is necessary to disconnect/connect

hoses (as shown in the following procedures) so that oil

displaced from the LIFT ram (rod side) is fed through the

A.R.V.


i.e. 50°C (122°F).

Rest the shovel on the ground, stop the engine and vent all

services.

Disconnect hoses B and C from metal pipes B1 and C1

respectively, shown at X .

Screw a tee piece fitted with a 0-400 bar (0-6000 lbf/in2 )

pressure gauge to metal pipe B1, shown at Y.

Pull the hose C down from behind the loader arm and fit to

the other side of the tee piece as shown at Y.

Fit a cap to metal pipe C1 and fit a plug to hose B.

Note: For reference, C is the service hose for the shovel

ram, rod side. B is the service hose for the lift ram, rod side.

With the engine running at 1000 revs/min, select and

operate slowly the loader arms lift service until the ram

creeps, keep raising the arms slowly until a reading on thepressure gauge is obtained.

The highest pressure value shown on the gauge will be the

setting of the shovel ram rod side A.R.V. (see Technical

Data). If necessary, adjust as detailed below.

A.R.V . Adjustment




9803/3260

Section E

42 - 13

Issue 1

Valves

S132890

S132870

X

Y



43 - 2


9803/3260

Section E

43 - 2

Issue 1

Valves

161860



43 - 3

Excavator Valve





Check Valves

Each of the identical load hold check valves 4R to 4W can

be removed as shown at 4W. Make-up check valve 4X is a

smaller size but otherwise identical.

Ensure good condition of seating faces on poppets 4 and 8and on the mating faces in the valve block.

Spools

Spools 4A , 4B, 4E and 4F are identical but must not be

interchanged as they are matched to their bores. Stabiliserspools 4C and 4D are identical to each other but different

from the excavator spools.

All spools have the same centring and sealing components

items 9 to 21.

To completely dismantle a spool, follow the sequence 9 to

21. To prevent spool rotation when turning screw 15, hold a

rod through the eye end of the spool.

If only renewing the seals, dismantle as far as cap 14 then

remove items 15 to 22 as an assembly.

Lubricate new seals with JCB Hydraulic Fluid and take care

to prevent them from being damaged by the sharp edges of

the spool.

Apply JCB Lock and Seal to threads of screw 15.

Relief Valves

A.R.V's 4H to 4P appear identical but have various pressure

settings (see page E/1 - 1). Ensure that they are correctly

adjusted and fitted in their specified positions.

For dismantling and assembly procedure see page E/43 - 4.




Torque Settings


1 122 12.4 90

5 80 8.3 6013 7 0.7 5

15 11 1.1 8

23 95 10 70


9803/3260

Section E

43 - 3

Issue 1

Valves



43 - 4

Excavator Valve - Relief Valves


Eight A.R.V's are fitted at positions 4H to 4Q. These are

identical in design but have various pressure settings (seeTechnical Data).

Note: Valve 4Q is only fitted to machines equipped with a

Powerbreaker.




When Dismantling

Dismantle sub-assembly 14 from item 1 using a special

tool(see Service Tools, Section 1). The special spannerlocates in cross holes B.

Dismantle sub-assembly 14 into its component parts.

Make sure that small drilling A is not blocked.

Discard old and worn O-rings and back-up rings.

When Assembling

Renew all O-rings and back-up rings.

Lubricate O-rings and back-up rings with JCB Hydraulic

Fluid.

Fit back-up ring 13 on the upper side of 'O' ring 12 as

shown in the inset.

Fit flat face of sleeve 9 against shoulder of poppet 10.

Torque tighten item 14 using the special tool (see ServiceTools, Section 1), until its shoulder seats firmly against item

1.

Pressure test the valve using the procedure described on

page E/45-1.

Torque Settings


1 65 6.6 48

3 24 2.5 18


9803/3260

Section E

43 - 4

Issue 1

Valves

161700161880



44 - 1

Hydraclamp Valve (Sideshift Machines)





When Dismantling

Plug hose 1 to prevent loss of oil and entry of dirt.

When Assembling

Ensure that orifice X is clear.

Lubricate new seals with JCB Hydraulic Fluid.

Screw item 8 fully home into housing then back-off by no

more than 180° until the flats align with capscrew centre-lineas shown at A . (This is the 'Clamps Off' position.) Fit plate 6

in position shown and connect clevis 2.

If necessary, adjust position of clevis 2 so that plate 6 can

be operated over full extent of its travel.

Torque Settings

Item Nm kgf m lbf ft14 7 0.7 5

16 7 0.7 5


9803/3260

Section E

44 - 1

Issue 1

Valves

164230

*

*



44 - 2


other type of damage, particularly on the poppet and seatfaces. Replace with new if required.

When Assembling

Renew all 'O' rings. The parts microfiche will identify thecorrect seal kit part numbers for items 2, 4, 6, 10 and 14.



Ensure that the small drilling through the centre of item 3, isclear.

Do not over-tighten the solenoid assembly, it may affect the

operation of the solenoid, use the spanner flats and torque

tighten to figure indicated in the table below (items 11 and

13 ). For information, the hydraclamp solenoid valve is thesame type as the 'Hydraulic Speed Control' solenoid valve,

shown on page E/41-30.

Check the operation of the electric hydraclamp, see page

E/11-4 for a description of operation.

Torque Settings


1 13.5 1.4 10

3 24.5 2.5 18

5 13.5 1.4 1011 5.5 0.5 4

13 24.5 2.5 18


9803/3260

Section E

44 - 2

Issue 1

Valves

S217500

Hydraclamp Valve - from Serial Number

430001 (Sideshift Machines)


The numerical sequence shown on the illustration isintended as a guide to dismantling. For assembly the

sequence should be reversed.


and assembling the valve:• CONTAMINATION• DAMAGE TO POPPET AND SEAT• DAMAGE TO SEAL GROOVES All or any of the above points may result in possible




grooves. Discard ALL 'O' rings DO NOT use worn ordamaged items.

Note that the hydraclamp comprises two separate valve

assemblies; 1) the check valve assembly (items 1 to 8 ); 2)

the solenoid assembly (items 11 to 14 ).

When Dismantling

Loosen nut 1 (turn anti-clockwise) and then remove the

check valve assembly from the valve block. If required, the

check valve assembly can be dismantled into its component

parts (items 1 to 8 ).

13

12

11

14

10

9

5 6 78

3

1 2 4



45 - 1

Excavator A.R.V.'s (Using Hand Pump)

To pressure test and re-set the auxiliary relief valves(A.R.V.'s), service kit 892/00309 must be used.

The service kit comprises; a test block 1, a setting body 2

with adjusting pin 3, a special spanner 4, a T-bar adjuster

key 5 and an anti-cavitation lock out bung 6. A.R.V. cartridge

removal tool 892/00335 comprises; an extractor cap 11 anda 'C' washer 12.

Note: Later type LOADER valve blocks are the 'Husco' type,

the A.R.V.'s in these valve blocks must be set using the

procedures described below.

Hydraulics

9803/3260

45 - 1

Issue 3*

Valves

Section E Section E

1 Remove the complete A.R.V. assembly from theexcavator valve block. If the A.R.V. sub-assembly 7

remains in the valve block, proceed as follows:

1.1 Fit extractor cap 11 over the A.R.V. sub-assembly

7, into the excavator valve block E.

1.2 Fit 'C' washer 12 on top of the extractor cap, but

under the anti-cavitation spring seat as shown.

1.3 Unscrew the extractor cap, - the A.R.V. sub-

assembly will withdraw with the extractor cap.

2 Use special spanner 4 located in cross holes A and

separate the A.R.V. sub-assembly 7 from its cap 8.

3 Install adjusting pin 3 into setting body 2.

Note: Earlier type service kits comprised two types of

adjusting pin; one has a screwdriver form and the other an

hexagonal form (see inset). Fit the adjusting pin to suit the

form in the A.R.V. adjusting screw. Later type kits have a

single adjusting pin that can be used on all A.R.V.'s.

Excavator Valve - Pressure Testing

*

*

*

S162570B

S162570C

S162560

S162570A

3

5

E!@7

7

4

8

3

2

A

1

4

@!

26



45 - 2

Section F Hydraulics

9803/3260

Section F

45 - 2

Issue 1

Valves

4 Install the A.R.V. sub-assembly into setting body 2.

Make sure that the adjusting pin 3 correctly locates in

adjusting screw 9.

Make sure that the lock nut 10 correctly locates in the

setting body socket - the anti-cavitation cone should

still be closed, as shown at B.

5 Install the A.R.V. sub-assembly and setting body intotest block 1. Make sure that the assembly is installed in

the port marked 'RV ' (relief valve).

6 Connect a hydraulic hand pump to port 'P' (pump) ofthe test block 1. Make sure that the hand pump is filled

with JCB Hydraulic fluid.

Connect a 0 to 400 bar (0 to 6000 lbf/in2) pressure test

gauge to port 'G' (gauge) of the test block 1.

Port 'T' (tank) can be left open when using a hydraulic

hand pump.

7 Raise the pressure at the valve inlet using the hydraulichand pump, when the A.R.V. 'cracks' and oil escapes

from the port marked 'T' the pressure gauge will

indicate the A.R.V. setting.

If the A.R.V. setting is correct, move to step 12.

If the A.R.V. setting is not correct, move to step 8.




45 - 3


9803/3260

Section F

45 - 3

Issue 1

Valves

8 Use the hand pump to raise approximately 172 bar

(2500 lbf/in2) pressure at the valve inlet.

Note: Raising the pressure at the valve inlet locks the anti-

cavitation cone C onto its seat, this allows the A.R.V.

adjusting screw lock nut 10 to be loosened (step 10).

If the pressure is maintained move to step 10.

If the pressure falls off rapidly, or if no pressure can be

obtained it is possible that the anti-cavitation cone is

not seating effectively, in this instance move to step 9.

9 If no pressure can be raised (see step 8) at the valveinlet, remove the A.R.V. assembly and install anti-

cavitation lock-out bung 6 in the port marked 'RV ',

make sure that the bung O-ring face seal D is facing

out. Re-fit the A.R.V. assembly.

Note: The anti-cavitation lock-out bung seals and locks the A.R.V. anti-cavitation function. The bung is only suitable for

the test block application and must NEVER be fitted to the

excavator valve block.

The bung can be extracted using a 3/8 - 16 UNC

threaded bolt.

10 Release the A.R.V. adjusting screw lock nut (see note):

Engage the nut at the end of setting body 2 using the

slot in special spanner 4, turn the nut anti-clockwise to

release the A.R.V. adjusting screw lock nut.

Note: Remember, it will not be possible to release the locknut if there is not approximately 172 bar (2500 lbf/in2)

pressure at the valve inlet.

11 Insert T-bar adjuster key 5 into adjusting pin 3. Pushthe adjusting pin down and make sure it has engaged

with the A.R.V. adjusting screw.

Rotate the T-bar clockwise to increase the pressure

setting and anti-clockwise to decrease the pressure

setting.

After adjustment, use the slot in spanner 4 to lock the

A.R.V. adjusting screw lock nut (see note).

Note: Remember, pressure must be maintained at the valveinlet to ensure the lock nut is tightened.




45 - 4


9803/3260

Section F

45 - 4

Issue 1

Valves

12 When the correct A.R.V. setting has been attained,

release the pressure in the test block. Remove the

A.R.V. sub-assembly and its setting body from the testblock.

Separate the A.R.V. sub-assembly from its setting

body.

Install the A.R.V. sub-assembly into its cap.




45 - 5


9803/3260

Section F

45 - 5

Issue 1

Valves



45 - 6


(Sideshift Machines)

Excavator A.R.V.'s (In Position)


hand pump method as described on pages E/45-1 to E/45-4. However, the procedure described below can be used to

check the A.R.V. pressure setting.

1 - Preparation

Position kingpost to the side of the machine as shown at A .

Slew kingpost to the operator's right and engage boom lockZ. Stop engine.

Operate boom and dipper controls to vent pressure.

Note: View X shows the normal pipework connections. View

Y shows the pipework connected ready for the test. Theupper hoses K are for the attachment service. When no

attachment is fitted, hose E will be the top hose on the

kingpost.

!WARNINGIt is dangerous to disconnect hoses without engaging

the boom lock first.HYD 2-1

Disconnect hose B from pipe C and fit plug 892/00057 to

hose B.

Fit tee-piece D (892/00048) to pipe C and connect a 0-400

bar (0-6000 lbf/in2) gauge as shown.

Disconnect hose E from pipe F and fit plug 892/00057 tohose E.

Fit additional test hose G (613/02000) between tee piece D

and pipe F. This links the rod side of the dipper ram to the

boom rod side port on the valve block. Connections will now

be as shown at view Y .

2 - Testing

Start engine and close dipper ram by selecting 'boom raise'

at the same time as 'dipper out'.

Run engine at 1000 revs/min and slowly select 'dipper in'.

When the dipper ram just starts to open, check gauge

reading which will indicate the operating pressure of boomrod side A.R.V. (see Technical Data for correct pressure).

If the pressure is incorrect, the A.R.V. msut be adjusted


Note: The position of the boom rod side A.R.V. variesaccording to the excavator control pattern (see table).

Move each A.R.V. in turn to the boom rod side position and

repeat the test for each A.R.V.

When testing is complete, return all A.R.V's to their originalpositions and reconnect pipework as shown at X .

A.R.V. Position Key

Control Layout

JCB ISO Case Ford

Slew Right 4H 4H 4H 4H

Slew Left 4J 4J 4J 4J

Boom Rod 4K 4M 4M 4K

Boom Head 4L 4N 4N 4L

Dipper Rod 4N 4L 4K 4N

Dipper Head 4M 4K 4L 4M

Bucket Rod 4Q 4Q 4Q 4P

Bucket Head 4P 4P 4P 4Q

Note: The bucket rod side A.R.V. is only fitted to machines

equipped with a Powerbreaker.


9803/3260

Section F

45 - 6

Issue 2*

Valves

4Q 4N 4L 4J

4P 4M 4K 4H



45 - 7


9803/3260

Section F

45 - 7

Issue 1

Valves



45 - 8


(Centremount Machines)

Excavator A.R.V's. (In Position)


hand pump method as described on pages E/45-1 to E/45-4). However, the procedure described below is a secondary

checking method which can be used if no hand pump is

available.

1 Preparation

Position boom central as at A and engage boom lock Z.Stop engine.

Operate boom and dipper controls to vent pressure.

Note: Views X show the normal pipework connections. View

Y shows the pipework connected ready for the test. Theupper pipes K are for the attachment service. If no

attachment is fitted, hose E will be the top hose on the

kingpost.

!WARNINGIt is dangerous to disconnect hoses without engaging

the boom lock first.HYD 2-1

Disconnect hose B from pipe C and fit plug 892/00057 to

hose B.

Fit tee-piece D (892/00048) to pipe C and connect a 0-400

bar (0-6000lbf/in2) gauge as shown.

Disconnect hose E from pipe F and re-connect hose E to

tee-piece D.

Connections will now be as shown at Y .

2 Testing

Start engine and close dipper ram by selecting 'boom raise'

at the same time as 'dipper out'.

Run engine at 1000 revs/min and slowly select 'dipper in'.

When the dipper ram just starts to open, check gauge

reading which will indicate the operating pressure of the

boom rod side A.R.V. (see Technical Data for correct

pressure).



Note: The position of the boom rod side A.R.V. varies

according to the excavator control pattern (see table).

Move each A.R.V. in turn to the boom rod side position and

repeat the test for each A.R.V.

When testing is complete, return all A.R.V's to their original

positions and reconnect pipework as shown at X .

A.R.V. Position Key

Control Layout

JCB ISO Case Ford

Slew Right 4H 4H 4H 4H

Slew Left 4J 4J 4J 4J

Boom Rod 4K 4M 4M 4K

Boom Head 4L 4N 4N 4L

Dipper Rod 4N 4L 4K 4N

Dipper Head 4M 4K 4L 4M

Bucket Rod 4Q 4Q 4Q 4P

Bucket Head 4P 4P 4P 4Q

Note: The bucket rod side A.R.V. is only fitted to machines

equipped with a Powerbreaker.


9803/3260

Section F

45 - 8

Issue 1

Valves

4Q 4N 4L 4J

4P 4M 4K 4H



46 - 2


9803/3260

Section E

46 - 2

Issue 1

Valves

108100



46 - 3

Hose Burst Protection Valve

(to Machine Serial No. 402173)

This type of HBPV is fitted to the dipper and boom rams.





Note: Port connections are identified by the codes C1 , C2,

V1, and V2 which are stamped on the body of the valve.

When Dismantling

To avoid disturbing pressure settings, remove cartridges byunscrewing hexagons 1 and 5 and do not remove capnuts

22 or 25.

To eject piston 12, apply compressed air to the small pilot

drilling inside port V1. Then use a thin rod to push out spool15 in the opposite direction to piston 12.

Do not try to dismantle sequence valve cartridge 1. To

clean, use a non-metallic probe to operate the plunger while

the nose of the cartridge is submersed in cleaning fluid.

When Assembling

Check condition of all visible seating faces. If any are

damaged, renew complete cartridge or valve assembly.

Ensure that small drilling A through poppet 3 is not blocked.

Renew all seals, ensuring that the black 'O' rings are fitted

into the grooves before the white back-up rings.

When refitting valve to machine, ensure that pressure

settings are correct (seeTechnical Data).


9803/3260

Section E

46 - 3

Issue 2*

Valves

*



46 - 4


9803/3260

Section E

46 - 4

Issue 1

Valves



46 - 5

Hose Burst Protection Valves


Pressure Testing - Dipper Ram

Preparation

Before starting the pressure testing procedure vent hydraulic

system pressure as follows:

1 Fully extend the dipper and then operate the dipper

control lever to retract the dipper slightly, this will

reduce pressure on the dipper ram rod side.

2 Lower the boom until the bucket is resting on the

ground as shown at X .

3 Switch off the engine.

4 Operate all the excavator control levers back and forth

to vent hydraulic pressure from the services.

Relief Valve Pressure Test

If the hose burst protection valve has been stripped andcleaned, then pre-set the valve as detailed in step 1. The

pressure test procedure is described in steps 2 to 5. For

information; one full turn of the relief valve adjusting screw is

equivalent to approximately 90 bar (1300 lbf/in2).

1 Pre-set the relief valve:

a Remove cap B and its copper washer. Using an Allen key, turn the adjusting screw anti-clockwise

to remove all tension

b Using your fingers, turn the adjusting screwclockwise until a soft force (resistance) is felt.

c Using an Allen key, turn the adjusting screw a

further 3 1/2 turns (315 bar, 4570 lbf/in2 ) to pre-set

the relief valve. Refit the cap and washer.

2 Remove plug A and screw a tee piece fitted with a 0-

400 bar(0-6000 lbf/in2 ) pressure gauge to the valve in

place of A.

3 Connect a hand pump to the other end of the tee piece

as shown at Y . Make sure that the hand pump hasbeen filled with oil.

4 Use the hand pump to increase the pressure, the

maximum gauge reading will be the setting of the hose

burst relief valve (see Technical Data). If necessary,

adjust as detailed in the next paragraph.

5 Remove cap B and its copper washer. Using an allen

key, turn the adjusting screw clockwise to increase the

pressure and anti-clockwise to decrease the pressure.

Replace the cap and washer. Repeat pressure test,

adjust as necessary.

Sequence Valve Setting Procedure

The sequence valve is set using a functional test. Beforecommencing with the test allow the machine hydraulics to

warm up.

1 Make sure that the relief valve is set at the correct

pressure, as detailed in 'Relief Valve Pressure Test'.

2 Position the machine so that the boom is raised and the

dipper extended, as shown at Z.

3 Set the engine revs to 1000 RPM.

4 Operate the dipper control lever to bring the dipper inslowly, the dipper movement should be smooth.

5 If the dipper movement is irregular or 'juddering'

remove cap C and its copper washer, adjust the

sequence valve setting:

a Using an Allen key, turn the adjusting screw anti-

clockwise to remove all tension.

b Turn the adjusting screw clockwise until 'judder' is

removed.

c Refit the cap and washer.


9803/3260

Section E

46 - 5

Issue 2*

Valves

*



46 - 6


9803/3260

Section E

46 - 6

Issue 1

Valves

147050



46 - 7



Pressure Testing - Boom Ram

Preparation



1 Bring the dipper in and fully raise the boom, operate the

boom control lever to lower the boom slightly, this will

reduce pressure on the boom ram rod side.

2 Slew the backhoe to one side as shown.

3 Move the dipper out slightly and bring the bucket to

rest on a block of wood, as shown at X (see Note ).


5 Operate all control levers back and forth to vent

hydraulic system pressure from the services.

Note: When testing the H.B.P.V. on the boom ram, a handpump is attached to the 'raise' (rod) side of the boom ram. If

the bucket is brought to rest on the ground during the

preparation stage, the boom will have to travel further (than

if brought to rest on a block of wood) before the H.B.P.V.

'cracks' or opens.


If the hose burst protection valve has been stripped and

cleaned, then pre-set the valve as detailed in step 1. The

pressure test procedure is described in steps 2 to 5. For

information; one full turn of the relief valve adjusting screw isequivalent to approximately 90 bar (1300 lbf/in2).


a Remove cap B and its copper washer. Using an

Allen key, turn the adjusting screw anti-clockwiseto remove all tension.

b Using your fingers, turn the adjusting screw

clockwise until a soft force (resistance) is felt.

c Using an Allen key, turn the adjusting screw afurther 3 1/2 turns to pre-set the relief valve. Refit

the cap and washer.

2 Remove plug A and screw an elbow joint piece fitted

with a length of hose in place of A .

3 Connect a hand pump fitted with a 0-400 bar (0-6000

lbf/in2) pressure gauge to the other end of the hose as

shown at Y . Make sure that the hand pump has been

filled with hydraulic oil.

4 Use the hand pump to increase the pressure, the

maximum gauge reading will be the setting of the hose

burst relief valve (see Technical Data). If necesary,

adjust as detailed in the next paragraph.

5 Remove cap B and its copper washer. Using an allenkey, turn the adjusting screw clockwise to increase the

pressure and anti-clockwise to decrease the pressure.

Replace the cap and washer. Repeat pressure test,

adjust as necessary.

Sequence Valve Setting Procedure

The sequence valve is set using a functional test. Before

commencing with the test allow the machine hydraulics to

warm up.

1 Make sure that the relief valve is set at the correctpressure, as detailed in 'Relief Valve Pressure Test'.

2 Raise the boom as shown at Z.

3 Set the engine revs to 1000 RPM.

4 Operate the boom control lever to lower the boom

slowly, the boom movement should be smooth.

5 If the boom movement is irregular or 'juddering' remove

cap C and its copper washer, adjust the sequence

valve setting:

a Using an Allen key, turn the adjusting screw anti-

clockwise to remove all tension.

b Turn the adjusting screw clockwise until 'judder' is

removed.

c Refit the cap and washer.


9803/3260

Section E

46 - 7

Issue 2*

Valves

*



47 - 1


9803/3260

Section E

47 - 1

Issue 1

Valves



47 - 2


(from Machine Serial No. 402174)

This type of HBPV is fitted to the dipper, boom and loader

arm rams.





When Dismantling

If possible, avoid disturbing pressure settings, remove

cartridges by unscrewing hexagons 1 and 13 and do not

remove capnuts 3 and 16.

Spool 2 and check valve 11 each have a Teflon ring fitted

(items A and B respectively). These Teflon rings should only

be removed and replaced with new ones if they are

damaged.

Do not try to dismantle items 20, 21 and 22 (these items are

shown for pictorial reference only). To clean, use a non-

metallic probe to move the ball 21 against spring 22 whilst

assembly 17 is submersed in cleaning fluid.

Note: HBPV's fitted to the loader arm lift circuits do not have

restrictor ball 21 fitted.

Check condition of all visible seating faces. If any aredamaged, renew complete cartridge or valve assembly.

Check valve bores and spools for nicks, scratches or

scoring, if necessary, renew complete cartridge or valve

assembly.

When Assembling

DO NOT apply JCB Lock & Seal or any other type of lockingfluid to the threads of item 17. The threads form an integral

part of the valve operating sequences - applying locking

fluid to the threads will seriously effect the operation of the

valve.

Ensure that the small drilled holes C and D in items 2 and 17

respectively are not blocked.

Renew all seals. If fitting new Teflon rings A & B, use a

conical guide, such as item E, to expand the rings gradually.

Complete the ring fitting procedure as quickly as possible,

otherwise the ring will stretch. See below.

Note: There is an O-ring F fitted underneath each Teflon

ring, if the Teflon rings are to be renewed, make sure that

new O-rings are fitted first.

After assembly, make sure that the valve parts move freely,if they don't, check that all the seals are correctly fitted.

After refitting the valve to the machine, ensure that pressure

settings are correct (see Technical Data, page E/1-2).

If the pressure settings were disturbed, then the valve mustbe re-set, refer to the pressure testing procedures on pages

E/47-3 to E/47-8.


9803/3260

Section E

47 - 2

Issue 2

Valves

11

F

B

E

A183490



47 - 3


9803/3260

Section E

47 - 3

Issue 1

Valves

181480



47 - 4



Pressure Testing - Dipper Ram

Preparation

Before starting the pressure testing procedure, vent

hydraulic system pressure as follows:



Lower the loader arms to the ground.

2 Lower the stabilisers so that the stabiliser pads are just

touching the ground (not lifting the machine).

3 Manoeuvre the boom and dipper into the position

shown at Y (on sideshift machines, make sure thebackhoe assembly is set central). Make sure dipper ram

rod extension is approximately 25 - 50 mm (1 - 2 in),

shown at W.

4 Select 'BOOM LOWER' to raise the stabiliser pads

approximately 25 - 50 mm (1 - 2 in) off the ground,shown at X .


6 Make sure all personnel are clear of the machine before

completing step 7.

7 Select 'DIPPER OUT' - this will vent residual hydraulicpressure from the dipper ram (rod side), shown at Z.

8 Move all the backhoe control levers back and forth to

vent any other residual hydraulic pressure from thebackhoe service hoses.

Pilot Valve Setting Procedure

The pilot valve assembly, shown at C, must be set correctly

before doing the relief valve pressure test. If the pilot valve isscrewed too far into the HBPV it will create a flow path

connection from port C2 to port V2 (see descriptions of

operation).

To Set the pilot valve assembly:

1 Remove pilot housing, item D, from the HBPV.

2 Check that the end face of the pilot valve assembly,

item C, is flush (level) with the end face of its housing

D, as shown at E.

3 If necessary, remove end cap F and, using a suitable

Allen key, adjust the pilot valve as required.

4 Refit the end cap.



pressure test and setting procedure is described in steps 2

to 7.



Allen key, turn the adjusting screw anti-clockwise

to remove all tension.




further 21/4 turns to pre-set the relief valve. Refit

the cap and washer.

2 Remove hose G from port C2. Plug and cap the hoseand valve port adapter respectively (the valve port

adapter MUST be capped, otherwise the test

procedure will not work).

3 Remove hose J from port V2, plug the hose but DO

NOT cap the valve port adapter.

4 Remove plug A and screw a tee piece fitted with a 0-400 bar (0-6000 lbf/in2) pressure gauge to the valve in

place of A .

5 Connect a hand pump to the other end of the tee pieceas shown at Y . Make sure that the hand pump has

been filled with hydraulic oil.

6 Use the hand pump to increase the pressure. When the

pressure reaches the setting of the relief valve, oil will

escape from port V2, shown at K . Note the maximumgauge reading (the setting of the hose burst relief valve)

which should be 250 bar (3625 lbf/in2).

7 If necessary, adjust the pressure setting as follows:

a Remove cap B and its copper washer.

b Using an Allen key, turn the adjusting screw

clockwise to increase the pressure or anti-

clockwise to decrease the pressure. For

information; one full turn of the relief valve adjusting

screw is equivalent to approximately 110 bar (1595lbf/in2).

c Replace the cap and washer.

d Repeat pressure test, adjust as necessary.


9803/3260

Section E

47 - 4

Issue 1

Valves



47 - 5


9803/3260

Section E

47 - 5

Issue 1

Valves



47 - 6



Pressure Testing - Boom Ram

Preparation




parking brake and set the transmission to neutral.Lower the loader arms to the ground.

2 Lower the stabilisers so that the stabiliser pads are just

touching the ground (not lifting the machine).

3 Manoeuvre the boom and dipper into the positionshown at Y (on sideshift machines, make sure the

backhoe assembly is set central).

4 Select 'DIPPER LOWER' to raise the stabiliser pads

approximately 25 - 50 mm (1 - 2 in) off the ground,shown at Z.



completing step 7.

7 Select 'BOOM RAISE' - this will vent residual hydraulic

pressure from the boom ram (rod side), shown at X .





before doing the relief valve pressure test. If the pilot valve isscrewed too far into the HBPV it will create a flow path

connection from port C2 to port V2 (see descriptions of

operation).

To set the pilot valve assembly:




D, as shown at E.





If the hose burst protection valve has been stripped and

cleaned, then pre-set the valve as detailed in step 1. The

pressure test procedure is described in steps 2 to 6.



Allen key, turn the adjusting screw anti-clockwise


b Using your fingers, turn the adjusting screwclockwise until a soft force (resistance) is felt.


further 21 /4 turns to pre-set the relief valve. Refit

the cap and washer.

2 Remove hose G from port C2. Cap and plug the hose

and valve port adapter (the valve port adapter MUST be

plugged, otherwise the test procedure will not work).

3 Remove hose J from port V2. Plug the hose but DO

NOT cap the valve port adapter.

4 Remove plug A and in its place fit a 0-400 bar (0-6000lbf/in2) pressure gauge connected to a hand pump.

Note: The working space around the boom ram HBPV is

limited, for this reason it may be necessary to fit an elbow

joint in place of plug A . Connect a hose of suitable length to

the elbow joint and then connect a hand pump and pressure

gauge to the other end of the hose.

5 Use the hand pump to increase the pressure. When the

pressure reaches the setting of the relief valve, oil will

escape from port V2, shown at K . Note the maximum

gauge reading (the setting of the hose burst relief valve)

which should be 250 bar (3625 lbf/in2 ).



b Using an Allen key, turn the adjusting screwclockwise to increase the pressure or anti-

clockwise to decrease the pressure. For

information; one full turn of the relief valve adjusting

screw is equivalent to approximately 110 bar (1595

lbf/in2 ).




9803/3260

Section E

47 - 6

Issue 1

Valves



47 - 7


9803/3260

Section E

47 - 7

Issue 1

Valves



47 - 8

Hose Burst Protection Valves (H.B.P.V.)


Pressure Testing - Loader Arms Lift Ram

The following text describes the pilot valve settingprocedures and pressure testing sequences for ONE HBPV

only, repeat the procedures for BOTH loader arm lift rams.

Preparation

Before starting the pressure testing procedure vent hydraulicsystem pressure as follows:



2 Lower the loader arms to the ground (not lifting themachine).

3 Select 'ARMS LOWER' to raise the front wheels

approximately 25 - 50 mm (1 - 2 in) off the ground.



completing step 6.

6 Select 'ARMS RAISE' - this will vent residual hydraulicpressure from the loader rams (head side).





before doing the relief valve pressure test. If the pilot valve is

screwed too far into the HBPV it will create a flow path

connection from port C2 to port V2 (see descriptions ofoperation).

To set the pilot valve assembly:




D, as shown at E.






pressure test procedure is described in steps 2 to 6.


a Remove cap B and its copper washer. Using an Allen key, turn the adjusting screw anti-clockwise





further 21 /4 turns to pre-set the relief valve. Refit

the cap and washer.

2 Remove hose G from port C2. Cap and plug the hose

and valve port adapter (the valve port adapter MUST be

plugged, otherwise the test procedure will not work).

3 Remove hose J from port V2. Plug the hose but DONOT cap the valve port adapter.

4 Remove plug A and in its place fit a 0-400 bar (0-6000

lbf/in2 ) pressure gauge connected to a hand pump.

5 Use the hand pump to increase the pressure. When thepressure reaches the setting of the relief valve, oil will

escape from port V2, shown at K . Note the maximum

gauge reading (the setting of the hose burst relief valve)

which should be 250 bar (3625 lbf/in2 ).



b Using an Allen key, turn the adjusting screw

clockwise to increase the pressure or anti-

clockwise to decrease the pressure. Forinformation; one full turn of the relief valve adjusting

screw is equivalent to approximately 110 bar (1595

lbf/in2 ).




9803/3260

Section E

47 - 8

Issue 1

Valves



48 - 2

Stabiliser Check Valve (With Relief Valve)





When Assembling

Renew all seals and 'O' rings. Lubricate with JCB 'Special'

Hydraulic Fluid.

Torque Settings


1 61 6.2 45

Relief Valve Pressure Testing

Connect a hydraulic hand pump and pressure gauge to the

port identified 'C' on the valve block. Raise the pressure untilhydraulic fluid emerges through drilling A, indicating that the

relief valve has opened. Check that the pressure gauge

reading is as given in Technical Data. Adjust at 12 if

necessary.


9803/3260

Section E

48 - 2

Issue 1

Valves



48 - 4

Stabiliser Check Valve





When Assembling

Renew all seals and 'O' rings. Lubricate with JCB 'Special'

Hydraulic Fluid.

Torque Settings


1 61 6.2 45


9803/3260

Section E

48 - 4

Issue 1

Valves



49 - 1





When Dismantling

Press out the spool item 14 using a nylon pin. Take care not

to damage the bores of the valve.

When Assembling

Make sure that spring seat of spool 14 faces toward LS

connection.

Clean all parts in clean paraffin.

Lubricate all parts with hydraulic fluid.

Renew aluminium washers 8 and 12.




Torque Settings

Item Nm lbf ft

7 50 37

11 50 37

!WARNINGMake the machine safe before getting beneath it. Lower



To bleed the LS line, start the engine, loosen the connection

on the valve, turn and hold the steering wheel fully in either

direction. When bubble free oil flows from the joint, tighten

the connection.


9803/3260

Section E

49 - 1

Issue 2*

Valves

Priority Valve


The priority valve is mounted on the left hand side chassis

member, behind the hydraulic tank. It is attached to thechassis member by one bolt A , and is accessible from

below.

There are four connections to the valve as follows:

P - from hydraulic pump

CF - to steering valve

EF - to valve block

LS - pilot connection from steering valve

PP - port is plugged

When replacing always renew sealing washers 2, 4, 6, and

10.

*

*



50 - 1

Hydraulic Steering Unit


When Removing

Park the machine on level ground, engage the parking brake

and set the transmission to neutral. Lower the attachments

to the ground. Stop the engine and remove the starter key.

Turn the steering wheel to the left and to the right several

times to vent system pressure.

Remove bolts A and take off the steering pedestal cover B

to gain access to the steering unit.

Disconnect and cap all hydraulic hoses from the steering

unit. Label the hoses to ensure correct refitting.

Take hold of the steering unit, loosen and remove bolts C.

Lift the steering unit from the machine.

When Replacing



connections are as follows:

P - to priority valve (CF port)

L - to steering valve assembly (P port)

R - to front axleLS - to priority valve (pilot connection, LS port)

T - to tank

Bleed the steering system, see page E/52 - 1.

If a new steering unit has been fitted then the system reliefvalve must be tested for correct pressure setting, see page

E/50 - 7.





9803/3260

Section E

50 - 1

Issue 1

Valves

S147670



50 - 2


9803/3260

Section E

50 - 2

Issue 1

Valves

S10221A



50 - 3

Hydraulic Steering Unit


Use the numerical sequence on page E/50 - 2 as a guide to dismantling.

During manufacture, a small mark X will have been made on sleeve 12 and spool 15, close to one of the slots for the centringsprings 13. Before removing the centring springs, check that this mark is visible; if not, make a new mark to ensure correct

assembly.

Shock valves (items 29 to 35 ) are pressure set during manufacture and the adjusting screw 31 secured with Loctite. Due to thedifficulty of resetting the pressure it is recommended that the valves are not disturbed. If dismantling is unavoidable, however,

measure and record the depth of adjusting screw 31 below the top face of the steering unit before removing the screw.

Assembly

Note: The unit illustrated in the following sequence represents a typical Danfoss valve. The relief valve (items 25 to 28 ) and

shock valves (items 29 to 35 ) are not therefore shown in the photographs.


9803/3260

Section E

50 - 3

Issue 1

Valves

1 Fit spool 15 into sleeve 12, aligning slots for centring

springs 13 and checking that the small marks X are

aligned. Ensure that three slots in spool partiallyuncover three holes in sleeve, as at A .

2 Fit two flat centring springs 13 with four curved springs

between them, as shown at B.

3 Fit seal 24 into steer unit body and insert sleeve of tool

892/00180. Fit back up ring 20 and seal 21 onto

plastic boss, and position on tool spindle, as shown.



50 - 4


9803/3260

Section E

50 - 4

Issue 1

Valves

4 Lower steering unit body and tool sleeve over toolspindle until plastic bush is flush with end of bore.

Assemble sleeves 12 and 15 with cross pin 14 and

centring springs13

. Fit bearing components16

to19

with chamfered face of 17 facing away from bearing 18.

5 Remove body from tool leaving plastic bush in position,

and lower body over assembled spool.

6 Apply downward pressure on body until plastic boss is

forced out of bore, leaving seals correctly located.

7 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 (support

example is a pump drive housing). Place ball 23 into

check valve hole and fit bush 22.

Hydraulic Steering Unit - Assembly (continued)



50 - 5


9803/3260

Section E

50 - 5

Issue 1

Valves

8 Fit new 'O' ring 10.

9 Fit distributor plate 9 ensuring that holes align. Locate

shaft 11 onto cross-pin 14, noting position of slot. Whenrotor 7 is fitted, slot must align with hollows of rotor as

shown at C.

10 Use a suitable piece of rigid flat material, 0.25mm

(0.010 in.) thick, to support the shaft and ensure positive

engagement with the splines of rotor 7.

11 Locate rotor onto shaft, ensuring alignment as at C. Fit

spacing bush 6 into rotor.




50 - 6


9803/3260

Section E

50 - 6

Issue 1

Valves

12 Fit 'O' rings 4 and 8 each side of body 5, then positionbody over rotor.

13 Refit the end plate and fit at least one bolt 2 before

removing support material.

14 Fit remaining bolts, ensuring that special bolt 1 is

correctly located. Tighten all bolts to 29Nm (22 lbf ft).

Pressure Relief Valve Cartridge

After renewing the 'O' ring, torque tighten the cartr idge to 50Nm (37lbf ft). The valve is preset at 120bar (122kgf/cm2,

1740lbf/in2 ) but the setting should be rechecked after fitting the steering unit to the machine (see page E/50 - 7).

Shock Valves

If the shock valves have been dismantled, clean the threads of adjusting screw 31 and the threads in the bore of the steering

unit body using Super Clean Safety Solvent and allow to dry. Assemble seat 35, ball 34, cap 33 and spring 32 then coat

threads of screw 31 with JCB Lock and Seal. Assemble screw to depth measured during dismantling (see page E/50 - 3) then

fit plug 29 and washer 30.




50 - 7


9803/3260

Section E

50 - 7

Issue 2*

Valves

*

Steering System - Pressure Testing


and set the transmission to neutral. Lower the attachmentsto the ground. Stop the engine and remove the starter key.









The pressure test point for the steering circuit is fitted nextto the priority valve as shown. Connect a 0-400 bar (0-6000

lbf/in2 ) pressure gauge to test adaptor A .

Run the engine at 1500 revs/min and turn the steering to full

lock. Check the gauge reading which should equal the relief

valve pressure given in Technical Data.

Note: The steering wheel must be held on full lock whilst thegauge reading is being checked.

If necessary, adjust the pressure setting by removing plug B,

on the orbitrol steering unit.

Adjust screw C using an 'allen key' until the correct pressureis shown on the gauge.

Refit plug B.



When Replacing


Make sure that the electrical solenoid connections are

refitted in the correct position.


connections from the steer valve assembly are as follows:

P - to orbitrol steer unit (L port)

B - to left hand rear steer ram (rod side) A - to right hand rear steer ram (rod side)

T - to front steer rams (rod side - right hand

ram, head side left hand ram)

Note: The steer valve ports should be stamped 'P', 'B', 'A'

and 'T'. Left and right hand are as viewed from the rear ofthe machine.

For reference, the electrical connections are as follows:

Connector A feeds the 2 WHEEL STEER solenoid

Connector B feeds the 4 WHEEL STEER/CRAB solenoidConnector C feeds the CRAB STEER solenoid

Connector D feeds the 4 WHEEL STEER solenoid.

Bleed the steering system, see page E/52 - 1.

Steering Valve Assembly (AWS Machines)


When Removing


and set the transmission to neutral. Lower the attachments

to the ground. Stop the engine and remove the starter key.









The steer valve assembly is fitted to a bracket which is

mounted on the right hand side of the machine in front of the

rear axle. Early type machines have the valve mounted

vertically, as shown at Y , and later types are mounted

horizontally, as shown at X .

Disconnect the electrical solenoid connections, the wires

should be identified A , B, C and D as shown.

Disconnect and cap all hydraulic hoses from the steering

valve assembly. Label the hoses to ensure correct refitting.

Take hold of the steering valve, loosen and remove bolts E.

Lift the steering valve and its retaining bracket from the

machine.

51 - 1


9803/3260

Section E

51 - 1

Issue 3*

Valves

S147661 S217510

**

*

Y X



51 - 2

Steering Valve Assembly (AWS Machines)





When Dismantling

Before dismantling scratch an alignment mark X along the

faces of the solenoid valves and the manifold block.

Take care not to lose the detent balls A from items 16 and

18.

When Assembling


Lubricate parts with JCB Special Hydraulic fluid before

assembling.

Use the alignment marks X (see dismantling) to ensure that

the solenoids and the manifold block are assembled

correctly.

Torque Settings

Item Nm lbf in

1 7.1-9.1 63-80


9803/3260

Section E

51 - 2

Issue 2*

Valves

S147650

*

*



52 - 1

Steering System - Bleeding Procedure

Whenever any hydraulic steering component is

disconnected or removed the system must be bled asfollows.

With the engine running, this procedure must be carried out

in the correct order that is laid down. You must not alter the

order of selections and operations.

1 Select 2 Wheel Steer

(a) Turn steering wheel to left, until front wheels are

fully locked to the left.

(b) Turn steering wheel to right, until front wheels arefully locked to the right.





(a) Turn steering wheel to full right lock.

(b) Turn steering wheel to full left lock.

(c) Turn steering wheel to full right lock.


(a) Turn steering wheel to left, until the front wheels

are fully locked to the left.













(a) Turn steering wheel to left, until the front and rear

wheels are fully locked.


9803/3260

Section E

52 - 1

Issue 1

Valves



61 - 1

Typical Ram


When Dismantling

Place ram assembly on a locally manufactured strip/rebuild

bench as shown.

If a split replacement seal is available it is not necessary toremove the piston head in order to renew the wiper seal H.

Renew snap ring J.

Slacken end cap using special spanner (see Service Tools,

Section 1) and remove the piston rod assembly from the

cylinder.

!WARNINGIf air or hydraulic pressure is used to force out the piston

assembly, ensure that the end cap is securely fitted.

Severe injury can be caused by a suddenly released

piston rod.HYD 1-2

Position piston rod assembly on bench in place of ram

cylinder. Remove seals and back-up rings from piston head.

Remove snap ring C.

Heat piston head to 180-210 °C to degrade the Loctite

between piston head and rod. To check temperature, use

Surface Temperature Probe (see Service Tools, Section 1).

CAUTION: Do not exceed 300 °C or the Loctite will char,

causing thread pick-up.

!WARNINGTo avoid burning, wear protective gloves when handling

hot components. To protect your eyes, wear goggles

when using a wire brush to clean components.HYD 1-3

Remove piston head from rod using special spanner (see


Remove gland bearing and end cap from piston rod and

remove the seals and back-up rings.

Ensure that metal components are free from scoring, nicksand burrs. A damaged rod will impair the life of the gland

seal.

When Assembling

Clean threads of piston rod, piston head, end cap and

cylinder using a wire brush.

Use JCB Cleaner & Degreaser to ensure that all threads are

free from grease, hydraulic oil and old Loctite. Allow 15minutes for solvent to dry before applying Loctite.

Ensure that lubricants used during assembly do not come

into contact with Loctite.....cont'd


9803/3260

Section E

61 - 1

Issue 2*

Rams

S249860

S249870

*

J

H

E

B A

A

B

J

H

X

D

C



61 - 2

Typical Ram

When Assembling (cont'd)

Refer to the 'Gland Seal Fitting Procedure' on page E/64-1.

Fit seal H into end cap first, followed by ring J. Insert seal A

and back-up ring B into the end cap. Renew external 'O'

ring.

Use sleeve F (see Service Tools, Section 1) fitted over piston

rod threads to protect the gland seals from damage and the

threads from oil and grease. Fit gland bearing into end cap

and push the assembly over the sleeve onto the rod.

Apply Loctite Activator N to threads of piston rod, end capand cylinder. Allow Activator to dry for 15 minutes before

bringing into contact with Loctite.

Note: Neither Loctite nor Activator must be allowed tocontact seals, bearing rings, or 'O' rings.

Apply Loctite 262 to all threads of piston rod. Renew 'O'

ring in piston head, lubricating only the 'O' ring with JCB

MPL Grease. Fit and torque tighten the piston head. Fit a

new snap ring C. DO NOT re-use the original snap ring.

Ensure that end damping spring X is engaged with collarand piston head.

Note: The end damping spring and collar X are fitted to the

dipper ram only.

Fit new seals and bearing rings to piston head.

Position cylinder on bench and install rod assembly into

cylinder.

Apply Loctite 932 to thread of end cap, fit a new 'O' ring and

torque tighten the end cap into the cylinder.

Note: If hydraulic oil contacts uncured Loctite a weakening

of the bond will result. Cure times vary according to the

ambient temperature and type of Activator used. The

following approximate cure times apply at 20 °C and are the

minimum periods between assembly and filling the ram withoil.

Loctite 262 or 932 with Activator N - 1 hour

Loctite 262 or 932 with Activator T - 2 hours

Torque Settings


D 405 41.3 300

E 678 69.2 500

Note: Cold weather operation. When operating in conditionswhich are consistently below freezing, it is recommended

that the rams are operated slowly to their full extent before

commencing normal working.


9803/3260

Section E

61 - 2

Issue 1

Rams

8030A



61 - 3

Typical Ram (with dowelled piston head)


When Dismantling

Place ram assembly on a locally manufactured strip/rebuildbench as shown.

Slacken end cap using special spanner (see Service Tools,

Section 1) and remove the piston rod assembly from thecylinder.




piston rod.HYD 1-2


cylinder. Remove seals and back-up rings from piston head.

Extract dowel C from the piston head using a metricscrew(M3, M4, or M6 depending on ram size) threaded into

the extractor hole.



Remove gland bearing and end cap from piston rod and

remove the seals and back-up rings. Ensure that metal

components are free from scoring, nicks and burrs. A

damaged rod will impair the life of the gland seal.

When Assembling


cylinder using a wire brush. Use JCB Cleaner & Degreaser to

ensure that all threads are free from grease, hydraulic oil and

old Loctite. Allow 15 minutes for solvent to dry before

applying Loctite.


into contact with Loctite.


Fit seal H into end cap first, followed by circlip J. Insert seal

A and back-up ring B into the end cap. Renew external 'O'ring.

Use sleeve F, shown overleaf, fitted over piston rod threads

to protect the seals from damage and the threads from oil

and grease. Fit gland bearing into end cap and push theassembly over the sleeve onto the rod.

Apply Loctite Activator T to threads of end cap and cylinder.

Allow Activator to dry for 15 minutes before bringing into

contact with Loctite.

Note: Neither Loctite nor Activator must be allowed to

contact seals, bearing rings, or 'O' rings.

Ensure that end damping spring X , shown overleaf, is

engaged with collar and piston head (dipper ram only).


9803/3260

Section E

61 - 3

Issue 2*

Rams

S249860

J

H

E

B A

A

B

J

H

S151930

X

Y

C L

K

*



61 - 4

Typical Ram (with dowelled piston head)

When Assembling (cont'd)

Fit locking dowel C to piston head/rod as follows:

1 Fit 'O' ring L into piston head K .

2 Fit piston head to piston rod and torque tighten to 405

Nm (300 lbf ft).

3 New ram Shaft and piston head fitted.

- If both are required, the following procedure should

be followed:

i Drill through piston head into piston rod, shown atZ. Use an undersized diameter drill first as a guide

and then drill with the correct size diameter drill to

suit; refer to the table for drill diameters and

depths.

ii Remove all swarf and contamination. Insert dowelC into drilled hole, make sure tapped extractor hole

is to outside.

4 New piston head fitted on a pre-drilled piston rod.

- Re-dri ll and dowel BOTH the piston head and

piston rod at 90° from the existing drilled dowelhole in the piston rod. Follow the procedures

described in step 3.

5 New piston rod fitted to a pre-drilled piston head.

- Use the pre-drilled hole in the piston head. Care

must be taken not to elongate the existing hole inthe piston head.

i Use a drill the same diameter as the pre-drilled hole

in the piston head to make a 'centre mark' in the

piston rod. DO NOT drill the piston rod at this

stage.

ii Use an undersized diameter drill as a guide and

drill into the piston rod to the required depth (see

table), make sure the drill has centred correctly on

the 'centre mark' made at step 5i.

iii Use the correct size diameter drill to suit the dowel

and drill to the required depth (see table).

iv Remove all swarf and contamination, insert the

dowel.


cylinder.

Apply Loctite 932 to first three threads of cylinder, torque

tighten the end cap to 678 Nm (500 lbf ft).



ambient temperature and type of Activator used. Thefollowing approximate cure times apply at 20 °C and are the

minimum periods between assembly and filling the ram withoil.

Note: Cold weather operation. When operating in conditions

which are consistently below freezing, it is recommendedthat the rams are operated slowly to their full extent before


DRILLING DETAILS FOR PISTON HEAD RETENTION

(all dimensions in mm)

Ram Dowel Guide Guide Dowel Dowel

Size Size Drill Ø Drill Drill Ø X Drill

Depth Depth Y

80 x 50 6Ø x 20 4 21 6.02/6.10 22/23

90 x 50 8Ø x 25 5 24 8.02/8.10 27/28

100 x 60

110 x 60 12Ø x 30 8 28 12.02/12.10 32/33

110 x 65

120 x 65 12Ø x 35 8 33 12.02/12.10 37/38

130 x 75


9803/3260

Section E

61 - 4

Issue 1

Rams

8030A



62 - 1

Steer Ram


This procedure is for a typical steering ram removal and

replacement.!WARNING

Make the machine safe before working underneath it.






!WARNINGRaised loader arms can drop suddenly and cause

serious injury. Before working under raised loader arms,

fit the loader arm safety strut.GEN 3-2

When Removing

Disconnect and cap hydraulic hoses to prevent loss of fluid

and ingress of dirt. Label hoses for identification and correct

refitting.

Remove locking bolts A and pivot pins B.

Remove steering ram from machine.

When Replacing

Replace steering ram by reversing the removal procedure.

Apply anti-seize paste, part number 4003/0211 to pivot pins

B, to facilitate subsequent removal.

After connecting hoses check hydraulic fluid level, ifnecessary top up.

Bleed hydraulic steering system (see page E/52 - 1).


9803/3260

Section E

62 - 1

Issue 1

Rams



62 - 2


9803/3260

Section E

62 - 2

Issue 1

Rams



62 - 3

Steer Ram





When Dismantling

Place ram assembly on a locally manufactured strip/rebuild

bench as shown.

Slacken end cap 1 using special spanner (see Service Tools,

Section 1) and remove the piston rod assembly 2 from thecylinder.




piston rod.HYD 1-2


cylinder. Remove seal and wear rings from piston head.

Remove locking ring 3.

Heat piston head to 180-210 °C to degrade the Loctite

between piston head and rod. To check temperature, use

Surface Temperature Probe (see Service Tools, Section 1).

CAUTION: Do not exceed 300 °C or the Loctite will char,causing thread pick-up.

!WARNINGTo avoid burning, wear protective gloves when handling

hot components. To protect your eyes, wear goggles

when using a wire brush to clean components.HYD 1-3



Remove end cap from piston rod and remove the seals and

'O' ring.

Ensure that metal components are free from scoring, nicks

and burrs. A damaged rod will impair the life of the gland

seal.

When Assembling


cylinder using a wire brush.

Use JCB Cleaner & Degreaser to ensure that all threads arefree from grease, hydraulic oil and old Loctite. Allow 15

minutes for solvent to dry before applying Loctite.


into contact with Loctite.


Fit seals 10 and 11 into end cap then fit the end cap onto

the piston rod.

Apply Loctite Activator N to threads of piston rod, end cap

and cylinder. Allow Activator to dry for 15 minutes beforebringing into contact with Loctite.

Note: Neither Loctite nor Activator must be allowed to

contact seals, bearing rings, or 'O' rings.

Apply Loctite 262 to all threads of piston rod. Renew 'O'ring in piston head, lubricating only the 'O' ring with JCB

MPL Grease. Fit and torque tighten the piston head. Fit a

new locking ring 3.

Fit new seal and wear rings to piston head.


cylinder.

Apply Loctite 932 to thread of end cap, fit a new 'O' ring 9

and torque tighten the end cap into the cylinder.



ambient temperature and type of Activator used. The

following approximate cure times apply at 20 °C and are the

minimum periods between assembly and filling the ram with

oil.

Loctite 262 or 932 with Activator N - 1 hour

Loctite 262 or 932 with Activator T - 2 hours

Torque Settings


7 405 41.3 300

1 678 69.2 500

Note: Cold weather operation. When operating in conditions

which are consistently below freezing, it is recommendedthat the rams are operated slowly to their full extent before



9803/3260

Section E

62 - 3

Issue 2*

Rams

*



Gland Seal Fitting Procedure

The size (diameter) and position of pins A is determined by

the diameter and radial width of the gland seal being fitted.

The pins are screwed into threaded holes in the tool body,

the spacing of the holes are designed to suit small or large

diameter gland seals.

To fit a new gland seal:

1 Open the tool as shown at X and insert the new gland

seal, the seal must be fitted behind the two front pins

but in front of the rear pin as shown.

2 Close the tool as shown at Y . The seal must form a

reniform (kidney shape).

3 Locate the seal in the end cap groove, shown at Z,

when the seal is in position, open the tool to release the

seal. Make sure the seal is correctly installed in its

groove and remove the tool.

64 - 1

Section F Transmission

9803/3260

Section F

64 - 1

Issue 1

Rams



i


9803/3260

Section F

i

Issue 6*

Contents Page No.

Technical Data

Front Axle

- All Wheel Steer Machines 1 - 1

- 2 Wheel Steer Machines 1 - 1

- 2 Wheel Steer (2 Wheel Drive) Machines 1 - 1

Rear Axle



Tyre Sizes and Pressures



Syncro Shuttle Transmission 1 - 4

Powershift Transmission 1 - 6

Pump/Transmission Stall Speed Combinations

* - AWS m/c with 11 inch convertor 1 - 8

* - 2WS m/c with 11 inch convertor 1 - 9

* - AWS m/c with 12.2 inch convertor 1 - 10* - 2WS m/c with 12.2 inch convertor 1 - 11

Towing Procedure

* Syncro Shuttle Gearbox 1 - 12

* Powershift Gearbox 1 - 12

Descriptions

Cutaway of Front Axle 2 - 1

Cutaway of Rear Axle 2 - 2


- General Description and Operation 3 - 1

- Syncromesh 3 - 4

- Clutch Operation 3 - 5- 4 Wheel Drive Operation 3 - 6

- 2 Wheel Drive Operation 3 - 7

- 4 Wheel Drive Operation (from M/C 415012) 3 - 8

-2 Wheel Drive Operation (from M/C 415012) 3 - 9


- General Description 4 - 1

- Hydraulic Operation 5 - 1

- Drivepaths 6 - 1

- Clutch Operation 7 - 1

- 2/4 Wheel Drive Operation 7 - 1

Fault Finding

Syncro Shuttle Transmission 12 - 12/4 Wheel Drive Clutch 13 - 1

Powershift Transmission 14 - 1

2/4 Wheel Drive Clutch (from M/C 415012) 15 - 1

Propshafts


Front Axle

Torque Figures 20 - 1

Removal & Replacement 21 - 1

Proximity Switch Setting Procedure 21 - 3

Renewing the Pinion Oil Seal 22 - 1

Hub and Driveshaft - Dismantling 23 - 1Hub and Driveshaft - Assembly 23 - 7

Drivehead - Dismantling (AWS Machines) 24 - 1

Drivehead - Assembly (AWS Machines) 24 - 3



ii


9803/3260

Section F

ii

Issue 6*

Contents Page No.

* Drivehead - Dismantling (2WS Machines) 25 - 1

* Drivehead - Assembly (2WS Machines) 25 - 3

* Removal & Replacement (2 Wheel Drive Machines) 26 - 1

* Dismantling and Assembly (2 Wheel Drive Machines) 27 - 1

Rear Axle

Torque Figures 40 - 1


Proximity Switch Setting Procedure 41 - 3

Renewing the Pinion Oil Seal 42 - 1

Brakes - Dismantling 43 - 1

Brakes - Assembly 43 - 4

Hub and Driveshaft - Dismantling 44 - 1

Hub and Driveshaft - Assembly 44 - 1

Drivehead - Dismantling 45 - 1

Drivehead - Assembly 45 - 4

Limited Slip Differential




Gearbox - Dismantling 62 - 1

Gearbox - Assembly 62 - 11

Solenoid Valve - Dismantling and Assembly 63 - 1

Reverser Unit - Dismantling 64 - 1

Reverser Unit - Assembly 64 - 3

Hydraulic 2/4 Wheel Drive Unit

- Dismantling and Assembly (to serial no. 400077) 65 - 1- Dismantling and Assembly (from 400078 to 415011) 65 - 11

- Dismantling and Assembly (from serial no. 415012) 65 - 14

Torque Converter - Removal 66 - 1

Torque Converter - Replacement 66 - 1

Torque Converter Stall Test 67 - 1

Pressure and Flow Testing 67 - 1

Polytetrafluoroethene (PTFE) Piston Ring Seals

- Fitting Procedure 68 - 1



Gearbox - Dismantling 82 - 1

Gearbox - Assembly 82 - 10Input Clutch & Reverser Clutch

- Dismantling 83 - 1

- Assembly 83 - 3

Mainshaft - Dismantling 85 - 1

Mainshaft - Assembly 85 - 5

Layshaft - Dismantling 86 - 1

Layshaft - Assembly 86 - 5

2/4 Wheel Drive Unit - Dismantling & Assembly 88 - 1

Torque Converter - Removal & Replacement 88 - 1

Solenoid Identification 91 - 1

Torque Converter Stall Test 91 - 1

Testing for Clutch Leakage 91 - 2Pressure & Flow Testing 91 - 3



1 - 1


9803/3260

Section F

1 - 1

Issue 2*

Technical Data

Front Axle

Note: It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axlewith a different ratio to the axle being replaced.

ALL WHEEL STEER MACHINES

Type JCB spiral bevel input with epicyclic hub reduction

Designation SD70

Installation Centre pivotNumber of steer rams 2

Weight

(dry, with no steer rams and without wheels) 385 kg (850 lbs) approximately

Overall Gear Ratio 24.975:1

Crownwheel and Pinion Ratio 4.625:1

Number of TeethCrownwheel 37

Pinion 8

Hub Reduction 5.4:1

Input Type YokeOscillation ± 5°

Toe - in 0 °Castor Angle 0 °

Camber Angle 1 °

King - pin inclination 0 °

2 WHEEL STEER MACHINES (4 Wheel Drive)

Type JCB spiral bevel input with epicyclic hub reduction

Designation SD55

Installation Centre pivot

Number of steer rams 1

Weight

(dry, with no steer rams and without wheels) 330 kg (728 lbs) approximatelyHub Reduction 5.4:1

Input Type Yoke

Oscillation ± 5°

Toe - in 0 °

Castor Angle 0 °

Camber Angle 1 °King - pin inclination 0 °

Ratios OPTION 1 OPTION 2

Overall 16.2:1 19.2:1

Crownwheel and Pinion 3:1 3.556:1

Number of Teeth

Crownwheel 33 32Pinion 11 9

2 WHEEL STEER MACHINES (2 Wheel Drive)

Type JCB centre oscillation, non-driven

Installation Centre pivot

Weight(dry, with steer ram and without wheels) 239 kg (525 lbs)

Oscillation ± 5°

Toe - in 0°

Castor Angle 0°

Camber Angle 3 ° positive

*

*

*

*



1 - 2


9803/3260

Section F

1 - 2

Issue 3*

Technical Data

Rear Axle

Note: It is essential that the correct ratio axle in relationship to the gearbox ratio is fitted to the machine. Do not fit a new axle

with a different ratio to the axle being replaced.


Type 3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard braking

Designation SD70

Installation Rigid pad mount

Number of steer rams 2Weight (dry, with no steer rams 410 kg (904 lbs) approx.

and without wheels)

Half (Axle) Shaft Braking/Type 5 plate (each half shaft)

Input Type Yoke

Oscillation ± 5°

Toe - in 0 °Castor Angle 0 °

Camber Angle 1 °King - pin inclination 0 °

Hub Reduction 5.4:1


Overall 15.78:1 18.16:1Crownwheel and Pinion 2.923:1 3.363:1

Number of Teeth

Crownwheel 38 37

Pinion 13 11

2 WHEEL STEER MACHINES

Type 3 piece, JCB spiral bevel input with epicyclic hub reduction and inboard brakingDesignation PD70

Installation Rigid pad mount

Weight (dry and without wheels) 386 kg (851 lbs) approx.Half (Axle) Shaft Braking/Type 5 plate (each half shaft)

Input Type Yoke

Hub Reduction 5.4:1


Overall 15.78:1 18.16:1

Crownwheel and Pinion 2.923:1 3.363:1Number of Teeth

Crownwheel 38 37

Pinion 13 11

*



1 - 3


9803/3260

Section F

1 - 3

Issue 3*

Technical Data

Tyre Pressures

Note: If the tyres fitted to your machine are not listed, then contact JCB for advice, DO NOT guess tyre pressures.

Two Wheel Steer Machines

Type Size Ply Pressure

bar lbf/in2

Front - 2WD

Ribbed (Armstrong) 11L x 16 12 4.4 64

Ribbed (Goodyear) 11.0 x 16 12 4.2 60Industrial 11L x 16 12 4.4 64

Industrial 10.5 x 18 10 3.8 55

Industrial 12.0 x 18 12 3.5 50

Front - 4WD

† Industrial 14 x 17.5 10 3.8 55Traction 10.5 x 18 10 3.8 55

Industrial (Firestone) 12.0 x 18 12 3.5 50

Industrial (Olympic) 12.0 x 18 12 4.5 65Radial 335/80 x R18 XM27 3.5 50

Industrial 12.5/80 x 18 10 4.25 61

† Radial 335/80 - R20 XM27 3.0 43.5† Radial 12.5 - R20 XM27 3.0 43.5

Industrial 12.5/12.0 x 18 12 3.5 50

* Radial 340/80 x R18 3.2 46

Rear - 2WD & 4WD

Industrial 16.9 x 24 10 2.2 32* Industrial 16.9 x 24 12 2.2 32

Industrial 19.5L x 24 10 1.9 27.5

Industrial 19.5L x 24 12 2.3 33

Industrial 21L x 24 12 2.2 32

Traction (Goodyear) 18.4 x 26 12 2.5 36

Traction (Olympic) 18.4 x 26 12 2.0 29Industrial 18.4 x 26 12 2.0 29

* Traction 16.9 x 28 12 2.2 32

Industrial 16.9 x 28 12 2.2 32

Radial 16.9 - R28 XM27 3.1 45

Industrial 18.4 x 30 14 2.0 29

All Wheel Steer Machines

Front and Rear - 4WD

* Industrial 14.9 x 24 12 2.75 40

† Industrial 16.9 x 28 10 2.2 32† Industrial 16.9 x 28 12 2.6 38

* † Traction 16.9 x 28 12 2.6 38

† Industrial 16.9 x 28 14 2.6 38

* † Industrial 16.9 x 24 12 2.6 38

* † Radial (Michelin) 16.9 x R28 XM27 2.7 39

* † Radial (Goodyear) 16.9 x R28 2.5 36Radial 15.5 x 25 XTLA 2.5 36

Note: 12 ply tyres must be fitted on rear wheels when any backhoe attachment is used. For the correct pressure see the table

above. The front wheels from machine serial number 400001 are made from a stronger construction than front wheels fitted

prior to 400001. Wheels fitted to Backhoe Loaders prior to 400001 must not be used on the new Backhoe Loaders.

† Steering lock restriction stops must be fitted to 4 wheel drive machines that have this type of tyre fitted, consult your JCB

Distributor for advice.

*



1 - 4


9803/3260

Section F

1 - 4

Issue 4*

Technical Data

Syncro Shuttle

Description Combined torque converter, reverser, and gearbox unit with

integral parking brake.

Designation SS640 (4 wheel drive)

Weight (dry)

2WD 157 kg (346 lb)

4WD 176 kg (388 lb)

Number of Teeth Std Ratio Low Ratio

Transfer Gear 36 38

Layshaft 19 17

Gear Ratios Std Ratio Low Ratio

1st 5.56:1 6.56:1

2nd 3.45:1 4.06:1

3rd 1.83:1 1.90:1

4th 1.00:1 1.00:1

Torque Convertor (machines up to serial no. TBA)

Torque Converter Dia. 279mm (11in.)

Torque Multiplication at Stall 2.20:1 or 2.40:1 or 2.80:1

Torque Converter Colour Coded Dots 2 purple 2 Orange 3 Brown

1 White 1 Green

Minimum Engine Rev/Min at Converter Stall See page 1 - 8 and 1 - 9

Torque Convertor (machines from serial no. TBA)

Torque Converter Dia. 310 mm (12.2 in.)

Torque Converter Identification 12.2” - D 12.2” - P

Torque Multiplication at Stall 2.82:1 2.54:1

Torque Convertor Colour Coded Dots 2 Purple 2 Orange

1 Yellow 1 Yellow


Converter Pressures (in neutral) bar kgf/cm2 lbf/in2

Converter In at 50 deg.C 1000 rev/min 2.4 - 3.4 2.5 - 3.5 35 - 50

2000 rev/min 5.2 - 6.5 5.3 - 6.7 75 - 95


2000 rev/min 5.2 - 5.9 5.3 - 6.0 75 - 85

Converter Out at 50 deg.C 1000 rev/min 1.0 - 1.7 1.1 - 1.8 15 - 252000 rev/min 2.0 max 2.0 max 29 max

Converter Out at 100 deg.C 1000 rev/min 0.3 - 0.6 0.3 - 0.6 4.0 - 8.0

2000 rev/min 1.0 - 1.7 1.1 - 1.8 15 - 25

Converter Inlet Relief Valve Pressure (max.) 6.5 6.7 95

.....cont'd

*

*

*



1 - 5


9803/3260

Section F

1 - 5

Issue 3*

Technical Data

Syncro Shuttle (cont'd)

Lubrication Pressures (in neutral) bar kgf/cm2 lbf/in2

At 50 deg.C 1000 rev/min 0.2 - 0.3 0.2 - 0.4 3.0 - 5.02000 rev/min 0.4 - 0.7 0.4 - 0.7 6.0 - 10.0

At 100 deg.C 1000 rev/min 0.1 - 0.2 0.1 - 0.2 2.0 - 3.0

2000 rev/min 0.3 - 0.6 0.3 - 0.6 4.0 - 8.0

Main Line Pressure (in neutral) †

11inch convertor - m/c’s up to serial number TBA bar kgf/cm2 lbf/in2

At 50 deg. C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150

2000 rev/min 10.7 - 11.7 10.9 - 12.0 155 - 170

At 100 deg.C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150

2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150


12.2 inch convertor - m/c’s from serial number TBA bar kgf/cm2 lbf/in2

At 50 deg. C 1000 rev/min 9.7 - 12.8 9.8 - 13.0 140 - 185

2000 rev/min 11.4 - 14.1 11.6 - 14.4 165 - 205

At 100 deg.C 1000 rev/min 11.4 - 12.8 11.6 - 13.0 165 - 185

2000 rev/min 11.4 - 13.4 11.6 - 13.7 165 - 195

Clutch Pressures † All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2 ):

Flow Rates (in neutral) L/min US gal/min UK gal/minCooler at 50 deg.C 1000 rev/min 10.4 - 13.6 2.8 - 3.6 2.3 - 3.0

2000 rev/min 14.5 - 20.0 3.8 - 5.3 3.2 - 4.4

Cooler at 100 deg.C 1000 rev/min 10.2 - 12.5 2.7 - 3.3 2.3 - 2.8

2000 rev/min 22.7 - 26.1 6.0 - 6.9 5.0 - 5.7

Pump at 50 deg.C 1000 rev/min 11.0 - 15.0 2.9 - 4.0 2.5 - 3.3

2000 rev/min 22.5 - 29.5 6.0 - 7.8

† Note: For brand new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will

be slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2

).

*

*

*

*



1 - 6


9803/3260

Section F

1 - 6

Issue 3*

Technical Data

Powershift

Description Full electro-hydraulic transmission unit with input, reverse,

layshaft, mainshaft and 4 wheel drive clutch packs. Torque

converter and parking brake integral .

Designation PS740 (4 wheel drive)Weight (dry)

2WD 220 kg (484 lb)4WD 236 kg (519 lb)

Number of Teeth Std Ratio Low Ratio

Transfer Gear 45 46

Layshaft 18 16

Gear Ratios Std Ratio Low Ratio

1st 5.72:1 6.58:1

2nd 3.23:1 3.71:1

3rd 1.77:1 1.77:1

4th 1.00:1 1.00:1


Torque Converter Dia. 279mm (11in.)

Torque Multiplication at Stall 2.20:1 or 2.40:1 or 2.80:1

Torque Converter Colour Coded Dots 2 purple 2 Orange 3 Brown

1 White 1 Green



Torque Converter Dia. 310 mm (12.2 in.)

Torque Converter Identification 12.2” - D 12.2” - P

Torque Multiplication at Stall 2.82:1 2.54:1Torque Convertor Colour Coded Dots 2 Purple 2 Orange

1 Yellow 1 Yellow


Converter Pressures (in neutral) bar kgf/cm2 lbf/in2


2000 rev/min 4.8 - 6.2 4.9 - 6.3 70 - 90

Converter Out at 50 deg.C 1000 rev/min 1.9 - 2.3 1.9 - 2.3 27 - 33

2000 rev/min 2.3 - 2.7 2.3 - 2.7 33 - 39

Converter Inlet Relief Valve Pressure (max.) 6.5 6.7 95

..... continued

*

*

*



1 - 7


9803/3260

Section F

1 - 7

Issue 2*

Technical Data

Powershift (cont'd)

Lubrication Pressures (in neutral) bar kgf/cm2 lbf/in2

At 50 deg.C 1000 rev/min 0.14 - 0.28 0.14 - 0.28 2.0 - 4.0

2000 rev/min 0.28 - 0.55 0.28 - 0.56 4.0 - 8.0

Mainline Pressure (in neutral) †

11 inch convertor - m/c’s up to serial number TBA bar kgf/cm2 lbf/in2

At 50 deg. C 1000 rev/min 9.0 - 10.0 9.1 - 10.2 130 - 145

2000 rev/min 9.7 - 11.0 9.8 - 11.3 140 - 160


12.2 inch convertor - m/c’s from serial number TBA bar kgf/cm2 lbf/in2

At 50 deg. C 1000 rev/min 9.7 - 12.8 9.8 - 13.0 140 - 185

2000 rev/min 11.4 - 14.1 11.6 - 14.4 165 - 205

Clutch Pressures † All clutch pressures should be the same as Mainline Pressure to within 0.7 bar (10 lbf/in2 ):

Flow Rates (in neutral) litres/min US gal/min UK gal/min

Cooler at 50 deg.C 1000 rev/min 10.4 - 13.6 2.8 - 3.6 2.3 - 3.0

2000 rev/min 14.5 - 20.0 3.8 - 5.3 3.2 - 4.4

Pump at 50 deg.C 1000 rev/min 11.0 - 15.0 2.9 - 4.0 2.5 - 3.3

2000 rev/min 22.5 - 29.5 6.0 - 7.8 5.0 - 6.5

† Note: For brand new gearboxes (i.e. under 100 hours service), or gearboxes that have been fully serviced, the pressures will

be slightly higher than those shown (approximately 0.7 - 1.0 bar; 10 - 15 lbf/in2 ).*

*

*

*

*



1 - 8


9803/3260

Section F

1 - 8

Issue 4*

Technical Data

Pump/Transmission Stall Speed Combinations - All Wheel Steer Machines with 11 inch

Convertors

The figures given below and on the following page apply to 'bedded-in' engines, i.e. engines that have done a minimum of 250working hours, therefore they should not be used for PDI checks. They are intended to be used as guideline figures only and

should not be considered as servicing parameters.


4CX 4CX 4CX 4CX 217S214S option option N.Am.

215S Nordic Malasia

N.Am. Iceland

ServoPlus

Engine Stall Speed

1 Converter only

max r.p.m. 2170 2130 2160 2120 2100

min. r.p.m. 2100 2065 2085 2055 2030

2 Converter + MRV

max. r.p.m. 1795 1770 1685 1660 1640min. r.p.m. 1700 1670 1575 1550 1530

Build Specification

Engine Size N.A. (74 bhp)

T2 (90 bhp)

T3 (96 bhp) ● ● ● ● ●

Converter Type SSL 11 (2.8:1)

WH 11 (2.4:1) ● ● ● ● ●

W11 (2.2:1)

Pump Size 26 gal

(UK gals) 28 gal

30 gal ● ●

34 gal ● ● ●

Fan Ratio 1 to 1 ● ●

1 to 1.25 ● ●

1 to 1.36 ●

*



1 - 9


9803/3260

Section F

1 - 9

Issue 2*

Technical Data

P u m p / T r a n s m i s s i o n S t a l l S p e e d

C o m b i n a t i o n s - T w o W h e e

l S t e e r M a c h i n e s w i t h 1 1 i n c h C o n v e r t o r s

N o t e : A l l t e s t s c o n d u c t e d w i t h s i n g l e p u m p o

p t i o n s e l e c t e d u n l e s s s p e c i f i e d t h u s #

, t h e n t e s t s t o b e c o n d u c t e d w i t h d o u b l e p u m p o p t i o n s e l e c t e d .

3 C X

3 C X

2 1 4

3 C X T

3 C X T

3 C X T +

3 C X T +

3 C X T

3 C

X T

2 1 4 T

2 1 5

2 1 7

N . A m .

o p t i o n

o p

t i o n

N . A m .

N . A m .

N . A m .

N o r d i c

S o

u t h

I c e l a n d

A f

r i c a

E n g i n e S t a l l S p e e d

1

C o n v

e r t o r O n l y

m a x r . p . m .

1 7 5 5

1 7 3 5

2 2 1 5 #

1 9 0 0

1 8 7 5

1 8 9 0

1 8 7 0

1 8 8 0

1 8

6 0

2 0 7 0

2 0 6 5

1 9 1 5

m i n r . p . m .

1 6 9 5

1 6 7 0

2 1 4 5 #

1 8 3 0

1 8 1 0

1 8 2 0

1 8 0 0

1 8 1 0

1 7

9 0

2 0 0 0

1 9 9 5

1 8 4 0

2

C o n v

e r t o r + M R V

m a x r . p . m .

1 3 6 0

1 3 4 0

1 8 3 0 #

1 5 2 5

1 5 1 0

1 5 1 5

1 4 9 5

1 3 8 0

1 3

6 5

1 7 3 0

1 6 7 5

1 4 6 5

m i n r . p . m .

1 2 6 0

1 2 4 5

1 7 3 0 #

1 4 2 0

1 4 0 5

1 4 1 0

1 3 9 0

1 2 2 0

1 2

0 0

1 6 3 0

1 5 7 0

1 3 4 5

B u i l d S p

e c i f i c a t i o n

E n g i n e S

i z e

N . A . ( 7 4 b h p )

●

●

●

T 2 ( 9 0 b h p )

●

●

●

●

●

●

●

●

T 3 ( 9 6 b h p )

●

C o n v e r t o r T y p e

S S L 1 1 ( 2 . 8 : 1 )

●

W H 1 1 ( 2 . 4 : 1 )

●

●

W 1 1 ( 2 . 2 : 1 )

●

●

●

●

●

●

●

●

●

P u m p S i z e

2 6 U K g a l .

●

●

●

●

( U . K . g a l s )

2 8 U K g a l .

●

●

3 0 U K g a l .

●

●

●

3 4 U K g a l .

●

●

●

F a n R a t i o

1 t o 1

●

●

●

●

1 t o 1 . 2 5

●

●

●

●

●

●

●

1 t o 1 . 3 6

●

*



1 - 10


9803/3260

Section F

1 - 10

Issue 2

Technical Data

Pump/Transmission Stall Speed Combinations - All Wheel Steer Machines with 12.2 inch

Convertors

NOTE. All tests conducted with single pump option selected

4C/4CN

4CX 4CX 4CX 4CX 217S 3CXSup. 3CXSup.

4CXSup. 214S option option U.S.A.

215S Nordic MalaysiaIceland

Engine Speed @ Stall Combination.

1.Convertor only.

Max.r.p.m. 2100 2065 2085 2060 2035 2040 2010Min.r.p.m. 2000 1970 1990 1960 1940 1935 1905

2.Convertor + M.R.V.Max.r.p.m. 1755 1730 1660 1640 1625 1635 1610

Min.r.p.m. 1665 1650 1570 1550 1530 1510 1485

Std. or High Lift Excavator

Build specification.

Engine size.

N.A.(74)T2(90) ● ●

T3(96) ● ● ● ● ●

Convertor type.

12.2D(2.82)12.2P(2.54) ● ● ● ● ● ● ●

Pump size.24 gal.

26 gal.

28 gal.

30 gal. ● ● ● ●

34 gal. ● ● ●

Fan Ratio.

1 to 1 ● ● ●

1 to 1.25 ● ● ●

1 to 1.36 ●



1 - 11


9803/3260

Section F

1 - 11

Issue 1

Technical Data

P u m p / T r

a n s m i s s i o n S t a l l S p e e d C o m b i n a t i o n s - T w o W h e e l S

t e e r M a c h i n e s w i t h 1 2 . 2 i n c h C o n v e r t o r s

N o t e . A l l t e

s t s c o n d u c t e d w i t h s i n g l e p u m p o p t i o n s e l e c t e d .

2 1 4 E

3 C X

3 C X

2 1 4

2 1 4

3 C X

3 C X . T

3 C X . T

3 C X S M +

3 C X S M +

3 C X . T

3 C X . T

2 1 4 T

2 1 5

2 1 7

U . S . A .

U . S . A .

U . S . A .

M a l a y s i a

o p t i o n

o p t i o n

U . S . A .

U . S . A .

U . S . A .

N o r d i c

S o u t h

I c e l a n d

A f r i c a

E n g i n e S p e

e d @ S t a l l C o m b i n a t i o n .

1 . C o n v e r t o r o n l y .

M a x . r . p . m .

2 1 0 5

1 8 9 5

1 8 7 0

2 1 2 0

2 1 2 0

1 8 6 0

2 0 5 0

2 0 2 0

2 0 4 0

2 0 1 0

2 0 2 5

1 9 9 5

2 0 1 0

2 0 1

0

2 0 3 5

M i n . r . p . m .

2 0 0 5

1 8 0 0

1 7 7 5

2 0 1 5

2 0 1 5

1 7 6 0

1 9 5 0

1 9 1 5

1 9 3 5

1 9 0 5

1 9 2 5

1 8 9 5

1 9 0 5

1 9 0

5

1 9 4 0

2 . C o n v e r t o r + M . R . V .

M a x . r . p . m .

1 3 6 5

1 4 7 0

1 4 5 0

1 7 1 0

1 6 4 5

1 4 3 5

1 6 5 0

1 6 2 5

1 6 3 5

1 6 1 0

1 4 8 0

1 4 5 0

1 6 1 0

1 6 1

0

1 6 2 5

M i n . r . p . m .

1 1 9 5

1 3 7 0

1 3 5 0

1 6 1 5

1 5 4 0

1 3 3 5

1 5 2 5

1 5 0 0

1 5 1 0

1 4 8 5

1 3 1 0

1 2 8 0

1 4 8 5

1 4 8

5

1 5 3 0

S t d . o r H i g h

L i f t E x c a v a t o r

H i g h

H i g h

H i g

h

B u i l d s p e c i f i c a t i o n .

E n g i n e s i z e .

N . A . ( 7 4 )

●

●

●

●

●

●

T 2 ( 9 0 )

●

●

●

●

●

●

●

●

T 3 ( 9 6 )

●

C o n v e r t o r t y p e .

1 2 . 2 D ( 2 . 8 2 )

●

●

●

1 2 . 2 P ( 2 . 5 4 )

●

●

●

●

●

●

●

●

●

●

●

●

P u m p s i z e .

2 4 g a l .

●

2 6 g a l .

●

●

●

●

2 8 g a l .

●

3 0 g a l .

●

●

●

●

●

●

3 4 g a l .

●

●

●

F a n R a t i o .

1 t o 1

●

●

●

●

1 t o 1 . 2 5

●

●

●

●

●

●

●

●

●

●

1 t o 1 . 3 6

●



1 - 12


9803/3260

Section F

1 - 12

Issue 1

Towing Procedure

Syncro Shuttle & Powershift Gearbox

If there is no transmission damage, the machine may be towed for a distance of approximately 1.5 kilometres (1 mile). Always

use a rigid tow bar, ensure that the gear lever is in neutral (applicable to Syncro Shuttle machines only). Restrict towing speedto 25 k.p.h. (15 m.p.h.).

If it is necessary to tow the machine for a distance in excess of 1.5 kilometres (1 mile) the propshafts should be disconnected

to prevent damage to the transmission system.

!WARNINGWhen the rear propshaft is disconnected the parking brake will not function. It is essential that the following procedure

be adopted.TRAN 1-5

Position the machine on firm level ground and block the wheels securely to prevent any movement. Select neutral (SyncroShuttle machines only) and release the parking brake.

Disconnect the rear propshaft from the axle, and tie up the shaft securely well clear of the rotating axle yoke. Alternatively

remove the shaft completely.

Connect the towing vehicle via the towbar BEFORE removing the blocks from the wheels. Restrict the towing speed to 25k.p.h. (15 m.p.h.).

When towing is complete, block the wheels securely BEFORE removing the towbar and reconnecting the propshafts.

Important: In some countries neither of the above procedures may be legally acceptable for towing on public highways.



W h

e n e i t h e r f o r w a r d o r r e v e r s e i s s e

l e c t e d , t h e

s o l e n o i d v a l v e E

d i v e r t s p r e s s u r i s e d

o i l v i a t h e

r e v

e r s e r s h a f t t o t h e a p p r o p r i a t e c l u t c h i n t h e

r e v

e r s e r u n i t A . A r e s t r i c t o r o r i f i c e P i n

t h e f e e d t o

t h e

s o l e n o i d v a l v e m o d u l a t e s t h e p r e s

s u r e t o t h e

c l u

t c h t o g i v e a s m o o t h e n g a g e m e n t . P r

e s s u r e f r o m

t h e

o t h e r c l u t c h i s v e n t e d b a c k t o t h e s

u m p v i a t h e

s o l e n o i d v a l v e s p o o l .

Transmission

9803/3260 Issue 1

S y n c r o S h u t t l e G e a r b o x

G e n e r a l

D e s c r i p t i o n a n d O p e r a t i o n

T h e J C B S y n c r o S h u t t l e c o n s i s t s o f a t

o r q u e

c o n v e r t e r , h y d r a u l i c r e v e r s e r u n i t , a n d i n

t e g r a l

m a n u a l 4 - s p e e d g e a r b o x .

T h e r e v

e r s e r u n i t A

h a s a p a i r o f h y d r a u

l i c a l l y

o p e r a t e d

c l u t c h e s g i v i n g f o r w a r d - n e u t r a l - r e v e r s e

d r i v e . O i l p r e s s u r e i s p r o v i d e d b y a c r e s c e n

t t y p e

p u m p B

d r i v e n a t e n g i n e s p e e d b y t h e d r i v e l u g s o f

t h e t o r q u e c o n v e r t e r C . T h e o i l p r e s s u r e i s

c o n t r o l l e d b y m a i n t e n a n c e v a l v e D , a n d c l u t c h

s e l e c t i o

n i s a c h i e v e d b y m e a n s o f a n e l e c t r i c

s o l e n o i d

v a l v e E .

D r i v e i s t r a n s f e r r e d f r o m

t h e r e v e r s e r u n i t b y

h e l i c a l

g e a r s t o

t h e m a i n s h a f t F , w h i c h c a r r i e s t h e 3

r d / 4 t h

s y n c h r o m e s h u n i t G , a n d t o t h e l a y s h a f t H ,

w h i c h

c a r r i e s

t h e 1 s t / 2 n d s y n c h r o m e s h u n i t J

. T h e

s y n c h r o m e s h u n i t s a r e o f t h e ' B l o c k i n g P i n ' t y p e , a

f u l l d e s c

r i p t i o n o f w h i c h i s g i v e n o n P a g e s F

/ 3 - 3

a n d F / 3 - 4 .

D r i v e i s t r a n s m i t t e d f i n a l l y v i a t h e o u t p u t s h a f t K

t o

t h e r e a r

a x l e . I f 4 w h e e l d r i v e i s s e l e c t e d , t h e f r o n t

w h e e l s a r e a l s o d r i v e n v i a 4 w h e e l d r i v e o u t p u t

f l a n g e L . A f u l l d e s c r i p t i o n o f 2 / 4 w h e e l d r i v e

c l u t c h

o p e r a t i o n i s g i v e n o n p a g e s F / 3 - 6 a n d F / 3 - 7 .

O i l f r o m

t h e p u m p B

i s f e d t h r o u g h a n i n t e r n a l

p a s s a g e

v i a

t h e f i l

t e r M

t o

t h e

p r e s s u r e

m a i n t e n a n c e v a l v e D , w

h i c h m a i n t a i n s p r e s s u r e t o

t h e s o l e n o i d v a l v e E

f o r

c l u t c h s e l e c t i o n . E x c e s s o i l

f r o m

t h e m a i n t e n a n c e v a l v e f l o w s b a c k t h r o u g h t h e

c a s i n g t o t h e t o r q u e

c o n v e r t e r . O i l e n t e r s t h e

c o n v e r t e r b e t w e e n t h e c

o n v e r t e r h u b a n d t h e s t a t o r

s u p p o r t , a n d l e a v e s b e t w e e n t h e s t a t o r a n d t h e

i n p u t s h a f t . P r e s s u r e i n

t h e c o n v e r t e r i s c o n t r o l l e d

b y r e l i e f v a l v e N

w h

i c h d u m p s o i l f r o m

t h e

c o n v e r t e r l i n e b a c k t o t h

e s u m p .

O i l f r o m

t h e t o r q u e c o n v e r t e r f l o w s o u t o f t h e

t r a n s m i s s i o n t o t h e e x t e r n a l o i l c o o l e r , r e t u r n i n g a t

t h e r e a r o f t h e t r a n s m i s s

i o n u n i t t o p a s s t h r o u g h t h e

c e n t r e o f t h e r e v e r s e r s h

a f t f o r c l u t c h l u b r i c a t i o n .

I n n e u t r a l t h e f l o w o f t h e p r e s s u r i s e d o i l i s b l o c k e d

a t t h e s o l e n o i d v a l v e .


Section F Section F



3 - 3


9803/3260

Section F

3 - 3

Issue 1

Descriptions



3 - 4

Synchromesh

Description

The gearbox is fitted with 'Blocking Pin' synchromesh,

comprising the following parts.

SYNCHRO HUB (A) controls the operation of the

synchromesh unit and gear selection, the selector fork fitting

into the outer groove. Internal dog teeth link the selected

gear to the drive shaft. Through the synchro hub centre are

two sets of holes for the blocker pins ( C ) and the spli t

energiser pins ( D ), spaced alternately.

SYNCHRO RINGS (B) are rigidly joined by the blocker pins,

with the split energiser pins held, in counterbores, between

the two synchro rings.

BLOCKER PINS (C) have a narrow neck in the centre,

against which the synchro hub transmits radial drive during

gear changes. The edges of the blocker pin neck and theirmating synchro hub holes are designed so that, as the radial

loads are reduced, the synchro hub can slide over the

shoulder of the blocker pin.

SPLIT ENERGISER PINS (D) take the initial axial load of the

synchro hub on the shoulder of the split energiser pin neck.

As the axial load reaches approximately 400 N (40.8 kg; 90lb) the internal springs allow the split energiser pin to

collapse and the synchro hub to move axially.

SYNCHRO CUPS (E) take the frictional drive from the

Operation

Diagram F shows the gearbox with first gear engaged.

Synchro ring B is in contact with synchro cup E and thesynchro hub dog teeth are linking first gear to the shaft gear.

In this position the split energiser pins D are 'collapsed'.

When selecting second gear the synchro hub A slides along

the split energiser pins until the pin recess and the synchro

hub flange are in line. At this point the split energiser pins

open and the synchro rings are moved by the synchro hub

pushing on the split energiser pin shoulder.

Initial contact between the synchro ring and the synchro cupstarts to synchronise the speed of the shaft and second

gear. The rotational force of the synchro ring is taken by the

blocker pin against the edge of the synchro hub hole, as at

G.

As the axial load on the synchro hub increases, the split

energiser pin 'collapses' and the conical faces of theblocking pin and synchro hub hole come into contact, as at

H.

Further increases in the axial loads increase the frictional

grip of the synchro ring and the synchro cup, causing the

shaft and gear speeds to synchronise.

As the speeds are synchronised the radial load on the

blocker pin and the synchro hub is reduced. This allows thesynchro hub to slide freely along the blocker pin and engage

its dog teeth with second gear, see diagram J.


9803/3260

Section F

3 - 4

Issue 1

Descriptions



Transmission

9803/3260 Issue 2


Section F Section F



Transmission

9803/3260 Issue 1

P o w e r s h i f t T r a n s m i s s i o n

5 t h G e

a r - 5 - S p e e d G e a r b o x e s O

n l y

T h e d r i v e f o r t h e 5 t h g e a r i s t r a n s m i t t e d b y c o

n s t a n t

m e s h f r o

m

g e a r ( i t e m

1 ) t h r o u g h t r a n s f e r g e a

r ( i t e m

2 ) t o t h e

5 t h s p e e d c l u t c h a s s e m b l y ( i t e m 3 ) .

I f t h e

c l u t c h p a c k i s n o t p r e s s u r i s e d ,

t h e 5 t h g e a r ( i t e m

6 )

i s m e s h e d a n d f r e e l y r o t a t i n g w i t h i n p u t g e a

r ( i t e m

9 ) - b u t n

o d r i v e i s b e i n g t r a n s f e r r e d .

G e a r ( i t e

m

1 ) i s m o u n t e d o n t h e i n p u t r e v e r s e

r s h a f t

( i t e m

4 ) a n d i s d r i v e n v i a t h e t o r q u e c o n v e r t e

r . T h e

c o n v e r t e

r h a s a n a d d i t i o n a l i n t e g r a l s p l i n e d

s p i g o t

w h e n c o m p a r e d t o a ' s t a n d a r d ' c o n v e r t e

r , t h i s

a d d i t i o n

a l s p l i n e i s u s e d t o d i r e c t l y d r i v e g e a r

a s s e m b l y ( i t e m 1 ) v i a g e a r ( i t e m 5 ) .

T h e c o n

s t a n t m e s h i n g g e a r s w i l l f r e e l y r o t a t

e u n t i l

t h e 5 t h s

p e e d c l u t c h s o l e n o i d ( i t e m

7 ) i s e n e r g i s e d .

W h e n t h

e s o l e n o i d i s e n e r g i s e d , p r e s s u r i s e d

o i l i s

d i v e r t e d

v i a a s o l e n o i d s p o o l t o t h e 5 t h s p e e d

c l u t c h ( i t

e m 3 ) .

T h e c l u t c h w o r k s o n a s i m i l a r p r i n c i p l e t o t h e

n o r m a l

' r e v e r s e r ' c l u t c h f o u n d i n t h e s t a

n d a r d

s y n c r o s

h u t t l e t r a n s m i s s i o n ( s e e p a g e F / 3 - 5

) , t h a t

i s ,

t h e p r e s s u r i s e d o i l e n t e r s t h e c l u t c h a n d f o

r c e s a

p i s t o n a

g a i n s t a f r i c t i o n / c o u n t e r p l a t e a s s e m b l y .

B e c a u s e t h e f r i c t i o n / c o u n t e r p l a t e s a r e f o r c e d

t o g e t h e r , d r i v e i s t r a n s m i t t e d t h r o u g h t h e

c l u t c h

p a c k t o t h e 5 t h g e a r ( i t e m 6 ) .

W h e n 5 t h g e a r i s s e l e c t e d ,

t h e 5 t h s p e e d

c l u t c h

( i t e m 3 )

A N D

t h e m a i n s h a f t c l u t c h ( i t e m

8 ) a r e

p r e s s u r i s e d , p a g e F / 6 - 7 s h o w s t h e d r i v e p a t h

f o r t h e

5 t h g e a r .

W h e n

t h e

s o l e n o i d

i s

d e - e n e r g i s e d

,

t h e

f r i c t i o n / c o u n t e r p l a t e s f r e e l y r o t a t e ,

t h e r e f o r e n o

d r i v e i s t

r a n s m i t t e d t h r o u g h t h e 5 t h g e a r ( i t e m

6 ) .


Section F Section F

S 2 3 5 6 4 0

A 2 3 5 6 6 1

➆

1

5

2

3

6

4

8

9



6 - 1


9803/3260

Section F

6 - 1

Issue 1

Descriptions



Powershift - Drivepaths

Figure 1 - 1st GEAR FORWARD (4 Wheel Drive)

Clutches Engaged Solenoids Active

F - Forward Low Ratio F - Forward Low

H - Layshaft H - Layshaft

K - 2/4 wheel drive (see note)

Note: Powershift transmissions installed in machines prior to serial number 415012 have the 4-wheel drive clutch spring

loaded in the 'on' position to give 4WD, as shown at K . On machines after serial number 415012, the clutch must be

pressurised to select 4WD. Refer to pages F/3-6 to F/3-9 for a description of the 4-wheel drive clutch operation.

Figure 2 - 2nd GEAR FORWARD (4 Wheel Drive)


E - Forward High Ratio E - Forward High


K - 2/4 wheel drive (see note above)

6 - 2


9803/3260

Section F

6 - 2

Issue 2*

Descriptions

*

*

*



6 - 3


9803/3260

Section F

6 - 3

Issue 1

Descriptions



Powershift - Drivepaths (cont'd)

Figure 3 - 3rd GEAR FORWARD (4 Wheel Drive)



G - Mainshaft G - Mainshaft

K - 2/4 wheel drive (see note)

Note: Powershift transmissions installed in machines prior to serial number 415012 have the 4-wheel drive clutch spring

loaded in the 'on' position to give 4WD, as shown at K . On machines after serial number 415012, the clutch must be

pressurised to select 4WD. Refer to pages F/3-6 to F/3-9 for a description of the 4-wheel drive clutch operation.

Figure 4 - 4th GEAR FORWARD (4 Wheel Drive)


E - Forward High Ratio E - Forward High


K - 2/4 Wheel Drive

Note that when 4th gear is selected, the 2/4 wheel drive clutch solenoid K is automatically energised, which therefore places

the transmission in 2 wheel drive (only applicable on machines up to serial number 409435). Refer also to the note above.

6 - 4


9803/3260

Section F

6 - 4

Issue 2*

Descriptions

*

*

*



6 - 5


9803/3260

Section F

6 - 5

Issue 1

Descriptions




Figure 5 - 1st GEAR FORWARD (2 Wheel Drive)




K - 2/4 Wheel Drive

Note that the 2/4 wheel drive clutch has been pressurised via solenoid valve K and therefore disengaged.

Note: Powershift transmissions installed in machines prior to serial number 415012 have the 4-wheel drive clutch springloaded in the 'on' position to give 4WD. On machines after serial number 415012, the clutch must be pressurised to select

4WD. Refer to pages F/3-6 to F/3-9 for a description of the 4-wheel drive clutch operation.

Figure 6 - 1st GEAR REVERSE (4 Wheel Drive)


I - Reverse Low Ratio I - Reverse Low


K - 2/4 wheel drive (see note above)

Note that reverse drive is achieved through the meshing of spur gears Z.

6 - 6


9803/3260

Section F

6 - 6

Issue 2*

Descriptions

*

*




Figure 7 - 5th GEAR FORWARD - 5 SPEED GEARBOX ONLY



L - 5th Speed L - 5th Speed

For 5-speed gearboxes the 1st, 2nd, 3rd and 4th gear clutch/solenoid combinations are the same as described on the previous

pages. Refer also to page F/5-3 for 5th speed drive description. Note that the 2/4 wheel drive clutch must be pressurised to

give 4 wheel drive.

6 - 7


9803/3260

Section F

6 - 7

Issue 1

Descriptions

G

L

L

G

Sxxxxxx

S



12 - 1


9803/3260

Section F

12 - 1

Issue 1

Fault Finding

Syncro Shutt le Gearbox

Before carrying out the checks listed the machine should, if possible, be operated to determine the fault area(s), and bring the

systems to their normal working temperatures.

Ensure that the correct quantity and grade of oil is used and that there are no obvious leaks.

A If the transmission is noisy, start at check 1.

B If the transmission is overheating, start at check 4.

C If the transmission will not pull, start at check 12.

D If there is no drive in one or both directions, start at check 17.

E If the transmission is jumping out of gear, start at check 29.

F If the transmission is sticking in gear, start at check 39.

G If ratios are 'crash changing', start at check 41.

CHECK ACTION

1 Is there noise when selecting direction? YES: Check 3

NO: Check 2

2 Is there noise when running with direction selector YES: Check 9

in neutral and ratio selector in 1st? NO: Check 19

3 Is there air in the hydraulic system? YES: Continue running to expel air.

NO: Check 4

4 Is the fluid level correct? YES: Check 5NO: Check level only when machine is cold and top-up as

required.

5 Are the oil passages restricted? YES: Clear the restriction.

NO: Check 6

6 Is the suction strainer restricted? YES: Remove and clean strainer.

NO: Check 7

7 Is pump pressure as specified? YES: Check 9

NO: Check clutch pressure maintenance valve is free tooperate.

8 When flow testing pump, is output low? YES: Renew pump.

NO: Check converter sprag clutch for wear or slip.

9 Does the noise continue when direction selector YES: Check 10

is in forward or reverse? NO: Check 11

10 Is transmission misaligned? YES: Renew mountings and check position.

NO: Check 'converter out' pressure and flow.

11 Are the pump bushes worn? YES: Renew

NO: Check converter for wear or cooler for restriction to

flow.

12 Is the transmission not pulling in one direction only? YES: Check 16



12 - 2


9803/3260

Section F

12 - 2

Issue 1

Fault Finding

Syncro Shuttle Gearbox (cont'd)

CHECK ACTION

14 Is 'converter in' pressure as specified? YES: Check 15

NO: Inspect converter relief valve for damage. Check

cooler bypass valve pressure setting.

15 Is pump being driven by converter? YES: Check pump pressure.

NO: Renew damaged parts.

16 Are clutch sealing rings damaged? YES: Tap pressure gauge into clutch feed lines to monitor

pressure.

NO: Check clutch plates for damage.

17 Is there drive in one direction only? YES: Check 19NO: Check 18

18 Is the start switch in the run position and supplying YES: Check 19

current to the neutral start relay? NO: Rectify.

19 Is the fault only when the transmission is hot? YES: Dismantle solenoid and check components.

NO: Check microswitches, relay and wiring loom.

20 Is the noise a growl, hum or grinding? YES: Check gears for damage or wear.

NO: Check 21

21 Is the noise a hiss, thump or bumping? YES: Check bearings for damage or wear.

NO: Check 22

22 Is the noise a squeal? YES: Check free running gears for seizure.

NO: Check 23

23 Is the noise present when in neutral or when in gear? NEUTRAL: Check 24

IN GEAR: Check 27

24 Is the countershaft or its bearings worn or damaged? YES: Renew damaged parts.

NO: Check 25

25 Is there excessive backlash in the gears? YES: Adjust by checking shaft end float.

NO: Check 26

26 Is the mainshaft pilot bearing worn? YES: Renew.

NO: Check gear teeth for scuffing.

27 Is the mainshaft rear bearing worn? YES: Renew.

NO: Check 28

28 Are the sliding gear teeth worn or damaged? YES: Renew gears.

NO: Check 29

29 Are the selector forks loose? YES: Tighten screws.

NO: Check 30

30 Are the selector fork pads or grooves in gears worn? YES: Renew worn parts.

NO: Check 31



12 - 3


9803/3260

Section F

12 - 3

Issue 1

Fault Finding

Syncro Shuttle Gearbox (cont'd)

CHECK ACTION

33 Are the selector rods worn or damaged? YES: Renew.

NO: Check 34

34 Are the selector fork pads out of position? YES: Reposition or renew (check interlock).

NO: Check 35

35 Is there excessive end float in gears or shafts? YES: Adjust.

NO: Check thrust washers and mating faces.

36 Is the synchroniser bronze worn? YES: Renew synchro pack.

NO: Check 37

37 Are steel chips embedded in the bronze? YES: Continue using, chips will either embed below bronze

or be rejected.NO: Check 38

38 Are the synchroniser components damaged? YES: Renew.

NO: Check free running gears for seizure or damage.

39 Are the sliding gears tight on the splines? YES: Free or renew.

NO: Check 40

40 Are chips wedged between splines of shaft YES: Remove chips.

or gear? NO: Ensure that clutch is disengaged when dump pedal ispressed.

41 Are steel chips embedded in the bronze? YES: Continue using, chips will either embed below bronze

or be rejected.

NO: Check 42

42 Are the synchroniser spring pins damaged? YES: Renew synchro.

NO: Check 43

43 Is the synchroniser bronze worn? YES: Renew synchro.

NO: Check blocker pins.



2/4 Wheel Drive Clutch

2WD Cannot be Engaged

In normal operation the 2/4 wheel drive clutch is spring loaded and therefore engaged to give 4 wheel drive. The clutch mustbe pressurised to give 2 wheel drive. Before starting the more detailed fault finding procedures - eliminate the obvious:

1 Check that the transmission oil level is correct.

2 Check that the fuse (C3) for the 2/4WD circuit is intact.

3 Check that the 4-wheel drive external pipework is not damaged.

4 Check that all the electrical connections are clean and secure.

5 Check that the mainline pressure is correct (see 'Low Mainline Pressure').

6 Check that the pump flow rate is correct.

Possible Cause

7 Low mainline pressure

(Minimum pressure required to disengage 2/4WD clutch

is 8.6 bar; 125 lb/in2 ).

8 Low mainline pressure (due to 2/4WD clutch):

8.1 2/4WD solenoid spool sticking.

8.2 2/4WD solenoid permanently energised.

8.3 2/4WD solenoid spool O-ring failed.

8.4 Clutch shaft sealing rings leaking.

8.5 Excessive clutch shaft end float.

8.6 Wrong type clutch piston fitted.

8.7 Clutch piston O-ring failed.

9 Defective 2/4WD clutch:

9.1 Worn pressure plate

9.2 Worn actuating sleeve.

(Later machines have a new type of 2/4WD clutch fitted,

Remedy

7 Identify if the fault is related to the 2/4WD disconnect:

7.1 Disconnect the external pipework to the 2/4WD

clutch. Cap and plug open orifices.

7.2 Check the mainline pressure - if the pressure is

correct, the fault must be within the 2/4WD (see

step 8). If the reading is still low check the

transmission in the normal manner.

8 Rectify fault:

8.1 Strip, clean and re-assemble solenoid valve, renew

valve if required.

8.2 Check the 2/4WD relay and select switch, replace

as necessary.

8.3 Renew O-ring.

8.4 Renew clutch shaft sealing rings.

8.5 Rectify fault, renew parts as required, reset end

float (should not exceed 0.03 mm; 0.001 in)

8.6 Fit correct type clutch piston (ie, without bleed

hole).

8.7 Replace clutch piston O-ring.

9 Rectify fault:

9.1 Inspect pressure plate, renew as required.

9.2 Measure length of actuating sleeve and renew as

required, sleeve length should be:

4WD Cannot be Engaged

No pressure is required to engage 4WD (spring loaded). Check that the front wheel drive train is intact (ie propshaft and axle). Also check that the solenoid spool is not sticking (in the 2WD position). Finally check the 2/4 wheel drive switch and relays.

13 - 1


9803/7110

Section F

13 - 1

Issue 1

Fault Finding



14 - 1

Powershift Fault Finding - Introduction

The Powershift fault finding procedures concern themselves

with general problems normally associated with this type oftransmission system, and so the layout is a 'Possible Cause

and Remedy' type.

Full flow, pressure and stall testing procedures for the

Powershift transmission start on page F/91-1.

Before commencing with the fault finding procedure make

sure that the correct type of transmission fluid has been

used (JCB Special Transmission Fluid).

Powershift Fault Finding - Index

Page No.

Lack of Power 14 - 2

Low Mainline Pressure 14 - 2

High Stall Speeds (On All Clutches) 14 - 2

Low Stall Speeds (On All Clutches) 14 - 2

Low Converter Out Pressure 14 - 2

Low Pump Flow 14 - 2

High Converter Out Pressure 14 - 2

Low Lubrication Pressure 14 - 3

Low Clutch Pressure and/or Clutch Slipping 14 - 3

Overheating 14 - 3


9803/3260

Section F

14 - 1

Issue 2*

Fault Finding

*



14 - 2

Powershift Fault Finding

LACK OF POWER

Possible Cause Remedy

1 Poor engine condition. 1 Check and if necessary repair engine.2 Low oil level. 2 Top up system.

3 Worn pump. 3 Check and if necessary repair or renew pump.

4 Torque converter damage. 4 Check and if necessary repair or renew torque converter.

5 Low mainline pressure. 5 See fault 'Low Mainline Pressure'.6 Clutches slipping. 6 Check clutch pressures, check clutch piston rings.

7 Internal leakage. 7 Check internal cored galleries and the casting for porosity.

8 High stall speeds. 8 See fault 'High Stall Speeds (on ALL clutches)'.

9 Low stall speeds. 9 See fault 'Low Stall Speeds (on ALL clutches)'.

10 Overheating 10 See fault 'Overheating'.

LOW MAINLINE PRESSURE


1 Worn pump. 1 Check and if necessary repair or renew pump.2 Blocked suction strainer. 2 Clean suction strainer.

3 Pressure maintaining valve sticking/leaking. 3 Free off or renew valve.4 Oil aerated (foaming). 4 a) Internal leakage (cored galleries) - inspect/repair

transmission.

b) Dirty suction strainer - clean strainer.

c) High oil level - drain to proper level.

d) Incorrect grade of oil - drain then refill with correct oil.

5 Oil leak thru' 2/4WD circuit. 5 a) Check external pipework for 2/4WD circuit.b) Check 2/4WD (pressure) circuit - refer to 2/4 wheel drive

clutch fault finding procedure on pages F/13-1 or F/15-

1.

HIGH STALL SPEEDS (ON ALL CLUTCHES)


1 Damaged converter blades. 1 Check and if necessary repair or renew converter.

2 Clutches slipping. 2 Strip, inspect and fit new clutch friction/counter plates.

3 Internal leakage. 3 Check internal cored galleries and the casting for porosity.

LOW STALL SPEEDS (ON ALL CLUTCHES)


1 Poor engine condition. 1 Check and if necessary repair engine.

2 Torque converter reaction member clutch slipping. 2 Check and if necessary repair torque converter.

LOW CONVERTER OUT PRESSURE


1 Low mainline pressure. 1 See fault heading 'Low Mainline Pressure'.

2 Converter internal leakage. 2 Check and if necessary renew converter.

3 Converter relief valve faulty. 3 Check and if necessary repair relief valve.

4 Restriction in converter feed. 4 See item 10 in fault 'Overheating'.

LOW PUMP FLOW


1 Low oil level 1 Top up system.2 Blocked suction strainer. 2 Clean suction strainer.

3 Worn Pump. 3 Repair or renew pump

HIGH CONVERTER OUT PRESSUREPossible Cause Remedy

1 Oil cooler/lines blockage. 1 Clean cooler, free blockage.

2 Converter in pressure incorrect. 2 Check converter in pressure correct.


9803/3260

Section F

14 - 2

Issue 2*

Fault Finding

*

**



14 - 3

Powershift Fault Finding

LOW LUBRICATION PRESSURE


1 Low mainline pressure 1 See fault 'Low Mainline Pressure'.2 Oil cooler/lines blockage. 2 Clean cooler, free blockage.

3 Ruptured lubrication line. 3 Repair line.

4 Converter internal leakage. 4 Check and if necessary renew converter.

5 Converter relief valve faulty. 5 Check and if necessary repair or renew relief valve.6 Leak at pump to case joint (indicated by low cooler flow) 6 Check and if necessary repair or replace as necessary.

7 Restriction in converter feed 7 See item 10 in fault 'Overheating'

LOW CLUTCH PRESSURE AND/OR CLUTCH SLIPPING


1 Low mainline pressure. 1 See fault heading 'Low Mainline Pressure'.2 Worn pump. 2 Check flow and if necessary repair or renew pump.

3 Blocked restrictor orifice in solenoid valve block. 3 Remove solenoid(s) and clear restriction in solenoid

valve block.

4 Clutch seals worn. 4 Confirm with a clutch leak test, if required renew clutchseals.

5 Clutch piston rings worn. 5 Confirm with a clutch leak test, renew piston rings.6 Mechanical failure. 6 Strip and rebuild clutch, renew parts as required.

OVERHEATING


1 Low oil level. 1 Top up system.

2 High oil level. 2 Drain oil to correct level.

3 Trapped or kinked hoses in cooler system. 3 Renew or repair hoses.

4 Low converter out pressure and flow rate. 4 Repair or renew the converter relief valve.

5 Oil cooler blockage. 5 Clean cooler.

6 Operating in wrong gear range usage. 6 Select correct gears to suit working conditions.7 Water system overheating. 7 Rectify water system problems, eg radiator, cooler lines,

low water level etc.

8 Oil aerated (foaming). 8 See fault 'Low Mainline Pressure', item 4.

9 Clutch piston(s) sticking on return stroke. 9 Check and repair clutch piston(s) and seal(s).

10 Cored galleries on front housing pump mounting

face wrong depth (indicated with an excessively lowpressure and flow on the converter out cooling line).

See illustration below. 10 Replace front housing (or rectify existing housing).

11 Leakage across pump mounting face and front case. 11 Check for damaged surface on both components and loose

pump mounting bolts.


9803/3260

Section F

14 - 3

Issue 2*

Fault Finding

S154080

**

***

*

*



15 - 1

2/4 Wheel Drive Clutch (from Machine No. 415012)

4WD CANNOT BE ENGAGED

In normal operation the 2/4 wheel drive clutch is spring loaded off and therefore disengaged to give 2 wheel drive. The clutch

must be pressurised to give 4 wheel drive. Before starting the more detailed fault finding procedures - eliminate the obvious:

1 Check that the transmission oil level is correct.

2 Check that the fuse (C3) for the 2/4WD circuit is intact.

3 Check that the 4-wheel drive external pipework is not damaged and that the drive train is intact.

4 Check that all the electrical connections are clean and secure. Also check that the solenoid spool is not sticking (in the

2WD position).

5 Check that the mainline pressure is correct (see 'Low Mainline Pressure').

6 Check that the pump flow rate is correct.

If the fault is not rectified after eliminating the obvious, check the following:


7 Low mainline pressure 7 Identify if the fault is related to the 2/4WD

disconnect:

7.1 Disconnect the external pipework to the 2/4WD

clutch. Cap and plug open orifices.

7.2 Check the mainline pressure - if the pressure is

correct, the fault must be within the 2/4WD

(see step 8). If the reading is still low check the

transmission in the normal manner.

8 Low mainline pressure (due to 2/4WD clutch): 8 Rectify fault:

8.1 2/4WD solenoid spool sticking. 8.1 Strip, clean and re-assemble solenoid valve,

renew valve if required.

8.2 2/4WD solenoid spool O-ring failed. 8.2 Renew O-ring.

8.3 Clutch shaft sealing rings leaking. 8.3 Renew clutch shaft sealing rings.

8.4 Excessive clutch shaft end float. 8.4 Rectify fault, renew parts as required, resetend float (should not exceed 0.03 mm; 0.001

in)

8.5 Wrong type clutch piston fitted. 8.5 Fit correct type clutch piston (ie, without bleed

hole).

8.6 Clutch piston O-ring failed. 8.6 Replace clutch piston O-ring.

9 Defective 2/4WD clutch: 9 Rectify fault:

9.1 Worn friction/counter plates 9.1 Inspect friction/counter plates, renew as

required.


9803/3260

Section F

15 - 1

Issue 1

Fault Finding



15 - 2

2/4 Wheel Drive Clutch (from Machine No. 415012) (cont'd)

2WD CANNOT BE ENGAGED

No pressure is required to engage 2WD(spring loaded). Check that the solenoid spool is not sticking (in the 4WD position), then

see below.


10 Incorrect type of solenoid valve fitted. 10 Check solenoid.

Note: Powershift and Syncro Shuttle machines

have different types of solenoid - check parts list.

11 Non-return valve faulty (noticeable because 2WD 11 Check the non-return valve.

cannot be engaged).

Note: NOT fitted on Powershift machines.

12 2/4WD solenoid permanently energised. 12 Check the 2/4WD relay and select switch, replace

as necessary.


9803/3260

Section F

15 - 2

Issue 1

Fault Finding



Transmission

9803/3260 Issue 1

F r o n t A x l e T o r q u e F i g u r e s

20 - 1 20 - 1Front Axle

Section F Section F

W h e e l N u t s -

6 8 0 N m

; 6 9 k g f m ; 5 0 0 l b f f t

D r a i n

& F i l l P l u g s -

7 9 N m ; 8 k g f m ; 6 0 l b f f t

C r o w n w h e e l R e t a i n i n g B o l t s -

A

W S M / c ’ s = 1 6 6 N m ; 1 6 . 9 k g f m ; 1 2 2 l b f f t

2 W S M / c ’ s = 9 4 N m ; 9 . 6 k g f m ;

7 0 l b f f t

T r u n n i o n B o l t s -

J C B

L o c k & S e a l

9 8 N m ; 1 0 k g f m ; 7 2 l b f f t

P r o p s h a f t R e t a i n i n g B o l t s ( 1 2 . 9 ) -

7 9 N m ; 8 k g f m ; 5 8 l b f f t

D r i v e h e a d B o l t s - J C B M u l t i - G a s k e t

A x

l e

B o l t

G r a d e

T o r q u

e

S D

5 5

M 1 0

8 . 8

5 6 N m

; 5 . 7 k g f m ; 4 2 l b f f t

S D

5 5

M 1 0

1 2 . 9

9 4 N m

; 9 . 6 k g f m ; 7 0 l b f f t

S D

7 0 , S D 8 0

M 1 2

8 . 8

9 8 N m

; 1 0 k g f m ; 7 2 l b f f t

S D

7 0 , S D 8 0

M 1 2

1 2 . 9

1 6 6 N m ; 1 7 k g f m ; 1 2 2 l b f f t

T y p i c a l a x l e s h o w n , t o r q u e f i g u r e s a p p l y t o A W S a n d 2 W S m a c h i n e s - d i f f e r e n c e s

a r e i n d i c a t e d i n

t e x t . W h

e n a p p r o p r i a t e , t h e g r a d e o f t h e b o l t i s i n d i c a t e d e i t h e r i n t h e t e x t o r i n p a r

e n t h e s i s , e . g .

‘ ( 1 2 . 9 ) ’ . R e f e r a l s o t o r e l e v a n t d i s m a n t l i n g a n d

a s s e m b l y p r o c e d u r e s .

S t a k e N u t -

S e e p a g e F / 2 2 - 1

S

1 6 1 4 4 0

P l a n e t C a r r i e r B o

l t s ( 8 . 8 ) -

J C B L o c k & S e a l

5 6 N m ; 6 k g f m ;

4 2 l b f f t

D i f f e r e n t i a l C a s e B o l t s - J C B L o c k & S e a l

M / C

G r a d e

T o r q u e

4 W

S

8 . 8

5 6 N m ; 5 . 7 k g f m ; 4 2 l b f f t

2 W

S

8 . 8

2 8 N m ; 2 . 9 k g f m ; 2 1 l b f f t

2 W

S

1 2 . 9

4 6 N m ; 4 . 7 k g f m ; 3 4 l b f f t



21 - 2


Note: The following procedure can be applied to both AWS

and 2WS machines. Dis-regard information not applicable toyour machine type, for instance, 2 wheel steer machines will

not have steering proximity switches fitted.


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 it.


started while you are beneath the machine.GEN 1-1

Removal


serious injury. Before working under raised loader arms,

fit the loader arm safety strut.GEN 3-2

1 Release screws J and remove the front grille.

2 Release bolts K and remove the proximity switch

bracket together with the proximity switch assembly.

3 Using tool 892/00822 remove bolts A to disconnect

the drive shaft from the axle.

4 Disconnect the hydraulic pipes B from the steer rams,

blank off all exposed connections.

5 Disconnect remote grease nipples H.

6 Loosen the road wheel retaining nuts D.

7 Make sure that the rear wheels are blocked, use the

loader arms to raise the front end of the machine.

8 Prop the machine on each side as shown at C.

9 Remove the front road wheels.

10 Position a jack underneath the balance point (see Note)

of the axle and support the axle weight.

Note: Because the drivehead assembly is offset, the balance

point of the axle is not the centre of the axle. Attach a

'cradle' to the jack that will partially embrace the axle.

11 Remove nut E and pivot pin retaining bolt F.

12 Use puller (tool no. 992/00800) and remove the pivot

pin G and axle shims.

13 Lower the jack so that the axle is clear of the mountingyoke and remove the axle.

Replacement

Replacement is the reverse of the removal sequence.

!WARNINGIf, for whatever reason, a wheel stud is renewed, all the

studs for that wheel must be changed as a set, since the

remaining studs may have been damaged.2-3-2-8

Whenever a wheel has been removed, check the wheel nut

torques every two hours until they stay correct.

Apply JCB Lock & Seal to the threads of bolts A .

The front axle must be shimmed to give a maximum fore andaft movement of 0.5mm (0.020 in.). If necessary add shims

to correct end float movement. The shims locate on the front

axle pivot pin G, in-between the front of the axle and the

axle yoke plate, as shown below.

#If the setting of the steering proximity switch has been

disturbed, then complete the front axle proximity switch

setting procedure, as described on page F/21-3.

Torque Settings


A 79 8 58

D 680 69 500


9803/3260

Section F

21 - 2

Issue 3*

Front Axle

*

*

S218110



21 - 3

Proximity Switch Setting Procedure


serious injury. Before working under raised loader arms,fit the loader arm safety strut.GEN 3-2

To set the front axle proximity switch:

1 Check wheels are in 'straight ahead' position asfollows:

2 Measure ram extension X (FIG 1), the measurement

should be the same for both the left and right hand

rams (on the front axle). If not, turn the steering wheel in

the required direction until the distances are equal forboth sides.

3 Adjust the proximity switch C (FIG 2) so that there is a

5mm (0.197in.) gap between the lower face of the

proximity switch and the top face of the sensor plate

(use 5mm [0.197in.] thick plate as a setting tool).

Note: The proximity switch to sensor plate setting figure

used to be 6mm (0.236in.). To improve performance, the

proximity switch is now set at 5mm (0.196in) above the

sensor plate.

4 Loosen the track rod sensing plate retaining bolts A

(FIG 2).

5 Move the sensor plate B (FIG 2) fully to the left then

gently adjust the plate to the right until the light emitting

diode (L.E.D.) on the proximity switch illuminates. Marktwo lines at each end of the slotted plate on the track

rod.

6 Move the sensor plate B (FIG 2) fully to the right then

gently adjust the plate to the left until the light emittingdiode (L.E.D.) on the proximity switch illuminates. Mark

two lines at each end of the slotted plate on the track

rod.

7 Set the sensor plate ends central to the markings madein steps 5 and 6 as shown at D (FIG 3).

8 Tighten the sensor plate retaining bolts A .

9 Fit the guard E (FIG 4), the guard must be set with 3mm

(0.125in) between the lower face of guard and top face

of the sensing plate B.


9803/3260

Section F

21 - 3

Issue 2

Front Axle

E

FIG 2

S186130

BA

C

FIG 3

S186160

D

FIG 4

S186120

B

±5mm (0.197in) Front

±6mm (0.236in) RearX

A 86 5

A186150

FIG 1



16 Remove and discard the wear ring; 'stretch' the ring bytapping the rubbing surface with a ball pein hammer,

then tap the ring off.

Note 1: Some axles have an O-ring fitted behind the wear

ring, remove and discard the O-ring if fitted.

Note 2: The latest type of axle has a combination seal fitted,

this seal is a combined oil seal and wear ring (no O-ring

required). When assembling the axle, a new combination

seal must be used.

17 Mark position of top and bottom trunnions H and

remove. Retain shims (see note 2) with each trunnion.Withdraw the hub carrier.

Note 1: Trunnions may be removed easily and without

damage to the shims by pumping grease through the grease

nipple.

Note 2: Later type axles are not fitted with shims (the top

face height of the swivel casting is increased by 1mm

(0.040in.). These castings are identified with a small drill

mark in the position shown at X (see illustration step 18 ).

18 Use adaptor 993/59500 with slide hammer tool

892/00224 and remove driveshaft seal and needle roller

bearing from the hub carrier.

19 Use a puller to remove the trunnion seal and bearing.

23 - 5


9803/3260

Section F

23 - 5

Issue 3*

Front Axle

Hub and Driveshaft - Dismantling (cont'd)

*

*

X

H

S248880

S248890

S248900



5 Fit driveshaft needle roller bearing to the hub carrier.Pack the cavity between the oil seal lips with grease

and then fit the seal.

6 Locate hub carrier and fit bottom trunnion. Apply JCB

Lock and Seal (part no. 4101/0202) to the bottomtrunnion bolt threads, fit and tighten to 98Nm (72 lbf ft).

Fit top trunnion and leave top trunnion bolts finger tight.

7 Attach a spring balance to track rod swivel as shown

and note the reading. Tighten the top trunnion bolts to

eliminate end float but no bearing pre-load, ie no

increase in spring balance reading.

8 Measure gap at top trunnion and subtract 1 mm (0.040

in) to give shim thickness (bearing pre-load).

For example:

Gap = 1.55 mm (0.061 in)less 1.00 mm (0.040 in)

Shim = 0.55 mm (0.021 in)

Note: Later type axles are not fitted with shims (the top face

height of the swivel casting is increased by 1mm (0.040in.).These castings are identified with a small drill mark in the

position shown at X (see illustration at step 5).

23 - 8


9803/3260

Section F

23 - 8

Issue 3*

Front Axle

Hub and Driveshaft - Assembly (cont'd)

*

S161460

X

S248890

S248860

S248850



S248850

A

B

9 Refit top trunnion. Apply JCB Lock and Seal to the toptrunnion bolt threads, fit and tighten to 98 Nm (72 lbf ft).

Check spring balance reading which should be 4.5 kgf

(10 lbf) more than the reading recorded at fig. 7.

10 Lightly oil the inner wheel bearing. Assemble the inner

and outer bearing cups, and the inner bearing cone into

the bearing carrier.

Measure the dimension between the wheel bearing face

and the outer face of the wheel bearing carrier.

If the dimension is 25 to 26mm (shown at A ) fit the oilseal by using service tool C (part number 892/00891)with the spacer D until the oil seal is level with the wheel

bearing carrier face as shown.

If the dimension is 28 to 30mm

(shown at B ) fi t the oi l seal by

using the service tool (but do notuse spacer). When fitted, the seal

will fit 2 to 3mm below the carrier

face as shown.

11 Fit the bearing carrier onto the axle arm. Lightly oil the

outer wheel bearing race. Fit the bearing onto the axle

arm. Rotate the bearing during fitting.

12 Assemble the annulus ring to the annulus carr ier.

Secure with the circlip G.

23 - 9


9803/3260

Section F

23 - 9

Issue 3*

S248920

S226311

S248910

Front Axle

*


G

C

D



13 Fit annulus assembly in the same angular position asremoval (see Note, page F/23 - 3, step 11) using new

'Verbus Ripp' bolts. Do not fully tighten bolts but allow

the bearing carrier to rock slightly. Measure seal dragrolling force - see step 14.

14 To measure seal drag rolling force:

- Refit the planet gear carrier - DO NOT FIT THE

DRIVESHAFT AND SUN GEAR.

- Use a spring balance and cord wrapped around the

planet carrier flange as shown.

- Pull the spring balance so that the hub rotates, do

several times to let the seal bed in and record the

reading.

- Remove planet gear carrier.

15 Tighten M14 Verbus Ripp bolts to 320 Nm (236 lbf ft, 33

kgf m) and then measure rolling force - see step 16.

16 To measure rolling force:

- Refit the planet gear carrier - DO NOT FIT THE

DRIVESHAFT AND SUN GEAR. Use a spring

balance and cord wrapped around the planet gear

carrier flange as shown. Pull the spring balance so

that the hub rotates and record the reading.

- To get the rolling force, subtract seal drag rolling

force (see step 14) from reading obtained at this

step, the result should be 14 to 152 N (3 to 34 lbf).

- If the resulting figure is outside these limits check:

the seal is fitted correctly; and/or renew bearings ifnecessary; and /or new fitted components.

- Remove planet gear carrier.

23 - 10


9803/3260

Section F

23 - 10

Issue 4*

Front Axle


*

S248540

S248540

S248870

S248870



24 - 1


9803/3260

Section F

24 - 1

Issue 1

Front Axle



24 - 2

Drive Head - Dismantling (All Wheel Steer

Machines)




1 Drain the oil from the axle centre casing. Remove the

propshaft from the gearbox to the front axle.

2 Remove both hub assemblies complete with

driveshafts (see pages F/23-1 to F/23-11).

3 Mark the installation position of the drive head carrier,

item 2.

4 Remove the drive head carrier retaining bolts, item 1,

and remove the drive head carrier 2 from the axle

casing.

5 Clean the drive head carrier and axle casing mating

faces.

6 Pull out tension pins 3 and 4, and remove castellated

nuts 5 and 6.

7 Remove bearing outer races 7 and 8.

8 Drive off the taper roller bearing cone 9 from the

crownwheel differential case half.

9 Remove the differential assembly 10 from the carrier.

10 Remove the differential assembly retaining bolts 11 and

separate case halves 12 and 13.

11 Remove the differential side gears and thrust washers

14 and 15 respectively (2 off each).

12 Remove planet gears and thrust washers 16 and 17

respectively (4 off each) from trunnion pins B.

13 Pull off taper roller bearing cone 18 from differential

case half 12.

14 Remove 'verbus ripp' bolts 19 and separate the

crownwheel 20 from the differential case half 13.

15 Use service tool 892/00812 to prevent drive flange 23

from rotating and remove pinion nut 21 and washer 22.

Remove the drive flange.

16 Press the pinion 24 from the drive head carrier 2.


9803/3260

Section F

24 - 2

Issue 2*

Front Axle

*



24 - 3

Drive Head - Assembly (Al l Wheel Steer

Machines)

Pinion Depth Setting Procedure

1 Place new pinion inner bearing 32 and outer race 29

(see page F/24-1) on a flat surface and position bearingcup 892/00174 over the bearing assembly.

2 Measure gap A (e.g. 0.20mm) and add this to the cup

depth stamped on the tool (e.g. 30.01mm) to obtain the

bearing depth.

3 From the face of the pinion, obtain the etched deviation

figure (e.g. + 2) which is in units of 0.01mm. If positive,add this to the bearing depth; if negative, subtract from

the bearing depth.

4 Obtain the deviation figure (e.g. —1) stamped on the

differential housing bolt flange. If negative, add to

bearing depth; if positive, subtract from bearing depth.

5 Subtract the total of the above figures from the

standard value of 31.19mm. The result will be the

thickness of shims required behind the pinion inner

bearing outer race.

Example (all dimensions in millimeters)

Cup Depth 30.01

Gap A + 0.20Bearing Depth 30.21

Pinion Deviation (+ 2) + 0.02

Housing Deviation (—1) + 0.01

Total 30.24

Standard Value 31.19

Less Total From Above 30.24

Shim Thickness 0.95

Note: In rare instances, it is possible that the setting data

stamp may be omitted from the drivehead casing. In thesecircumstances the following setting procedure should be

used:

Revise the shim pack size by the difference in setting height

marked on the old and new crownwheel and pinion sets.


9803/3260

Section F

24 - 3

Issue 2*

Front Axle

*



24 - 4


9803/3260

Section F

24 - 4

Issue 1

Front Axle



24 - 5


Machines)

Note 1: The crownwheel 20 and pinion 24 are matched and

should be renewed as a pair if either one is damaged orexcessively worn. The two differential case halves 12 and 13

are also matched as are gears 14 and 16. Do not use

unmatched halves or gears.

Make sure all bearings are lightly oiled before fitting andsetting. Make sure bearings are rotated whilst being set.

1 Fit to the drive head carrier 2 the pinion inner bearing

outer race 28 together with the required thickness of

shim(s) 29 to give correct pinion depth. (See Pinion

Depth Setting Procedure, page F/24-3). Fit the shims

behind the outer race as shown.

2 Fit new taper roller bearing cone 31 and a new

collapsible spacer 30 onto pinion 24.

3 Fit outer race 27 to the drive head carrier 2.

4 Insert the pinion 24 into its bore. (Before inserting,

ensure that the pinion matches the crownwheel. The

code numbers etched on the pinion end face and the

crownwheel perimeter should be the same).

5 Fit new taper roller bearing cone 26. Pack the cavity

between the lips of the new oil seal 25 with grease and

fit the seal to the drive head carrier 2.

6 Install the drive coupling yoke 23 and secure it with a

new stake nut 21 and washer 22:

6.1 Hold the yoke 23 with Service Tool 892/00812.

6.2 Tighten the stake nut until end float is almost zero

then check seal drag torque is between 0.40 to

0.75 Nm (3.5 to 6.6 lbf in).

6.3 Continue to tighten the stake nut to collapse

spacer 30 and give a rolling torque of 1.7 to 2.8 Nm

(1.3 to 2.1 lbf ft) excluding seal drag, crownwheel

not fitted.

IF THE STAKE NUT IS OVER-TIGHTENED, THE

COLLAPSIBLE SPACER MUST BE RENEWED.

Make sure that yoke 23 is rotated in both directions

to fully seat bearings before measuring rolling

torque.

6.4 When the torque is correct, stake the nut to thepinion shaft using a square ended staking tool,

shown at A.

9 Position top case half 12 onto bottom half assembly 13

aligning the match mark letters (see Note 1 opposite).

Apply JCB Lock & Seal to the threads of bolts 11 then

fit and torque tighten to 56 Nm (42 lbf ft; 6 kgf m).

Check the gears for free rotation.

10 Press taper roller bearing cone 18 onto the spigot of

case half 12.

11 Install the differential assembly 10 into the drive head

carrier 2.

12 Press taper roller bearing cone 9 onto the spigot of

case half 13.

13 Fit bearing outer races 7 and 8, castellated nuts 5 and 6

to the drive head carrier 2.

14 Adjust castellated nuts 5 and 6 to give a bearing pre-

load (see Note 2) of 1.36 to 2.5 Nm (1.0 to 1.84 lbf ft;

0.14 to 0.26 kgf m).

Note 2: Measure the pre-load by taking another rolling

torque reading and subtracting the torque figure measured

at step 6.3. The difference is the bearing pre-load.

15 Measure the crownwheel backlash which should be

0.13 to 0.2 mm (0.005 to 0.008 in). Adjust castellated

nuts 5 and 6 by equal amounts when altering backlash.When backlash and pre-load are both correct, fit

tension pins 3 and 4.

16 Verify crownwheel and pinion are set correctly: Use

engineers marker on three of the pinion teeth and

check markings on the crownwheel are as indicated on

page F/24-6. Adjust if necessary.

17 Apply JCB Mult i-Gasket to the drive head carrier

mating face then fit to the axle casing (the carrier

assembly locates on two dowels). Make sure the

assembly is fitted in the same match marked position(see step 3, dismantling, page F/24-2).

18 Apply JCB Lock & Seal to bolts 1 and torque tighten as

detailed in Notes 3 and 4.

19 Assemble both hub and driveshafts, refit the propshaft

to the gearbox.

20 Fill the axle with recommended oil.

Note 3: Torque tightening depends on bolt type. The grade

is stamped on the bolt head. If standard grade 8 bolt, tightento 98 Nm (72 lbf ft; 10 kg fm).

If Verbus Rip 12.9 grade bolt; tighten to 166 Nm (122 lbf ft;


9803/3260

Section F

24 - 5

Issue 3*

Front Axle

*

*

*



24 - 6

Crownwheel and Pinion Adjustment

Meshing of the gears should be checked by marking three ofthe pinion teeth with engineers marking compound and

rotating the pinion.

The marking will then be transferred to the crown wheel

teeth.


Machines)

Correct tooth marking.

Pinion too deeply in mesh.

Decrease the shim thickness between the pinion innerbearing cup and the axle casing. Move the crown wheel

towards the pinion to correct the backlash.

Pinion too far out of mesh.

Increase the shim thickness between the pinion innerbearing cup and the axle casing. Move the crown wheel

away from the pinion to correct the backlash.


9803/3260

Section F

24 - 6

Issue 2*

Front Axle

*



26 - 1

Removal and Replacement (2 Wheel Drive

Machines)

The removal and replacement procedures for the 2 wheel

drive axle (beam type) is the same as described on pages

F/21-1 and F/21-2. Dis-regard any information which is not

pertinent to the 2 wheel drive axle.

Please note when using a 'cradle' to remove the axle from

the machine, the balance point (see step 10, page F/21-2),

of the axle on 2 wheel drive machines will be the centre of

the axle, NOT offset as described on page F/21-2.


9803/3260

Section F

26 - 1

Issue 1

Front Axle




27 - 1

Bed in bearings 6 and 8 by rotating hub in each direction

whilst tightening nut 3. When correct torque setting has

been achieved, back off one flat and fit split pin 2.

Torque Settings


3 40† 4.0† 30†

9 30 3.0 21

11 30 3.0 21

† Back off one flat before fitting split pin.


9803/3260

Section F

27 - 1

Issue 1

Front Axle

Dismantling and Assembly (2 Wheel Drive

Machines)

When Dismantling



A suitable press will be required to remove and replace stub

axle 24.

When Assembling

Fit bushes 20 and 22 with open ends of grease grooves

facing the axle beam.

Add shims 18 as required to give zero to 0.1mm (0.004in)

clearance between axle beam and bearing 17.

Apply JCB Lock and Seal to threads of bolts 9 and 11.

Pack JCB Special MPL Grease into hubs 5 and between lips

of seals 7.



Transmission

9803/3260 Issue 1

R e a r A

x l e T o r q u e F i g u r e s

T y p i c a l a

x l e s h o w n , t o r q u e f i g u r e s a p p l y t o A W S a n d 2 W S m a c h i n e s - d i f f e r e n c e s a r e i n d i c a t e d i n

t e x t . W h e n a p p r o p r i a t e , t h e g r a d e o f t h e b o l t i s i n d i c a t e d e i t h e r i n t h e t e x t o r i n p a r e n t h e s i s , e . g .

‘ ( 1 2 . 9 ) ’ . R e f e r a l s o t o r e l e v a n t d i s m a n t l i n g a n d

a s s e m b l y p r o c e d u r e s .

40 - 1 40 - 1Rear Axle

Section F Section F

S 2 3 5 4 5 0

W h e e l N u t s -

6 8 0 N m

; 6 9 k g f m ; 5 0 0 l b f f t

T r u n n i o n B o l t s -


9 8 N m ; 1 0 k g f m ; 7 2 l b f f t

P r o

p s h a f t R e t a i n i n g B o l t s ( 1 2 . 9 ) -

7 9 N m ; 8 k g f m ; 5 8 l b f f t

D i f f e r e n t i a l C a s e B o l t s ( 8 . 8 ) -


5 6 N m ; 6 k g f m ; 4 2 l b f f t

A x l e A r m B o l t s -

J C B M u l t i - G a s k e t

G r a d e 8 . 8 - 2 4 4 N m ; 2 4 . 9 k g f m ; 1 7 8 l b f f t

G r a d e 1 2 . 9 - 4 0 0 N m ; 4 0 . 8 k g f m

; 2 9 5 l b f f t

S t a k e N u t -

S e e p a g e F / 2 2 - 1

D r a i n & F i l l P l u g s -

7 9 N m ; 8 k g f m ; 6 0 l b f f t

C

r o w n w h e e l R e t a i n i n g B o l t s ( 1 2 . 9 ) -

1 6 6 N m ; 1 6 . 9 k g f m ; 1 2 2 l b f f t

P l a n e t

C a r r i e r B o l t s ( 8 . 8 ) -

J C

B L o c k & S e a l

5 6 N m

; 6 k g f m ; 4 2 l b f f t

A x l e M o u n t i n g B o l t s -

6 0 7 N m ; 6 2 k g f m ; 4 4 8 l b f f t



41 - 1


9803/3260

Section F

41 - 1

Issue 1

Rear Axle



41 - 2



Position the machine on a firm, level surface beforeraising one end. Ensure the other end is securely





Removal

!WARNINGWhen the propshaft is disconnected the parking brake

will no longer function. The machine must be securely

chocked to prevent any machine movement before

disconnecting the propshaft.TRAN 1-3

Removing

1 Using tool 892/00822 remove bolts A to disconnect the

drive shaft from the axle.

2 Disconnect the brake pipes from the brake piston

housings, shown at H. Remove tee piece B retaining

bolt and remove the tee piece. Blank off exposed

connections.

3 Release bolts C and remove the proximity switchbracket together with the proximity switch assembly.

4 Label and then disconnect hydraulic pipes D from the

steer rams, blank off all exposed connections.

5 Loosen the road wheel retaining nuts E.

6 Make sure that the front wheels are blocked, use the

stabiliser legs to raise the rear end of the machine.

7 Prop the machine on each side as shown at F.

8 Remove the rear road wheels.

9 Position a jack underneath the balance point (centre) of

the axle and support the axle weight.

Note: Attach a 'cradle' to the jack that will partially embrace

the axle.

10 Remove nuts G, bolts J and washers K .

11 Lower the jack and remove the axle.

Replacement

Replacement is the reverse of the removal sequence.

!WARNINGIf, for whatever reason, a wheel stud is renewed, all the

studs for that wheel must be changed as a set, since the

remaining studs may have been damaged.2-3-2-8

Whenever a wheel has been removed, check the wheel nut

torques every two hours until they stay correct.

!WARNINGBleed the brake system before driving the machine.BRAK 1-6

Bleed the brake system as described on page G/11-1.

Apply JCB Lock & Seal to the threads of bolts A .

If the setting of the steering proximity switch has been

disturbed, then complete the rear axle proximity switch

setting procedure, as described on page F/41-3.

Torque Settings


A 79 8 58E 680 69 500

G 607 62 448


9803/3260

Section F

41 - 2

Issue 2*

Rear Axle

*



41 - 3

Proximity Switch Setting Procedure


Position the machine on a firm, level surface beforeraising one end. Ensure the other end is securely





To set the rear axle proximity switch:

1 Check wheels are in 'straight ahead' position as

follows:

2 Measure ram extension X (FIG 1), the measurement

should be the same for both the left and right hand

rams (on the rear axle). If not, turn the steering wheel in

the required direction until the distances are equal for

both sides.

3 Adjust the proximity switch C (FIG 2) so that there is a

5mm (0.197in.) gap between the lower face of the

proximity switch and the top face of the sensor plate

(use 5mm [0.197in.] thick plate as a setting tool).

Note: The proximity switch to sensor plate setting figure

used to be 6mm (0.236in.). To improve performance, theproximity switch is now set at 5mm (0.196in) above the

sensor plate.

4 Loosen the track rod sensing plate retaining bolts A

(FIG 2).

5 Move the sensor plate B (FIG 2) fully to the left then

gently adjust the plate to the right until the light emitting

diode (L.E.D.) on the proximity switch illuminates. Marktwo lines at each end of the slotted plate on the track

rod.

6 Move the sensor plate B (FIG 2) fully to the right then

gently adjust the plate to the left until the light emittingdiode (L.E.D.) on the proximity switch illuminates. Marktwo lines at each end of the slotted plate on the track

rod.

7 Set the sensor plate ends central to the markings made

in steps 5 and 6 as shown at D (FIG 3).

8 Tighten the sensor plate retaining bolts A .

9 Fit the guard E (FIG 4), the guard must be set with 3mm

(0.125in) between the lower face of guard and top face

of the sensing plate B.


9803/3260

Section F

41 - 3

Issue 2

Rear Axle

±5mm (0.197in) Front

±6mm (0.236in) RearX

A 86 5

FIG 1

E

FIG 2

S161290A

A

C

FIG 3

S161290B

D

FIG 4

S161290C

B

B



42 - 1

Renewing the Pinion Oil Seal

The procedure for renewing the rear axle pinion oil seal is the

same as for the front axle pinion oil seal. Please refer to

pages F/22-1 and F/22-2 for a full description of the

procedure.


9803/3260

Section F

42 - 1

Issue 1

Rear Axle





46 - 1


9803/3260

Section F

46 - 1

Issue 2

S212800

S171530S212790

86

2

1

5

4

63 7

89

10

11

12

13 14

10

79

15



46 - 2

Friction Plate Wear Limits

Measure and note the thickness of the friction plate, the

result must not be less than 1.25 mm (0.049 in).

Check the condition of the friction material, which should be

even over both surfaces.

If in doubt, discard the set (friction and counter plates).


9803/3260

Section F

46 - 2

Issue 2*




intended as a guide to dismantling

When Dismantling

Mark the two differential halves before dismantling, forsubsequent assembly.

Note the relative positions of the friction and counter plates

before dismantling, they must be fitted in the same

positions.

If worn, the friction and counter plates must be renewed as a

complete set.

When Assembling

1 Assemble trunnion pins 12, side gears 11 with pressureplates 10, counter plates 8, friction plates 9, planet

gears 13 and thrust washers 14 into the 'crownwheel

half of the differential assembly 5.

Note: Do not fit the shims 6 at this point.

2 Align the two halves of the differential assembly with

the marks made during dismantling. Assemble using

bolts 3.

3 Using a dial test indicator (or feeler gauges), with two

screwdrivers or suitable levers, gently apply pressure toside gear 11 away from the trunnion pins 12 as shown.

Measure and note the end-float of the side gear.

4 Turn the differential assembly over and repeat step 3

for the second side gear.

5 Dismantle the differential assembly. Add shims 6 to

give end-float between 0.1 and 0.2mm (0.004 and

0.008in.).

Note : Shimming must be carried out whenever the

differential is dismantled, however the end float 0.1 and 0.2mm (0.004 and 0.008 in.) can be exceeded on previously

assembled differential as this is only an initial setting figure

which allows for bedding in.

6 Repeat steps 2, 3, and 4. If the end float is correct,

tighten bolts 3 to 56 Nm (41 lbf ft).

7 Fit crownwheel 2 using new Verbus Ripp bolts 1, refer

to page F/20-1 for torque figures.

*

*

*

*



61 - 1


9803/3260

Section F

61 - 1

Issue 1

Synchro Shuttle Transmission



61 - 2


Park the machine on firm level ground.

!WARNING

A raised and badly supported mach ine can fal l on you.

Position the machine on a firm, level surface. Before

raising one end ensure the other end is securely


jacks to support the machine when working under it .



Removal

1 Rest the bucket on the ground and raise the stabiliserlegs sufficiently to allow room for the transmission to be

pulled clear. Block/support the machine.

2 Drain the transmission system, see page 3/8-1.

3 Remove the engine bonnet, see page B/1-1.

4 Remove the engine fan retaining bolts P (4 off) and

remove the fan, see note 1.

Note 1: At a later stage the transmission is tilted to give

access to retaining bolts, if the fan is not removed at this

stage it will foul.

5 Disconnect the gearshift lever from the top of the

transmission as shown at D.

6 Remove rear axle drive shaft bolts E.

7 Remove 4WD shaft bolts F (use tool 892/00822) and

4WD solenoid flying lead connector L.

8 Disengage the parking brake clevis at the parking brake

caliper and remove outer cable retaining circlip asshown at C.

9 Remove the transmission dipstick tube and filter.

10 Remove the access bung/plate at the bottom of the

flywheel housing. Through the access hole, loosen and

remove the torque convertor to engine flywheel

retaining bolts Q.

11 Support the transmission with a trolley jack as shown at

H, see note 2.

Note 2: Attach a 'cradle' to the trolley jack that will partially

embrace the transmission, see Service Tools, Section 1.

13 Using the trolley jack, lower the transmission and

engine to gain access to the top flywheel housing to

engine block retaining bolts J.

14 Disconnect the transmission oil cooler at the

transmission unit, shown at B and N.

15 Disconnect the transmission solenoid valve flying lead

connectors A and the pressure sender. Label the

connectors for identification when refitting.

16 Remove the breather pipe from the pressure

maintenance valve block to top of the dipstick tube as

shown at M.

17 Put a support under the engine as shown at G to

prevent it from dropping when the transmission isremoved.

18 Remove the flywheel housing to engine bolts J.

19 Manoeuvre the transmission with the torque convertor

clear of the engine housing.

20 Lower the trolley jack and pull the transmission and

torque convertor clear of the machine.

Replacement

Replacement is a reversal of the removal procedure.

Set the parking brake cable as described on page 3/15-1. If

the parking brake caliper has been removed reset central to

the parking brake disc, see page G/11 - 2.

Set the torque converter as described on page F/66 - 1.

Fill the transmission with the specified amount of JCB

Special Transmission Fluid (see page 3/1-1 for capacity).

Leave hose N off until the filling operation is complete. After

filling refit hose N.

Torque Settings


E 118 12 87

F 79 8 58

J 98 10 72

K 237 24 175

P 44 4.5 33

Q 19 2 14


9803/3260

Section F

61 - 2

Issue 1




63 - 1

Solenoid Valve





For clarity, only one solenoid has been numbered in the

dismantling sequence.

When Dismantling

Unscrew the knurled nut 2 and remove O-ring 3, withdraw

the solenoid 4 and O-ring 5.

Hold the solenoid valve body 6 in a vice, using the spanner

flats A, remove spindle 7 and O-ring 8.

Pull out actuating pin 9, spring 10, spring retainer 11 and

spool 12.

Dismantle the opposite solenoid in the same sequence as

described above.

Inspect the spool and spool bore for signs of wear, nicks

scratches etc.

When Assembling

Renew all O-rings.

Lightly lubricate all parts with clean transmission fluid before

assembling.

Check that the flying leads are secure and that theconnectors are intact.


9803/3260

Section F

63 - 1

Issue 1




1 Carefully remove piston ring seals.

Note: If the piston ring seals are excessively worn then

check for burrs or damage on the shaft grooves. If necessaryremove burrs with a fine grade abrasion paper and oil.

2 Loosen the clutch end bearing by tapping the assembly

on a piece of wood as shown. Remove the bearingusing pullers.

3 Remove the bearing, thrust washer and plastic type

washer.

Note: Earlier assemblies have one thick thrust washer, one

thrust bearing and one thin thrust washer, as shown at A .

4 Withdraw the gear and splined hub assembly with the

needle roller bearing.

5 Remove plastic type washer and thrust washer.

Note: Earlier assemblies have one thin thrust washer, one

thrust bearing and one thick thrust washer, as shown at B.

6 Remove the clutch friction/counter plates retaining

circlip.

7 Remove pressure (end) plate.

64 - 1


9803/3260

Section F

64 - 1

Issue 2


Reverser Unit - Dismantling

S232720

S232730

S232330

S217540

A232340

3

5

4

6

7

A

B

2

1



8 Remove the clutch friction/counter plates. Keep themtogether in sets, DO NOT mix the plates with those from

other clutches.

9 Remove pressure (end) plate.

10 Remove disc spring assembly.

Note: The disc spring is assembled within a liner (not shown)

to protect the hub support spline.

11 Position clutch assembly in press to compress piston

spring then remove circlip.

12 Lift off spring retaining plate.

13 Remove spring.

Note: Earlier assemblies have an oil baffle plate 13A fitted.

14 Knock the clutch shaft on a piece of aluminimum (or

wood) to remove the piston.

Note: If the piston does not loosen when the clutch shaft is

knocked on aluminimum, then hand pump air down the shaft

oil inlet hole.

15 Remove and discard piston and shaft ‘O’ rings. Make

sure the piston liner is secure. The liner must be a tight

fit on the piston.

Note: Earlier type piston 15A shown.

16 Repeat steps 2 to 15 to dismantle the opposite clutch.

64 - 2


9803/3260

Section F

64 - 2

Issue 2


Reverser Unit - Dismantling (cont'd)

S232740

S217560

S145000

S145010

S217570

8

9

10

11

12

13

13A

1515A



S217550

7

6

5

S217570

11A

1 Fit new 'O' rings onto the piston and shaft, lubricatewith oil then press piston fully into bore of clutch

housing.

Note: Earlier type piston 1A shown.

2 Install the piston spring, make sure the spring seats in

the piston.

Note: Earlier assemblies fitted with an aluminimum piston

must fit oil baffle plate 2A , make sure that the baffle plate

seats on the piston.

3 Fit the spring retaining plate.

4 Compress spring and secure with circlip.

5 Fit the disc spring assembly. Fit the assembly so that

the outer diameter curves away from the clutch piston.

Note: The disc spring is assembled within a liner (not shown)

to protect the hub support spline.

6 Fit pressure (end) plate. Make sure that the prongs on

the pressure plate DO NOT locate in the large grooves

in the hub (the ones with drilled holes).

7 Firstly, fit one friction plate followed by one steel

counter plate.

8 Continue fitting alternate friction and plain steel plates,finishing with a friction plate.

9 Fit the pressure (end) plate. Make sure that the prongs

on the pressure plate DO NOT locate in the large

grooves in the hub (the ones with drilled holes).

10 Fit the clutch friction/counter plates retaining circlip.

64 - 3


9803/3260

Section F

64 - 3

Issue 2


Reverser Unit - Assembly

S217580

S217560

S145000

4

3

2

2A

10

9



S232370

13

11 Using a dial test indicator as shown, measure the endfloat of the pressure (end) plate, which should be 3.2 to

4.4 mm (0.126 to 0.173 in). If necessary, fit shim

between the retaining circlip and pressure (end) plate tocorrect end float inaccuracies.

Note: Later type shim has teeth on the outside diameter; theteeth prevent it from spinning during operation. If the shim

removed from the clutch does not have teeth then discard it

and use the new type shim.

12 Fit thrust washer and plastic type washer.

Note: Earlier assemblies have one thick thrust washer, one

thrust bearing followed by one thin thrust washer shown at

B.

13 Fit gear and splined hub assembly.

Note: Prior to fitting gear, align teeth of clutch plates using a

thin rod (screwdriver).

14 Fit needle roller bearing.

15 Fit plastic type washer and thrust washer.

Note: Earlier assemblies have one thin thrust washer, one

thrust bearing followed by one thick thrust washer shown at

B.

16 Smear the clutch end bearing with JCB MPL Grease

and press the bearing onto shaft.

17 Fit piston ring seals.

Note: If the piston ring seals are the polytetrafluoroethene

(PTFE) type then see page F/68-1 for the correct fitting

procedure.

18 Repeat steps 1 to 16 for the opposite clutch, make sure

that the opposite clutch end taper roller bearing ispacked with grease.

64 - 4


9803/3260

Section F

64 - 4

Issue 2


Reverser Unit - Assembly (cont'd)

S217600

S232720

12

A232340

B

14 A232360

B

15

S217590

17

16



Hydraulic 2/4 Wheel Drive Unit (from machine serial number 400077 to 415011)

65 - 11


9803/3260

Section F

65 - 11

Issue 2*


S173590

*



Hydraulic 2/4 Wheel Drive Unit (from

machine serial number 400077 to 415011)

Later type 2/4 wheel drive clutch assemblies have been

revised in order to simplify the clutch pack settingprocedure. The new clutch has no middle spacer, ie the

actuating sleeve (item 15) is 12.2 mm; 0.480 inches longer.Detailed below is the correct dismantling and assembly

procedure for the new clutch.

Dismantling

1 Remove the 2/4WD unit from the transmission - loosenthe output yoke retaining nut before removal.

2 Remove bearing 1, only if to be renewed.

3 Remove seal ring 2. Note, If the piston ring seal is

damaged or excessively worn then check for burrs ordamage on the shaft groove. If necessary remove burrs

with a fine grade abrasion paper and oil.

4 Pull off the 4WD output gear 5, together with its bearing

3, needle roller bearing 6 and thrust washer 4.

5 Using a suitable press, compress disc springs 8A , 8B

and remove the circlip 7.

CAUTION: There is approximately 26700N (6000lbf)

clamping force acting on the springs.

6 Remove disc springs 8A, 8B, pressure plate 9, shim(s)

10 (keep the shim(s) separate from the counter plates),and clutch pack friction plates and counter plates 11.

7 Remove the clutch drum retaining circlip 12 an dsupport washer 13.

8 Remove clutch drum 14 and actuating sleeve 15 .

9 Remove disc spring 16.

10 Remove the piston 17 and its spring steel ring 18.

11 Remove and discard piston O-rings 19 and 20.

12 Remove the piston housing 21 only if necessary, the

housing is a press fit on shaft 22.

Assembly

Note: There is now a presure test adaptor and clampassembly that can be used to 'bench test' the clutch. Bench

testing will ensure the clutch operates correctly prior to re-

assembling and installing in the machine. Refer to 'PressureTesting the 2/4WD Clutch' on page F/65-13.

1 Grease the shaft 22 then fit the piston housing 21 bypressing the shaft squarely into the housing (make sure

the housing is securely supported).

2 Fit new O-rings 19 and 20 to piston 17, locate the

piston into housing 21. Fit spring steel ring 18 ensuring

that it seats firmly in its groove.

3 Place the disc spring 16 into the housing 21.

4 Position the actuating sleeve 15 onto the disc spring 16.

5 Install the clutch drum 14 in the housing. Fit supportwasher 13 and drum securing circlip 12.

6 Build up the clutch pack 11, installing friction plates and

counter plates alternately, starting with a counterplate

and finishing with a friction plate.

7 Install shim(s) 10 and pressure plate 9.

8 Use the output gear 5 to align the clutch plate splines.

Ensure that all the plates are engaged with the gear

shaft splines. Rotate the output gear back and forth to

create maximum backlash then withdraw the geartaking care not to disturb the pack.

9 Place the first two disc springs 8B with their convex

sides uppermost, onto the clutch pack. (There are four

disc springs, which are identical). Place the other two

disc springs 8A, with their convex sides down, onto thefirst two - refer to inset A .

10 Using a suitable press, compress the disc springs 8A

and 8B, fit circlip 7.

11 Use levers to remove free play, as shown at B. Measurethe gap between pressure plate 9 and actuating sleeve

15. The gap should be 0.75 - 1.5 mm; 0.030 - 0.059inches. If necessary fit new shim 10 to achieve the

correct gap. (Shim 10 can be a combination of a single

counter plate, shim (thinner than the counter plate) or

both counter plate and shim). Check that the clutchpack splines are still aligned - see step 8.

12 Install the 4WD output gear 5 and its needle roller

bearing 6.

13 Install thrust washer 4 and bearing 3.

14 Fit sealing ring 2 and bearing 1.

15 Fit the 2/4WD unit to the transmission using a newgasket C. Apply JCB Lock & Seal to the mounting bolts

D, torque tighten the bolts to 56 Nm; 42 lbf ft.

65 - 12


9803/3260

Section F

65 - 12

Issue 2*


*

*



Hydraulic 2/4 Wheel Drive Unit (from

machine serial number 400077 to 415011)

Assembly (cont'd)

16 Fit the output yoke E retaining nut F and washer G,

torque tighten the nut to 400 Nm; 295 lbf ft. Checkshaft end float which should not exceed 0.03 mm; 0.001

inch. Note, rotate shaft whilst measuring to fully seat

bearings.

17 If the end float is incorrect, remove the output yoke E

and bearing retaining circlip H. Note, if the end float iscorrect, it will still be necessary to remove the yoke - to

fit the oil seal, see step 19.

18 Add or subtract shims J to obtain correct setting. Shims

should be fitted between bearing outer race K and

spacer L. Replace the circlip and yoke and re-check theshaft end float.

19 When the shaft end float is correct, remove the yoke

and fit a new oil seal M.

20 Refit the output yoke E and tighten the new retainingnut F to 400 Nm; 295 lbf ft, stake the nut to the shaft

using a square ended staking tool, as shown at N.

21 Refit the hydraulic pipework and electrical connections.

65 - 13


9803/3260

Section F

65 - 13

Issue 2*


Pressure Testing the 2/4WD Clutch

1 Assemble the 2/4 wheel drive clutch, as described in'Assembly'.

2 Check the clutch pack end float and adjust as required

(see Assembly, step 11 ).

3 Insert the adaptor A into the oil gallery in the end of the

2/4 wheel drive clutch shaft as shown. Hold the adaptorin position with clamp B.

4 Use a hand pump to pressurise the clutch assembly

until gear, item 5 can be turned by hand. Note the

pressure gauge reading - DO NOT EXCEED 200 lbf/in2

(13.8 bar).

5 If the pressure gauge reading is between 125 - 135

lbf/in2

(8.6 - 9.3 bar) then the clutch is operating

correctly and can be fitted in the transmission.

6 If however the pressure gauge reading is above 135lbf/in

2(9.3 bar) then re-check the clutch for assembly

defects, especially the clutch pack end float (the shim

may not be to the correct thickness). Re-test after

checking for (and rectifying) assembly defects.

*

A

B

S185720

*



65 - 14


9803/3260

Section F

65 - 14

Issue 1





from M415012

The gearbox may incorporate this type of 2/4 Wheel Drive

Unit, which can be distinguished from the other two types by

its external appearance. The Pressure-ON(4WD)/Spring-OFF(2WD) Unit can be recognised by the 4 groups of 3 holeslocated around the clutch pack housing.

Note: This type of unit is not interchangeable with the other

types, which are Spring-ON (4WD)/Pressure- OFF (2WD).

Dismantling

Note: To aid working on this item, use the output yoke as astand.

1 Remove the 2/4WD unit from the casing - (loosen the

output yoke retaining nut before removal if there is to be

a complete strip down of the unit).

2 Remove the shaft components E - M.

3 Remove bearing 1, only if to be renewed.

4 Remove seal ring 2. Note, If the piston ring seal is

damaged or excessively worn then check for burrs or

damage on the shaft groove. If necessary remove burrswith a fine grade abrasion paper and oil.

5 Pull off the 4WD output gear 5, together with its bearing

3, needle roller bearings 6 and thrust washer 4. Remove

thrust washer 7. (Note that thrust washers 4 and 7 arenot interchangeable).

6 Remove circlip 8 and shim(s) 9 if fitted. Retain anyshims as a set for reassembly.

Note: If only the clutch pack was to be removed, the job is

now complete.

7 Remove pressure plate 10, the clutch pack friction

plates 11 and counter plates 12.

8 Using a suitable press and an adapter similar to Y ,

compress spring 15 and remove circlip 13.

9 Remove spring retainer plate 14 and spring 15.

10 Withdraw piston 16 then remove and discard 'O' rings

17 and 18.

Note: The piston housing cannot be separated from the

shaft, as on the other types of 2/4WD units.

Assembly

If only the clutch pack has been removed, begin at step 4.

1 Grease the shaft, fit new 'O' rings 17 and 18 then locatepiston 16 over the shaft and into the housing.

2 Locate spring 15 into the piston and position the

retainer plate 14 over the spring.

3 Using a press and adapter Y , compress spring 15 and

fit circlip 13.

65 - 15


9803/3260

Section F

65 - 15

Issue 2*


4 Build up the clutch pack, installing friction plates 11 and

counter plates 12 alternately, starting with a counter

plate and ending with a friction plate. Use the 4WD

output gear 5 to align the clutch plate splines. Ensurethat all the plates are engaged with the gear shaft

splines. Rotate the output gear back and forth to create

maximum backlash then withdraw the gear taking carenot to disturb the pack.

5 Install pressure plate 10, shim(s) 9 and circlip 8 (Notethat the shimming should be such that it is just possible

to fit the circlip).

6 Measure the clutch pack end float using two

screwdrivers as shown at B. End float should bebetween 1.0 mm and 2.3 mm. Adjust as necessary, by

adding or removing shims 9.

7 Fit thrust washer 7, 4WD gear 5, needle roller bearings 6

and thrust washer 4.

8 Press bearing 3 squarely onto the shaft to seat on thrust

washer 4, taking care not to exert any force on the

housing i.e. rest the unit on the opposite shaft end, notthe housing.

9 Fit new seal 2.

10 If required, press a new bearing 1 into position, taking

care not to exert any force on the housing (see Step 8).

11 Fit the 2/4WD unit to the transmission using a newgasket C. Apply JCB Lock & Seal to the mounting bolts

D, torque tighten the bolts to 56 Nm; 42 lbf ft.

12 Fit the output yoke E, retaining nut F and washer G,torque tighten the nut to 400 Nm; 295 lbf ft. Check shaftend float which must not exceed 0.03 mm; 0.001 in.

Note: Rotate shaft whilst measuring to fully seat bearings.

Later assemblies use a flanged bolt in place of items F and G

(the 4WD shaft has an internal thread). This bolt must betorque tightened to 395 Nm; 291 lbf ft.

13 If the end float is incorrect, remove the output yoke E

and bearing retaining circlip H. Note, if the end float iscorrect, it will still be necessary to remove the yoke - to

fit the oil seal, see step 15.

14 Add or subtract shims

Jto obtain correct setting. Shimsmust be fitted between bearing outer race K and spacer

L. Replace the circlip and yoke and re-check the shaft

end float.

15 When the shaft end float is correct, remove the yoke

and fit a new oil seal M.

16 Refit the output yoke E and tighten the new retaining

nut F to 400 Nm; 295 lbf ft. Stake the nut to the shaft

using a square ended staking tool, as shown at N.

17 Refit the hydraulic pipework and electrical connections.

*

*



66 - 1

Torque Converter


Removal

See pages F/61-1 and F/61-2 for transmission/torque

converter removal.

Before Replacing

Ensure that flywheel face, drive plate, and hardware are

clean and free from burrs or other surface imperfections.

When Replacing

Attach drive plate 1 and drive plate annulus 2 to torque

converter, tightening bolts 3 finger tight only.

Bolt drive plate to flywheel and check that run-out of pumpdrive shaft A does not exceed maximum permissible

0.38mm (0.015in.). If incorrect, tap torque converter by handto reposition.

When correct, remove the torque converter and drive

plate/annulus sub-assembly from the flywheel.

Torque tighten converter drive plate/annulus bolts 3.

Install the torque converter with its drive plate/annulus sub-

assembly onto the transmission input shaft, make sure that

the dogs on the converter pump drive shaft engage with the

recesses in the pump, also take care not to damage the oil

seal.

Rotate the engine flywheel so that one bolt hole is in a six O'

clock position.

Rotate the torque converter and drive plate assembly so that

one bolt hole is in a six O' clock position.

Install the transmission/torque converter assembly to the

engine.

Remove the access plate from the bottom of the engine

flywheel housing and through the access hole fit and handtighten one bolt (item 5) in the six 'O' clock position

Note: It is important to mount washers 4 with the outside

diameter radius against the drive plate, (ie) facing toward the

flywheel.

Rotate the flywheel until the next bolt hole is accessible, fit

and hand tighten the next bolt 5. Repeat the operation until

all bolts are fitted. Finally torque tighten bolts, rotating the

flywheel each time to align bolts 5 with access hole. Refit

plate.

Torque Settings

Item Nm kgf m lbf ft3 40 5 30

5 19 2 14


9803/3260

Section F

66 - 1

Issue 1


A



67 - 1


9803/3260

Section F

67 - 1

Issue 1




67 - 2

Torque Converter Stall Test

Ensure that the engine and transmission are at normal

working temperature. Run engine at maximum speed andcheck the No Load Speed (High Idle Speed - U.S.A). See

Engine Technical Data for correct figure; adjust if necessary.

Apply parking brake and footbrake firmly, select 4th Speed

Forward and open throttle fully. Engine speed should be as

specified at Torque Converter Stall in TransmissionTechnical Data. Select Reverse and repeat test.

Note: On machines from serial number 413772, when fully

engaged, the parking brake electrically disconnects the

transmission drive; this prevents the machine from being

driven with the parkbrake on. Therefore, so that we cancomplete the test, move the parkbrake lever fractionally

forward until the warning light is just extinguished; hold the

lever in this position for the duration of the test. DO NOT

move the lever too far forward, otherwise the parkbrake willnot be fully operational. Alternatively, disconnect the switch

at the park brake.

DO NOT stall the converter for longer than 10 seconds or

the transmission fluid will overheat.

If engine speeds are higher than the stated figures check the

transmission for clutch slippage or internal leakage.

If engine speeds are below the stated figures either the

engine is losing power and should be serviced/overhauled or

the torque converter reaction member clutch is slipping. To

check the engine, select Neutral, open throttle fully and

operate an excavator service to 'blow off' the main reliefvalve. Engine speed should fall to slightly above the

Maximum Governed Speed (see Engine Technical Data). If

engine speed is correct the torque converter is faulty.

Note: Maximum Governed Speed is a datum figure only. It

cannot be adjusted or checked with the engine installed inthe machine.

Pressure and Flow Test

Note: The tests must be carried out only in the following

order, step by step.


fittings as the oil will be HOT.

Trans 1-2

1 Stop engine, remove transmission filter, and screw

adapter A (892/00304) on to the threaded spigot. Fittest adapter B (892/00301) and secure with adapter C

(892/00302). Connect flowmeter D (892/00229) as

shown and connect a 0-20 bar (0-300 lbf/in2) pressure

gauge to test connector E (see Service Tools, Section

1).

2 Start engine and run at 1000 rev/min. The flowmeter will

show the Pump Flow which should be as shown inTechnical Data. A low reading indicates a worn pump

or blocked suction strainer. The pressure gauge willshow the Main Line Pressure (see Technical Data). A

low reading can be caused by either a faulty pressure

maintenance valve or a worn pump. A high reading

indicates a faulty pressure maintenance valve or, if thepump flow is low, the oil cooler may be blocked.

3 Stop engine, remove flow test adapters and refit filter.

Connect pressure gauge and flowmeter into converter

out line as shown at F. Run engine at 1000 rev/min with

transmission in Neutral and note Converter Out

Pressure and Oil Cooler Flow, which should be as

shown in Technical Data. A high pressure together with

low flow could be caused by a blocked oil cooler. (See

also check 7.)

4 With parking brake and footbrake firmly applied, selectForward and check flow reading, which should not fall

by more than 4.5 litres (1 UK gal; 1.2 US gal) per

minute. A low reading indicates a high leakage rate in

that particular clutch, which could be caused by worn

or broken piston seals or shaft sealing rings. Select

Reverse and repeat the test.

5 If the clutch leakage rate is high, the Clutch Pressures

may be checked by connecting the pressure gauge into

ports G and H and repeating test 4. A low reading (see

Technical Data) would confirm a high leakage rate in

the particular clutch selected.

6 Stop engine, connect the pressure gauge into port J in

the transmission, and fit a load valve L into the

converter out line (see note).

Note: Make sure that the load valve L has been screwedfully out before starting the engine, otherwise the converter

seals will be damaged.

Start engine, run at 1000 rev/min and slowly screw

down the load valve whilst observing the gauge

reading, which should rise to the setting of theConverter Relief (Safety) Valve (see Technical Data).

DO NOT allow the pressure to exceed 10.3 bar (150

lbf/in2 ) or damage to the converter seals will be caused.

If the reading is higher than specified, the relief (safety)

valve must be faulty. A low reading indicates a faultyrelief (safety) valve, leaking converter 'piston ring' type

seal or leaking pump seal.

7 Stop engine and connect pressure gauge and

flowmeter into return line from oil cooler to transmissionas shown at K . Start engine, and with transmission in

Neutral check flowmeter reading, which will show the

Cooler Flow Rate (see Technical Data). The pressure

gauge will show the Lubrication Pressure (seeTechnical Data). Low flow and pressure readings could

indicate a blocked oil cooler.


9803/3260

Section F

67 - 2

Issue 2*


*

*



1 Wind the PTFE piston ring seal around your finger as

shown, so that the seal forms a 'coil'.

2 Smear the seal with grease and then fit the seal to the

shaft.

Make sure that the seal sits below or flush with the

outer diameter of the shaft. If necessary, use finger

pressure as shown to make the seal flush with the shaft.

CAUTION: If the seal is not set below or flush with the outer

diameter of the shaft, then the seal will 'cut' when the shaft is

fitted to its mating component.

68 - 1


9803/3260

Section F

68 - 1

Issue 1




81 - 1


9803/3260

Section F

81 - 1

Issue 1




81 - 2


Park the machine on firm level ground.

!WARNING

A raised and badly supported mach ine can fal l on you.

Position the machine on a firm, level surface. Before

raising one end ensure the other end is securely


jacks to support the machine when working under it .



Removal

1 Rest the bucket on the ground and raise the stabiliserlegs sufficiently to allow room for the transmission to be

pulled clear. Block/support the machine.

2 Drain the transmission system, see page 3/8-2.

3 Remove the engine bonnet, see page B/1-1.

4 Remove the engine fan retaining bolts P (4 off) and

remove the fan, see note 1.

Note 1: At a later stage the transmission is tilted to give

access to retaining bolts, if the fan is not removed at this

stage it will foul.

5 Remove rear axle drive shaft bolts E.

6 Remove 4WD shaft bolts F (use tool 892/00822).

7 Disengage the parking brake clevis at the parking brake

caliper and remove outer cable retaining circlip as

shown at C.

8 Remove the transmission dipstick tube and filter,

shown at M.

9 Remove the access bung/plate at the bottom of the

flywheel housing. Through the access hole, loosen and

remove the torque convertor to engine flywheel

retaining bolts Q.

10 Support the transmission with a trolley jack attachment

as shown at H (see Section 1, Tools), refer to note 2.

Note 2: The Powershift weight distribution is unbalanced. It

is very important that the transmission is securely supported

before attempting to complete the removal procedure. Thetrolley jack attachment prevents the transmission from

moving side to side AND front to back when being removed.

12 Using the trolley jack, lower the transmission and

engine to gain access to the top flywheel housing to

engine block retaining bolts J - do not remove bolts at

this stage.

13 Disconnect the transmission oil cooler at the

transmission unit, shown at B and N.

14 Disconnect the transmission solenoid valve flying lead

connectors A. Label the connectors for identification

when refitting.

15 Put a support under the engine as shown at G to

prevent it from dropping when the transmission is

removed.

16 Remove the flywheel housing to engine bolts J.

17 Manoeuvre the transmission with the torque convertor

clear of the engine housing.

18 Lower the trolley jack and pull the transmission and

torque convertor clear of the machine.

Replacement

Replacement is a reversal of the removal procedure.

The solenoids should have been labelled before removing

connecters, however page F/91-1 identifies the solenoidsand the correct electrical connections.

Set the parking brake cable as described on page 3/15-1. If

the parking brake caliper has been removed reset central to

the parking brake disc, see page G/20 - 2.

Set the torque converter as described on page F/66 - 1.

Fill the transmission with the specified amount of JCB

Special Transmission Fluid (see page 3/1-1 for capacity).

Torque Settings


E 118 12 87

F 79 8 58

J 98 10 72

K 237 24 175

P 44 4.5 33

Q 19 2 14


9803/3260

Section F

81 - 2

Issue 1




88 - 1



The Powershift 2/4 wheel drive unit dismantling and

assembly procedures are the same as for the Syncro Shuttletransmission 2/4 wheel drive units (later type), described on

pages F/65-11 to F/65-13, or (from M/C No. 415012) of the

'Pressure-ON/Spring-OFF' type, described on pages F/65-

14 to F/65-15.

Note that the Powershift 2/4 wheel drive clutch assembly isthe latest type, that is the new type of clutch has no middle

spacer, therefor the actuating sleeve is 12.2 mm (0.480

inches) longer. This arrangement simplifies the clutch pack

setting procedure.

Torque Converter


The Powershift torque converter removal and replacement

procedures are the same as for the Syncro Shuttle

transmission, described on page F/66-1.


9803/3260

Section F

88 - 1

Issue 2*


*



91 - 1

Torque Converter Stall Test

Note: DO NOT stall the converter for longer than 10 seconds

or the transmission fluid will overheat. Make sure that the oillevel is correct and at normal operating temperature.

Before completing the following test, remove the

transmission dipstick. If there is any sign of smoke emitting

from the dipstick tube STOP THE TEST IMMEDIATELY and

dismantle the transmission for servicing.

1 Ensure that the engine and transmission are at normal

working temperature. Run engine at maximum speed

and check the No Load Speed (High Idle Speed -

U.S.A). See Engine Technical Data for correct figure;

adjust if necessary.

2 Apply parking brake and footbrake firmly. If necessary,

set the machine against a fixed obstruction.




driven with the parkbrake on. Therefore, so that we can

complete the test, move the parkbrake lever fractionally

forward until the warning light is just extinguished; hold thelever in this position for the duration of the test. DO NOT

move the lever too far forward, otherwise the parkbrake will

not be fully operational. Alternatively, disconnect the switch

at the park brake.

3 Select 2nd speed forward drive and open throttle fully.

Record the engine speed from the tachometer. Repeatthe test for 3rd speed forward and record the reading.

4 Repeat step 3 except this time select 2nd and 3rd gear

reverse drive respectively. Record the readings.

Note: Using 2nd and 3rd gears in forward and reverse drive

will ensure that ALL clutches are energised during the test.

5 All recorded readings should be as specified at Torque

Converter Stall in Transmission Technical Data, pages

F/1-8 to F/1-9.

If engine speeds are below the stated figures either the

engine is losing power and should be serviced/overhauled or

the torque converter reaction member clutch is slipping. To

check the engine, select Neutral, open throttle fully and

operate an excavator service to 'blow off' the main relief

valve. Engine speed should fall to slightly above theMaximum Governed Speed (see Engine Technical Data). If

engine speed is correct the torque converter reaction

member clutch is slipping.

If engine speeds are higher than the stated figures check the

transmission for clutch slippage or internal leakage. Toisolate a suspect clutch, tabulate the recorded readings as

shown in the example below:

Gear Direction Mainshaft or RPM

Select Clutch Layshaft Clutch

2nd Forward High Layshaft 20603rd Forward Low Mainshaft 1990

2nd Reverse High Layshaft 19853rd Reverse Low Mainshaft 1980

In the example shown, we can see that the engine speed is

abnormally high when 2nd speed forward drive is selected,indicating a slipping clutch.

From the table we can see that the layshaft clutch is working

normally (2nd speed reverse drive indicates 1985 rev/min).Therefore it follows that the suspect clutch is the forward

high. Assuming all other possible faults have been

eliminated (see Powershift fault finding) this clutch would be

dismantled for servicing.


9803/3260

Section F

91 - 1

Issue 2




91 - 2

Testing For Clutch Leakage

!WARNINGDO NOT go underneath the machine with the engine

running. Switch off the engine, apply the parking brake

and chock both sides of all wheels before goingunderneath the machine.Trans 2-1

Solenoid Identification

When testing individual clutch pressures (see page F/91-3),

it is necessary to isolate the clutch being tested. So for

instance, to check the layshaft clutch we could select 1st

gear forward - this would energise the layshaft and forward

low clutches. Because we only want to check the layshaft

clutch pressure and not the forward low clutch pressure,remove the electrical connector to the forward low clutch

BEFORE selecting 1st gear.

Use the table below to determine which solenoid electricalconnectors should be removed when pressure testing

individual clutches.

Gear Clutches Engaged (Solenoids Engaged)

Selected

1st Forward Forward Low & Layshaft (solenoids 2 & 4 )

2nd Forward Forward High & Layshaft (solenoids 1 & 4 )3rd Forward Forward Low & Mainshaft (solenoids 2 & 3)

4th Forward Forward High & Mainshaft (solenoids 1 & 3)

1st Reverse Reverse Low & Layshaft (solenoids 5 & 4 )

2nd Reverse Reverse High & Layshaft (solenoids 6 & 4 )

3rd Reverse Reverse Low & Mainshaft (solenoids 5 & 3)4th Reverse Reverse High & Mainshaft (solenoids 6 & 3)

Isolating a Suspect Clutch

1 Stop engine, connect a 0-20 bar (0-300 lbf/in2 ) pressure

gauge to test connector A (mainline pressure test

point).

2 Make sure that both sides of all four wheels arechocked. Apply the footbrake and parking brake.

Note: On machines from serial number 413772, when fullyengaged, the parking brake electrically disconnects the


driven with the parkbrake on. Therefore, so that we cancomplete the test, move the parkbrake lever fractionally





at the park brake.

3 Start engine and run at 1000 rev/min, engage 1st gear

forward. Record the pressure reading. Repeat the test

for all gear ratios in forward drive and record the

pressure readings as shown in the example below:

Example Only

Gear Ratio Mainshaft or bar lbf/in2

Select Clutch Layshaft Clutch

1st Forward Low Layshaft 9.65 140

2nd Forward High Layshaft 8.62 125

3rd Forward Low Mainshaft 9.65 140

4th Forward High Mainshaft 8.62 125

Readings should not vary between clutches by more than

0.7 bar (10 lbf/in2 ). In the example shown, we can see that

pressure is low when 2nd and 4th gear forward is selected,

indicating clutch leakage.

From the table we can see that the forward high clutch is

used for selection of both 2nd and 4th gear forward. Weknow from the table that the mainshaft and layshaft clutches

are working normally (1st and 3rd gear selection show

normal operating pressure). So we can assume that the

forward high clutch is leaking.

We can now confirm the forward high clutch is leaking by

completing an 'Individual Clutch Leakage Test', see next

page.

Note: Repeat above test using reverse ratios if necessary.


9803/3260

Section F

91 - 2

Issue 2


1 3 57

24 6

S247710

A



91 - 3

Testing For Clutch Leakage

Individual Clutch Leakage Test

In the following procedures the forward high clutch is tested,

therefore in step 2 a pressure gauge is connected to theforward high clutch test point.

When testing other suspect clutches connect a gauge to the

relevant suspect clutch test point. See page F/91-4 for theposition of individual clutch pressure test points. Because

the forward high clutch is suspect, a gear must be selected

that will use the forward high clutch, in this instance 2nd

gear forward.

1 Stop engine, connect a 0-20 bar (0-300 lbf/in2 ) pressuregauge to test connector A , (mainline pressure test

point), see page F/91-4 .

2 Connect a 0-20 bar (0-300 lbf/in2 ) pressure gauge totest connector G (forward high ratio clutch test point),

see page F/91-4 .

3 Remove the layshaft clutch solenoid feed connector 4,

this ensures that only the forward high clutch is

energised when 2nd gear forward is selected.

Note: See page F/91-2 for identification and position ofsolenoid feed connectors when testing other suspect

clutches.

4 Make sure that both sides of all four wheels are

chocked. Apply the footbrake and parking brake.






forward until the warning light is just extinguished; hold thelever in this position for the duration of the test. DO NOT



at the park brake.

5 Start engine and run at 1000 rev/min, select 2nd gearforward. Note the pressure readings on both gauges,

which should not vary by more than 0.7 bar (10 lbf/in 2 ).

If the difference on the gauges is greater than 0.7 bar

(10 lbf/in2 ) do the following:

a Stop the engine and interchange the gauges.

b Start the engine and run at 1000 rev/min, select

2nd gear forward. If the difference on the gauges is

still greater than 0.7 bar (10 lbf/in2 ) dismantle the

forward high clutch for servicing.

c If after interchanging the gauges, the readings are

different than at step 5, have the gauges calibrated

and repeat the testing procedure.


9803/3260

Section F

91 - 3

Issue 2


G

S247710

A

4



91 - 4


9803/3260

Section F

91 - 4

Issue 2


S144482



91 - 5

Pressure and Flow Testing

Before completing any of the transmission pressure/flow

tests, make sure that the oil level is correct and at normaloperating temperature.

All gauges etc used in the following pressure/flow tests are

shown in Section 1.

!WARNINGFine jets of hydraulic oil at high pressure can penetrate

the skin. Do not use your fingers to check for hydraulic

oil leaks. Do not put your face close to suspected leaks.

Hold a piece of cardboard close to suspected leaks and

then inspect the cardboard for signs of hydraulic oil. If

hydraulic oil penetrates your skin, get medical help

immediately.HYD 1-1


fittings as the oil will be HOT.Trans 1-2

!WARNINGDO NOT go underneath the machine with the engine

running. Switch off the engine, apply the parking brake

and chock both sides of all wheels before going

underneath the machine.Trans 2-1

!WARNING

Powershift transmission is in 4 wheel drive until de-selected by hydraulic pressure to 2 wheel drive. If the

machine is to be raised, make sure all four wheels are

off the ground. If only the rear wheels are raised, the

machine could still drive through the front axle.

TEST POINTS

A - Mainline pressure

B - Converter inlet/converter relief valve pressure

C - Converter outlet pressure

D - Mainshaft clutch pressure

E - Layshaft clutch pressureF - Pump flow (remove filter and fit adapters)

G - Forward high ratio clutch pressure

H - Forward low ratio clutch pressure

J - Lubrication pressure

K - Cooler flow (flowmeter in line from cooler to

transmission)

L - Reverse high ratio clutch pressure

M- Reverse low ratio clutch pressure

N - 2/4 wheel drive clutch pressure

P - Load Valve

Pump Flow

Refer to the illustration on page F/91-4

1 Stop engine, remove transmission filter, and screwadapter X (892/00304) on to the threaded spigot. Fit

test adapter Y (892/00301) and secure with adapter Z

(892/00302). Connect flowmeter W (892/00229).

2 Start engine and run at 1000 rev/min. With the

transmission in neutral the flowmeter will show the

Pump Flow which should be as shown in Technical

Data, page F/1-7. A low reading indicates a worn pump

or blocked suction strainer.

3 Repeat step 2 and note gauge readings with engine

running at 2000 rev/min.

4 Stop engine and remove test adapters, refit filter.

Mainline Pressure


1 Stop engine, connect a 0-20 bar (0-300 lbf/in2 ) pressure

gauge to test connector A .

2 Start engine and run at 1000 rev/min. With the

transmission in neutral the pressure gauge will show

the Main Line Pressure which should be as shown in

Technical Data, page F/1-7. A low reading can be

caused by either a faulty pressure maintenance valve or

a worn pump. A high or low reading may indicate afaulty pressure maintenance valve.



4 Stop engine and remove test gauge.

Converter Out Pressure/Oil Cooler Flow Rate


1 Stop engine, connect a 0-20 bar (0-300 lbf/in2 ) pressuregauge and flowmeter into the converter out line as

shown at C and K respectively.

2 Run the engine at 1000 rev/min with transmission in

neutral. The pressure gauge indicates the Converter

Out Pressure and the flowmeter indicates the Oil

Cooler Flow Rate, both readings should be as

specified in Technical Data, pages F/1-6 & F/1-7. A

high pressure together with low flow could be caused

by a blocked oil cooler.



4 Stop engine, remove test gauges and refit hoses tooriginal position.


9803/3260

Section F

91 - 5

Issue 2




91 - 6

Pressure and Flow Testing (cont'd)

Converter In Pressure


1 Stop engine, connect a 0-20 bar (0-300 lbf/in2

) pressuregauge to test point B.

2 Start the engine and run at 1000 rev/min. With the

transmission in neutral the pressure gauge will showConverter In Pressure which should be as shown in

Technical Data, page F/1-6. A high or low reading could

indicate a faulty converter relief valve.

3 Remove pressure test gauge.

Converter Relief (Safety) Valve Pressure


1 Connect a 0-20 bar (0-300 lbf/in2) pressure gauge to

test point B.

2 Fit a load valve P into the converter out line.

CAUTION: Make sure the load valve is in the OPEN

position(the adjusting knob screwed fully out) before starting

the following pressure test. If the load valve is not fully open,damage to the converter seals will be incurred.

CAUTION: DO NOT allow the pressure to exceed 10.3

bar(150 lbf/in2 ) or damage to the converter seals will be

caused.


transmission in neutral, slowly screw down the load

valve P whilst observing the gauge reading which

should rise to the Converter Relief (Safety) Valve

setting as specified in Technical Data, page F/1-6.

3 If the reading is higher than specified then the converter

relief valve is faulty. A low reading indicates a leaking

pump seal or a faulty converter relief valve.

4 Stop engine, remove test gauges and refit hoses to

original position.

Lubrication Pressure


1 Stop engine, connect a suitable pressure gauge intothe return line from the oil cooler to the transmission as

shown at J.


transmission in neutral the pressure gauge will indicate

the Lubrication Pressure which should be as specifiedin Technical Data, page F/1-6.

3 Repeat step 2 and note gauge readings with enginerunning at 2000 rev/min.

4 Stop engine and remove pressure gauge.


9803/3260

Section F

91 - 6

Issue 1




i

Section G Brakes

9803/3260

Section G

i

Issue 2*

Contents Page No.

Technical Data 1 - 1

Descriptions

Compensating Master Cylinder- Pedals Locked - Normal Operation 2 - 1

- Pedals Locked - Compensating Operation 2 - 3

- Pedals Unlocked - Normal Operation 2 - 5

Fault Finding

- Brake System 5 - 1

- Brake Piston Seal Leakage Test 5 - 4

Brake System

- Bleeding 11 - 1

Parking Brake Caliper (machines up to serial number 441101- Dismantling and Assembly 20 - 1

- Setting Procedure 21 - 1

Parking Brake Caliper (machines from serial number 441102)

- Adjusting the Parking Brake 22 - 1

- Testing the Parking Brake 22 - 1

- Adjusting the Brake Pads 22 - 2

- Adjusting the Cable Slack 22 - 2

- Renewing the Brake Pads 22 - 3


Service Brakes

- Dismantling and Assembly Refer to page F/43 - 1

Master Cylinder and Servo Unit



*

*******



5 - 1

FAULT

A One or both brakes do not apply.

(Brake travel not excessive, brakes

not pulling to one side).

B Pedal travel excessive (but not

touching floor).

C Applying one brake (pedals

unlocked) also partially engages

the other brake.

D Pedal hard to operate.

E Pedals touch floor under constantpressure - no fluid loss.

F Pedals touch floor under constant

pressure - and fluid loss.

G Pulling to one side when pedals

locked together.

Brake System

Note: The brakes generate a high temperature when operating, this means that the casing will be hot to touch, this condition is

normal.

POSSIBLE CAUSE

1 Master cylinder fault.

2 Friction/counter plate distortion.

1 Air in hydraulic system.

2 Leak in hydraulic system.


1 Valve stem seal inside (non-active)

master cylinder piston not sealing.

1 Tightness at pedal pivot.

2 Fluid contamination/seal damage.

3 Misaligned push rod/pedal.

4 Kinked or crushed brake pipes.

Items 5 to 7 are for machines fitted

with servo assisted brakes only:

5 Vacuum failure due to low vacuum

at source.

6 Blocked/leaking vacuum pipe.

7 Servo defect.



3 Air in hydraulic system.

1 External fluid leaks.

2 Internal fluid leaks.

1 Compensating feature not

working.

ACTION

1 Check master cylinder in single and

coupled pedal modes to identify fault

area, service as required.

2 Check friction/counter plates.

1 Check fluid reservoir level. Check for

fluid/air leaks, rectify as required.

2 Check for fluid loss at mastercylinder and brake piston, all pipes

and fittings for loose connections.

Rectify as required.

3 Renew friction/counter plates -

BOTH sides.

1 Renew master cylinder piston.

1 Inspect pedal pivot. Free-off/lubricate.

2 Flush system and renew all hydraulic

seals.

3 Check and rectify as required.

4 Check/renew brake pipework.

5 Inspect/service engine mounted

exhauster unit as required.

6 Check/renew vacuum pipe.

7 Renew servo unit.

1 Check master cylinder in single andcoupled pedal modes to identify fault


2 Renew friction/counter plates -BOTH sides.

3 See item B.1.

1 Visually check brake circuit for fluid

loss, service as required.

2 See 'Brake Piston Seal Leakage

Test' on page G/5-4.

1 Inspect master cyl inder

compensating operation. Check ifblockage in bridging pipe. Service as

required.

Section G Brakes

9803/3260

Section G

5 - 1

Issue 2*

Fault Finding

*

*

*

*

*

*

*



5 - 2

FAULT

G Pulling to one side when pedals

locked together (cont'd).

H Poor braking (not pulling to one

side).

J One or both brakes not releasing.

K Poor braking when hot.

POSSIBLE CAUSE

2 Braking system inoperative on

one side.

3 Friction plates worn beyond limits

or distorted on one side.

4 Badly adjusted push rods.

5 Annular piston fault (see item J6).

1 Friction plates worn beyond limits

or distorted on one side.


3 Annular piston fault (see item J6).

4 Incorrect/low axle oil.

5 Vacuum failure (machines fitted

with servo assisted brakes only).

1 Brake pedal spring fault.

2 Master cylinder fault (plunger

stuck in bore).

3 Blocked hole in master cylinder

reservoir cap.

4 Brake pedal free travel incorrect.

5 Fluid contamination/seal damage.

6 Annular brake piston(s) binding in

axle.

7 Kinked or crushed brake pipes.

8 Friction/counter plates not free on

splines and/or dowels.

1 Moisture in system vapourizing

when axle is hot.

ACTION

2 Unlatch pedals to test circuits

individually.

3 Renew frict ion/counter plates -

BOTH sides.

4 Adjust push rod (1mm minimum).

5 See item J6.

1 Renew frict ion/counter plates -

BOTH sides.

2 Check master cylinder in single and

coupled pedal modes to identify fault


3 See item J6.

4 Fill axle with correct type of oil.

5 Inspect vacuum source/pipes,

service as required.

1 Fit a new spring.

2 Service as required.

3 Fit a new reservoir cap.

4 Adjust pedal free travel.

5 Flush system and renew hydraulicseals.

6.1 Check that correct brake fluid has

been used (incorrect fluid could swell

the annular brake piston seals).

6.2 Check if annular brake piston sealsin good condition.

6.3 Check that annular brake piston

rotates freely in its housing with no

seals fitted.6.4 Check that the annular brake piston

seal retracts the pistonapproximately 0.5mm (0.020 in).

7 Check and renew pipes as required.

8 Check friction/counter plates for free

movement, replace if required -BOTH sides.

1 Strip axle and clean annular piston to

remove moisture. Remove master

cylinders and check for corrosion,

service as required. Flush hydraulicbrake system.

Section G Brakes

9803/3260

Section G

5 - 2

Issue 2*

Fault Finding

*

*

*

*



5 - 3

FAULT

L Excessive brake noise in operation.

Note: Due to the metal to metal contact

of oil immersed brakes, limited noise

can be heard which is consistent with

this type of design - this is normal.

M Fluid loss when machine standing,

for instance - overnight (see note).

Note: Confirm fault is as indicated by

checking that the pedals DO NOT touchfloor under constant pressure.

POSSIBLE CAUSE

1 Deterioration of axle oil or wrong

type of axle oil.

2 Axle oil loss.

3 Friction plates worn beyond limits.

4 Friction/counter plates in poor

condition.

1 Slight cut or nick in the brake

piston seal, see 'Brake Piston

Seal Leakage Test' page G/5-4.

ACTION

1 Change axle oil.

2 Refill axle with correct oil and check

for leaks.

3 Renew friction/counter plates.

4 Check for distort ion or surface

pitting and/or roughness of

friction/counter plates (annular

grooving of counter plates is

acceptable).

1 Strip axle, replace seal.

Section G Brakes

9803/3260

Section G

5 - 3

Issue 2*

Fault Finding

*

*



5 - 4

Brake Piston Seal Leakage Test

The following procedure explains how to check if a brake

piston seal is severely damaged/perished or if the seal has asmall cut or nick. The test must only be done when the axle

is COLD.

!WARNINGBefore working on the brake system make sure the

machine is on level ground and chock all four wheels.BRAK 1-4

!WARNINGDo not drive the machine with any part of its brake

system disconnected. When the following test has been

completed reconnect all brake pipes and bleed the brake

system using the recommended procedure.BRAK 2-1

1 Remove and cap brake piston feed pipe A.

2 Fill the brake piston housing with JCB Light Hydraulic

Fluid.

3 Check for severe piston seal damage:

3.1 Install a hand pump (see note 1) fitted with a 0 - 40

bar (0 - 600lbf/in2 ) pressure gauge to port B, as

shown at X .

Note 1: The hand pump MUST be filled with JCB Light

Hydraulic Fluid. DO NOT exceed 69bar (1000lbf/in2 ).

3.2 Use the hand pump to generate a pressure in the

brake piston housing.

3.3 If the pressure falls off rapidly, or if no pressure

reading can be obtained, the seal is severely

damaged and needs replacing with a new one.

4 Check for small cuts or nicks in the piston seal:

4.1 Install an adapter fitted with a piece of clear

tube(approximately 122mm [48in.] long) to the

brake piston port B, as shown at Y (see note 2).

Note 2: The tube must be kept vertical during the test, use

tape to attach the tube to the side of the machine.

4.2 Fill the tube until approximately three quarters full

with JCB Light Hydraulic Fluid

4.3 Using a suitable pen, mark the level line of the

brake fluid on the tube, as shown at C.

4.4 After approximately 1/2 hour, check if the level has

dropped below the original marked line, if it has

then check the brake piston seal for slight nicks,cuts or generally for wear.

5 Repeat steps 1 to 4 for the opposite brake piston seal.

6 Reconnect all brake pipes and bleed the brake system

as recommended on page G/11-1.

Section G Brakes

9803/3260

Section G

5 - 4

Issue 1

Fault Finding

S159830



11 - 1

Bleeding

!WARNINGBefore proceeding with the bleeding procedure it is

important to ensure that the parking brake is engagedand that one pair of wheels is blocked on both sides.BRAK 1-2



Fill the master cylinder reservoir with the correct fluid (see

Lubricants, page 3/1-1), and ensure that throughout the

bleeding process the level is not allowed to fall below the

MINIMUM mark.

Unlatch the pedals, and bleed each brake separately asfollows:

Right Hand Master Cylinder

Attach a tube to the right hand brake bleed screw A ,

ensuring that the free end of the tube is immersed influid contained in a suitable container.

Open the brake bleed screw and apply full pedal

strokes of the right hand brake pedal until all air is

expelled.

Close the brake bleed screw with the pedal fully

depressed.

Left Hand Master Cylinder

Repeat procedure as for 'Right Hand Master Cylinder'but use left hand bleed screw and pedal.

Bridge Pipe

Attach a tube to either the left or right hand brake bleed

screw, ensuring that the free end of the tube is

immersed in fluid contained in a suitable container.

Make sure that the brake pedals are locked together.

Open the bleed screw and apply full pedal strokes ofthe brake pedals until all air is expelled.

Close the bleed screw with the pedals fully depressed.

Repeat the procedures as necessary.

Top up the reservoir to the full mark.

Section G Brakes

9803/3260

Section G

11 - 1

Issue 1

Brake System

S107710

A



20 - 1

Section G Brakes

9803/3260

Section G

20 - 1

Issue 1

Parking Brake Caliper



20 - 2





When Dismantling

To dismantle the parking brake caliper safely the tension inspring 10 must be released; apply and keep hand pressure

to item 13, remove items 3 and 4. Allow the spring to open

out to its full travel by slowly releasing the hand pressure on

item 13.

When Assembling

Renew pads if thickness of friction lining is less than 3mm

(0.125 in.).

Lightly grease all pivots and working surfaces, taking care to

avoid grease contacting the brake pads.

Fit shims A between the mounting bracket 2 and caliper

bracket 19 as necessary to align the parking brake caliper

assembly centreline to within ± 0.5mm (0.020 in.) of the

brake disc centreline.

Tighten nut 5 sufficiently to allow lever 7 to move freely with

minimum side clearance.

Apply JCB Lock & Seal to threads of bolts 1.

Set the caliper as described on page G/21 - 1.

Torque Settings


1 118 12.0 87.0

17 6 0.6 4.4

Section G Brakes

9803/3260

Section G

20 - 2

Issue 1



The numerical sequence shown in the illustration is intended

as a guide to dismantling.



21 - 1

Section G Brakes

9803/3260

Section G

21 - 1

Issue 2


S152691

X



21 - 2

Setting Procedure

If the parking brake caliper assembly has been dismantled

or the brake pads renewed, then the caliper must be set asfollows:

!WARNINGBefore adjusting the parking brake, make sure that the

machine is on level ground. Put chocks each side of all

four wheels. Disconnect the battery so that the engine

cannot be started. If you do not take these precautions

the machine could run over you.BRAK - 008

1 Make sure that the caliper assembly is set central to the

parking brake disc (within ± 0.5 mm, ± 0.020 in), seepage G/20 - 2.

2 Disengage the parking brake (lever horizontal). Turn

handle grip A to bring pin B central to the slot.

3 Set the cable length:

i Disconnect clevis E from the caliper lever by

removing dowel pin G.

ii Set the caliper lever to 235 mm (9 1/4 in) from face

C by adjusting the cable length at adjusting nut D.Refit clevis E and torque tighten D to 27Nm (20 lbf

ft) after adjustment is achieved.

4 Set the caliper lever:

i Disconnect clevis E from the caliper lever byremoving dowel pin G.

ii Set the caliper lever to 225 mm (8 7/8 in) from face

C (or until the pads just touch the brake disc) by

adjusting nut F.

Note: Setting the 225 mm figure will ensure that correct

lever effort is applied to the parking brake handle

iii Refit clevis E to the caliper lever using dowel G.

5 Make sure that the parking brake switch (item X ) is

correctly adjusted, refer to Section C, 'ParkbrakeSwitch Adjustment'.

6 Test the parking brake:


engaged, the parking brake electrically disconnects thetransmission drive; this prevents the machine from being





move the lever too far forward, otherwise the parkbrake willnot be fully operational.

i Make sure the parking brake is fully engaged (lever

vertical - also see note above). Select 2 wheel driveand third gear.

ii Make sure the brake pedals are locked together,

push down hard on the brake pedals and select

forward drive.

!WARNINGIf the machine starts to move during the following test,

immediately apply the foot brakes and reduce the engine

speed.2-2-5-1

iii Slowly release the brake pedals, if the machine has

not moved use the accelerator to graduallyincrease the engine speed to 1500 RPM - the

machine should not move. DO NOT test for longer

than 20 seconds.

iv If the machine moved inspect the caliper/pads,

reset as described above.

Section G Brakes

9803/3260

Section G

21 - 2

Issue 1




22 - 1

Section G Brakes

9803/3260

Section G

22 - 1

Issue 1



Adjusting the Parking Brake

1 Disengage the parking brake (lever horizontal)

2 Turn adjuster A clockwise, half a turn.

3 Test the parking brake. See Testing the Parking

Brake.

4 If the brake fails the test, repeat steps 1 to 3.

Note: If after completing the above steps, the parking brake

does not pass the testing procedure. See Adjusting the

Brake Pads.

Testing the Parking Brake



transmission drive; this prevents the machine from beingdriven with the parkbrake on. Therefore, so that we can




move the lever too far forward, otherwise the parkbrake willnot be fully operational.

1 Make sure the parking brake is fully engaged (lever

vertical - also see note above). Select 2 wheel drive and

third gear.

2 Make sure the brake pedals are locked together, push

down hard on the brake pedals and select forward

drive.

!WARNINGIf the machine starts to move during the following test,

immediately apply the foot brakes and reduce the engine

speed.2-2-5-1

3 Slowly release the brake pedals, if the machine has not

moved use the accelerator to gradually increase theengine speed to 1500 RPM - the machine should not

move. DO NOT test for longer than 20 seconds.

4 If the machine moved inspect the caliper/pads, reset as

required.

A

S196790



22 - 2

Adjusting the Brake Pads

1 Turn adjuster A to return pin B to the bottom of the slot.

2 Check the pads just touch the disc when the parkingbrake is disengaged (lever horizontal).

3 If necessary, adjust the pad position by turning nut C

until the disc is clamped then back off nut C until the

pads have a clearance of 0.5 mm (0.020 in) between

the disc and one pad.

4 Engage the parking brake 3 times and repeat step 2.

Adjusting the Cable Slack

1 Loosen locknut E and remove pin G (at either end of

the cable).

2 Screw in the clevis F only enough to remove the cableslack.

3 Refit pin G and tighten locknut E to 27 Nm (19.9 lbf ft).

4 Test the parking brake, see Testing the Parking

Brake.

5 If the brake fails the test, repeat steps 1 to 4.

Note: The cable end must not contact lever H.

Note: If the brake cannot be adjusted by adjusting the padsand the cable slack, the cable must be replaced.

Section G Brakes

9803/3260

Section G

22 - 2

Issue 1



Note: Illustration shows typical caliper installation.

A

S196790

B

C

G

H

FE

S210850



22 - 3

Renewing the Brake Pads

Renew pads when thickness of friction material is 3mm

(0.125 in).

1 Back the pads away from the disc by removing nut A.

Retain washer B.

2 Loosen nuts C enough to lift spring lugs clear of items

D and E.

3 Remove nuts F. Remove the old pads

4 Fit the new pads and tighten nuts F to 6 Nm (4.4 lbf in).

5 Reseat spring lugs and tighten nuts C.

6 Refit washer B and nut A .

7 Adjust the pads. See Adjusting the Brake Pads.

Section G Brakes

9803/3260

Section G

22 - 3

Issue 1



A

B

C

E

D

F

F

S210860



22 - 4

Section G Brakes

9803/3260

Section G

22 - 4

Issue 1



S210860


When Assembling

Lightly grease all pivots and working surfaces, taking care toavoid grease contacting the brake pads.

Fit shims 2 to align the parking brake caliper centreline to

within ±0.5 mm (0.020 in) of the brake disc centreline.

Tighten nut 6 sufficiently to allow lever 8 to move freely with

minimum side clearance.


The numerical sequence shown in the illustration is intended

as a guide to dismantling.

12

3

4

5

6

7

8

9

0

!

@

£

$%

^

^

&



30 - 1

Section G Brakes

9803/3260

Section G

30 - 1

Issue 1




30 - 2


!WARNINGBefore working on the brake system make sure the

machine is on level ground and chock all four wheels.BRAK 1-4

Removal

1 Lift away cab floor mat from base of front controlconsoles.

2 Remove bolts A and take off the steering pedestal

cover B.

3 Remove the left hand side console. If necessary, labeland disconnect electrical wires to the switches and

radio (if fitted).

4 Loosen and remove brake pipe unions C, plug and capto prevent loss of fluid and ingress of dirt.

5 Remove the brake pipes from the master cylinders:

5.1 Remove the engine cover, see page B/1-1.

5.2 Remove the battery.

5.3 Working from access hole K loosen and remove

the master cylinders bridging pipe D, axle feed

pipes E and reservoir supply pipes H.

6 Remove the brake pedals clevis F and disengage the

brake pedal from the servo unit (both pedals).

7 Loosen and remove the servo unit retaining nuts G

(both units).

8 Remove the left and right hand master cylinder and

servo units.

Replacement




Fill the brake system with JCB Light Hydraulic Fluid, bleed

the system as described on page G/11 - 1 and set the

pedals (see below).

Set the Pedals

1 Unlatch pedals and ensure that pedal pads are level

with each other and fully back against their stops.

2 Adjust pedal linkages for free movement to give 1 mm

(0.040 in) on each pushrod.

3 With pedals still unlatched, apply an equal force to

each pedal and check if pedals remain level. If

necessary adjust by increasing the clearance on one of

the pushrods. Do not decrease either clearance below

1 mm (0.040 in).

4 Latch pedals and check for straight line braking; if

satisfactory straight line braking cannot be achieved

refer to fault finding, page G/5 - 1.

Torque Settings


H 30-34 3.0-3.5 22-25

Section G Brakes

9803/3260

Section G

30 - 2

Issue 2*


*



31 - 1

Section G Brakes

9803/3260

Section G

31 - 1

Issue 1




31 - 2


The servo unit (not shown) is a non serviceable part. Replace

a faulty servo unit with a new one

When Dismantling

Remove circlip 1 and washer 2. Shake the cylinder, or use

compressed air, to eject piston assembly 3.

Examine the working surfaces of piston and cylinder. If these

are not in perfect condition the master cylinder assembly

must be renewed.

Only seals and 'O' rings are serviceable. Replace a faulty

master cylinder and piston assembly with new ones.

When Assembling

!WARNING

Use of incorrect fluid will cause serious damage to the


Clean and lubricate all components, including new seals,

with JCB Special Hydraulic Fluid. DO NOT USE

CONVENTIONAL BRAKE FLUID OR SERIOUS DAMAGE

WILL BE CAUSED.

Take care not to damage the machined faces of piston 3

when assembling new seal 5, which must be located as

shown at A.

Section G Brakes

9803/3260

Section G

31 - 2

Issue 1




i

Section K Engine

9803/3260

Section K

i

Issue 4*

Contents Page No.

Technical Data 1 - 1

Exhaust System

Silencer Replacement 10 - 2

Engine

Removel & Replacement 15 - 1

*



1 - 1

Section K Engine

9803/3260

Section K

1 - 1

Issue 3

Technical Data

Type Perkins 1000 Series 4 cylinder Engines

AB - turbocharged, AA - Naturally AspiratedBore (nominal) 100mm (3.937 in)

Stroke 127mm (5.000 in)Swept Volume 4 litres (243 in3)

Compression Ratio Turbocharged 16.0:1, Naturally Aspirated 16.5:1

Compression Pressure 28 bar (400 lbf/in2 )

[maximum variation between cylinders 3.5 bar (50 lbf/in2)]Injection Sequence 1,3,4,2

Valve Clearance - Cold - Inlet 0.20mm (0.008 in)

- Exhaust 0.45mm (0.018 in)

Oil Pressure (hot) at maximum speed - AA 2.1 bar (30 lbf/in2)

- AB 2.6 bar (40 lbf/in2)

Maximum Air Cleaner Restriction 559mm (22 in H2O)

Fuel System

Injection System Details

Engine Injection Pump Injectors

Model Type BHP Code Static Timing Code Working/Setting

Pressures

All Wheel Steer Machines

AB50364 Turbocharged 96 CM78L/1100/1/2420 15.5° BTDC JG 230 atm

2 Wheel Steer Machines

AA50386 Naturally Aspirated 76 DM55L/1000/1/2420 16.5° BTDC HZ 220 atm

AB50388 Turbocharged 90 GM64L/1000/2/2420 23.0° BTDC JK 220 atm

AB50389 Turbocharged 96 CM78L/1100/1/2420 15.5° BTDC JG 230 atm

Idling Speed - All builds 750 rev/min

Maximum Governed Speed - All builds 2200 rev/min

Maximum No-load Speed (High Idle) - All builds 2320 - 2420 rev/min

Cooling System

Coolant Pressure 0.48 bar (7 lbf/in2)Coolant Temperature (Normal) 80-85 °C (176-185 °F)

Temperature Warning Light operates at: 98 °C (208 °F)



10 - 1

Section K Engine

9803/3260

Section K

10 - 1

Issue 1*

Exhaust System



10 - 2

Silencer Replacement

Naturally Aspirated Engines

Machines with serial numbers from 400030 onwards are

fitted from new with the latest type of silencer. Machineswith earlier serial numbers were fitted from new with a now

obsolete type of silencer. This should be replaced by one of

the latest type in event of failure.

To ensure that no unecessary mechanical stress are

imposed, adopt the following procedure when fitting a new

silencer:

1 When carrying out this preliminary installation all fixings

should be finger tightened only.

Using bolt/spring washer/plain washer A , attach

support bracket B to th engine. Mount the silencer

assembly C to the support bracket (usingscrews/washers D and backing strip E ) and the engine

exhaust manifold (using nuts/washers F ).

2 Once the silencer is loosely installed, tighten screw D to a

torque of 28 Nm (20.7 lbf ft). Then tighten nuts F to a

torque of 56 Nm (41.3 lbf ft). Finally tighten bolts A to a

torque of 56 Nm (41.3 lbf ft).

3 Clamp the exhaust pipe to the silencer outlet.

Turo Charged Engines

Machines from serial numbers 400841 onwards are fitted

with the latest typ of silencer. The latest type G differs fromits predecessor by the addition of welded strengthening

plates H on the lower tube and h introduction of a new

support bracket J.

In the event o failure, the latest type o silencer should be

fitted to all machines, including those previously fitted withthe earlir type.

Section K Engine

9803/3260

Section K

10 - 2

Issue 1

Exhaust System



15 - 1

Section K Engine

803/3260

Section K

15 - 1

Issue 1

Removal & Replacement

S24400

A B

C

D

E

FG

H

JKL

M

N

P

Q Q

R

S



15 - 2

Engine Removal and Replacement

The following procedures describe the removal and

replacement of an engine when installed in a two wheel

steer machine (3CX, 214). On four wheel steer machines the

hydraulic pump is mounted to the side of the engine.

When Removing



Chock the road wheels.

2 Raise the loader arms and fit the loader arm safety

strut.

Note: In the event of engine failure, the loader arms will have

to be raised using suitable lifting equipment. Make sure that

the loader control lever is in the ‘raise arms’ position before

manually lifting the loader arms.

3 Remove the engine side panels

4 Remove the engine cover (including the exhaust stack,and pre-cleaner).

5 Disconnect and remove the battery. When

disconnecting the battery, take off the earth (black) lead

first.

6 Remove retaining bolts and then lift off the front grille.

7 Remove retaining bolts A and B (both sides) and lift off

the front nose guard.

8 Disconnect the hydraulic oil cooler hoses C from thehydraulic oil cooler. Plug and cap open orifices to

prevent ingress of dirt.

9 Drain the cooling system.

0 Remove the transmission oil cooler hoses D and E.

11 Remove the radiator top hose and bottom hose.

12 Remove the coolant bottle pipe.

13 Make a suitable alignment mark to allow correctrepositioning of the radiator shroud, as shown at F.

14 If an engine fan guard is fitted, remove retaining bolts

and lift off the guard.

15 Remove retaining bolts G (both sides) and lift off theradiator sub-assembly including radiator, hydraulic

cooler, and shroud. Take care not to damage the

17 Loosen and remove the exhaust silencer retaining bolts,

remove the silencer.

18 Loosen and remove the retaining clamp for the heaterhose. Remove the hose.

19 Loosen and remove the retaining clamp for the air filter

intake hose.

20 Loosen and remove the brake master cylinder reservoir

retaining bolts. Do not remove the pipes attached to the

master cylinder reservoir but put the reservoir out of theway. Make sure that the fluid level does not drain down.

21 Loosen and remove the battery carrier retaining bolts

and lift off the carrier with the air filter assembly. Use

tape to close the opening in the air intake manifold, this

will prevent ingress of dirt.

22 Label and remove all electrical connections, the number

of connectors will vary depending on the ancillary

equipment fitted to the engine. Typical electrical

connectors are:

i) starter motorii) alternator

iii) coolant pressure switch

iv) coolant temperature sender

v) engine oil pressure switch

vi) engine temperature sender

vii) engine shut off solenoid

viii) ether cold start (if fitted)ix) air conditioning compressor (if fitted)

23 If air conditioning is fitted:

23.1 Remove the belt from the clutch of the airconditioning compressor.

23.2 Disconnect the high and low pressure electrical

connectors at the compressor.

23.3 Loosen and remove the air conditioningcompressor retaining bolts.

Note: The air conditioning is a pressurised closed loopsystem, do not disconnect the hoses to the compressor.

Leave the hoses to the compressor intact.

23.4 Put the air conditioning compressor out of the

way (do not allow the compressor to ‘hang’ on

its hoses).

24 Loosen and disconnect the fuel lines J from the fuel

sedimenter Plug and cap open orifices to prevent

Section K Engine Section K

15 - 2Removal & Replacement

manual de servicio - jcb - 214ss - 4x4x4.pdf

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