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jcb 2CX Service Manual

Backhoe loader
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Table of Contents

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Service
Manual
2CX
& VARIANTS
Backhoe
Loader
From M/c No. 930000 Onwards
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; © WORLD PARTS CENTRE,
WATERLOO PARK, UTTOXETER, ST14 5PA
ENGLAND
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9803/7130
General Information
Care & Safety
Routine Maintenance
Attachments
Body & Framework
Electrics
Controls
Hydraulics
Transmission
Brakes
Steering
Engine
www.maskinisten.net
1
2
3
A
B
C
D
E
F
G
H
K

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  • Page 1 Backhoe Transmission Loader From M/c No. 930000 Onwards Brakes PUBLISHED BY THE Steering TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; © WORLD PARTS CENTRE, WATERLOO PARK, UTTOXETER, ST14 5PA ENGLAND Engine Tel. ROCESTER (01889) 590312 PRINTED IN ENGLAND Publication No. 9803/7130...
  • Page 2 Machine Nomenclature In this Service Manual, reference is made to machine models, e.g. 2CX, 2CXU, these are European machine model names. North American machine models have different names, the table below shows the European and the equivalent North American nomenclature.
  • Page 3 Colour Coding The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service publications. Full Pressure Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and M.R.V. operating pressure.

  • Page 4: Table Of Contents

    Section 1 General Information Section 1 www.maskinisten.net Contents Page 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 Body and Framework...

  • Page 5: Machine Identification Plate

    Section 1 General Information Section 1 www.maskinisten.net 1 - 1 1 - 1 Machine Identification Plate Typical Machine Identification Number Your machine has an identification plate mounted on the right hand side of the machine just below the driver's cab 123456 door.

  • Page 6: Unit Identification

    Section 1 General Information Section 1 www.maskinisten.net 1 - 2 1 - 2 Unit Identification The engine serial number is stamped on a plate mounted on The rear axle serial number is stamped on a plate mounted the left hand side of the cylinder block (looking towards the to the front face of the axle, as shown below.

  • Page 7: Torque Settings

    (10) (12) (16) (20) (24) (30) 1633 1205 (36) 2854 2105 Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. 9803/7130 Issue 1...

  • Page 8: Service Tools Numerical List

    Section 1 General Information Section 1 www.maskinisten.net 3 - 1 3 - 1 Service Tools Numerical List Page No. Page No. 892/00301 Flow Test Adapter 4 - 10 816/00189 Blanking Cap 4 - 8 892/00302 Flow Test Adapter 4 - 10 816/00190 Blanking Ca 4 - 8...
  • Page 9 Section 1 General Information Section 1 www.maskinisten.net 3 - 2 3 - 2 Service Tools Numerical List (cont'd) Page No. 1606/0003 Adapter 4 - 7 1606/0004 Adapter 4 - 7 1606/0007 Adapter 4 - 7 1606/0008 Adapter 4 - 7 1606/0009 Adapter 4 - 7...

  • Page 10: Service Tools

    2 required to handle large panes of glass. No plug supplied. Note: 110V models available upon Ensure suction cups are protected from damage request - contact JCB Technical Service. during storage. JCB part number: JCB part number - 892/00842...
  • Page 11 'L' Blades - 25 mm (1 in) cut - replacement blades for cut-out knife (above). JCB part number - 992/12801 (unit quantity = 5 off) Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass.
  • Page 12 Section 1 General Information Section 1 www.maskinisten.net 4 - 3 4 - 3 Service Tools (cont'd) Section B - Body & Framework Slide Hammer Kit - 993/68100 :993/68101 Slide Hammer :993/68106 Adaptor - M20 x M24 :993/68102 End Stops :993/68107 Bar - M20 x M20 X 800MM :993/68103 Adaptor - M20 x 5/8"...
  • Page 13 Service Tools (cont'd) Section B - Body & Framework Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame. JCB part number - 926/15500 Nylon Spatula (unit quantity = 500 off) general tool...
  • Page 14 Section 1 Section 1 www.maskinisten.net General Information 4 - 5 4 - 5 Service Tools (cont'd) Section A - Attachments (Airmaster Compressor) 892/00878 Airmaster, Diaphram Assembly Tool - 892/00877 Airmaster, Air Test Silencer - safety Suction Unloader, tool shown in position device, attach to air delivery cocks when cocks are to be opened with no hose attached.
  • Page 15 Section 1 General Information Section 1 www.maskinisten.net 4 - 6 4 - 6 Service Tools (cont'd) Section E - Hydraulics Hydraulic Circuit Pressure Test Kit 892/00253 Pressure Test Kit 892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in 892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in 892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in 892/00254 Replacement Hose 892/00347 Gauge Connector...
  • Page 16 Section 1 General Information Section 1 www.maskinisten.net 4 - 7 4 - 7 Service Tools (cont'd) Section E - Hydraulics Tool Components for Hamworthy A.R.V. testing 892/00252 Test Block for A.R.V. 992/02400 Tee-piece 1606/0003 Adapter 3/8 in. x 1/4 in. BSP 1406/0011 Bonded Washer 2401/0103...
  • Page 17 Section 1 General Information Section 1 www.maskinisten.net 4 - 8 4 - 8 Service Tools (cont'd) Section E - Hydraulics S191750 S216250 892/00180 Seal Fitting Tool for fitting 'O' ring and kin ring to Danfoss Orbitrol Unit 892/00181 Replacement Plastic Boss 892/00334 Ram Seal Fitting Tool Female Cone Blanking Plug...
  • Page 18 Section 1 General Information Section 1 www.maskinisten.net 4 - 9 4 - 9 Service Tools (cont'd) Section E - Hydraulics 892/01027 Piston Seal Assembly Tool S338410 11 o Ram Seal Protection Sleeves 10mm 20mm 892/01016 For 25 mm Rod Diameter 892/01017 For 30 mm Rod Diameter 892/01018...
  • Page 19 Section 1 General Information Section 1 www.maskinisten.net 4 - 10 4 - 10 Service Tools (cont'd) Section F - Transmission 892/00179 Bearing Press (use with appropriate adapters) 892/00812 Drive Coupling Spanner for front and rear axle yoke couplings and for 4WD output coupling on Syncro Shuttle S107750 S188200...
  • Page 20 Section 1 General Information Section 1 www.maskinisten.net 4 - 11 4 - 11 Service Tools (cont'd) Section F - Transmission 992/04000 Torque Multiplier (use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts) S197030 992/00800 Extractor for removing front axle pivot pin 892/00174...
  • Page 21 Section 1 General Information Section 1 www.maskinisten.net 4 - 12 4 - 12 Service Tools (cont'd) Section F - Transmission Solid Spacer Setting Kit 892/00918 Setting Tool Kit 993/70111 Breakback Torque Wrench 921/52600 Spacer Kit 921/52627 Spacer 14.20 Service use Comprises of: 921/52601 Spacer 12.75...
  • Page 22 Section 1 General Information Section 1 www.maskinisten.net 4 - 13 4 - 13 Service Tools (cont'd) Section K - Engine 892/00041 De-glazing Tool for Cylinder Bores (to assist bedding-in of new piston rings) Note: For other engine tools refer to the Engine Service Manual.
  • Page 23 JCB Multi-Gasket A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65mm diameter. 4102/1212 JCB High Strength Threadlocker A high strength locking fluid for use with threaded components. 4102/0551 JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled.
  • Page 24 Section 2 Care & Safety Section 2 www.maskinisten.net Contents Page No. Safety Notices 1 - 1 General Safety 2 - 1 Operating Safety 3 - 1 Maintenance Safety 4 - 1 9803/7130 Issue 1...
  • Page 25 Section 2 Care & Safety Section 2 www.maskinisten.net 1 - 1 1 - 1 Safety Notices In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. DANGER Denotes an extreme hazard exists.
  • Page 26 2 - 1 All construction and agricultural equipment can be hazardous. When a JCB machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others.
  • Page 27 Section 2 Care & Safety Section 2 www.maskinisten.net 3 - 1 3 - 1 Operating Safety ! WARNING ! WARNING Machine Condition ROPS/FOPS Structure A defective machine can injure you or others. Do not operate The machine is fitted with a Roll Over Protection Structure a machine which is defective or has missing parts.
  • Page 28 Do not weld cast away from the battery. Do not smoke close to the battery. iron. Contact your JCB distributor for advice before Make sure there is good ventilation in closed areas where modifying the machine.
  • Page 29 Section 2 Care & Safety Section 2 www.maskinisten.net 4 - 2 4 - 2 Maintenance Safety (cont'd) ! WARNING ! WARNING Diesel Fuel Fires Diesel fuel is flammable; keep naked flames away from the If your machine is equipped with a fire extinguisher, make machine.
  • Page 30 To avoid burning, wear protective gloves when handling hot Fluoroelastomeric Materials components. To protect your eyes, wear goggles when Certain seals and gaskets (e.g. crankshaft oil seal) on JCB using a wire brush to clean components. machines contain fluoroelastomeric materials such as Viton, HYD 1-3 Fluorel and Technoflon.
  • Page 31 Section 3 Section 3 Routine Maintenance www.maskinisten.net Contents Page No. Service Requirements Introduction 1 - 1 Maintenance 1 - 1 Owner/Operator Support 1 - 1 Service/Maintenance Agreements 1 - 1 Lifting Regulations - Inspections and Tests 1 - 1 Lubricants - Health and Safety Hygiene 2 - 1 Storage...
  • Page 32 Section 3 Routine Maintenance Section 3 www.maskinisten.net Contents Page No. Lubrication Control Levers 11 - 1 Hinges 11 - 1 Tyres and Wheels Tyre Inflation 12 - 1 Checking the Road Wheel Tightness 12 - 1 Engine Air Filter Cleaning the Pre-Cleaner 13 - 1 Changing the Elements 13 - 2...
  • Page 33 Section 3 Section 3 Routine Maintenance www.maskinisten.net Contents Page No. Battery Warning Symbols 22 - 1 First Aid - Electrolyte 22 - 2 Checking the Electrolyte Level 22 - 2 Cab Heater Changing the Recirculation Filter 23 - 1 Windscreen Washer 24 - 1 Stabiliser Legs Wear Pads...

  • Page 34: Service Requirements

    JCB together with your Distributor wants you to be performance, economy and ease of use under a wide variety completely satisfied with your new JCB machine. If you do of operating conditions. Prior to delivery, your machine was encounter a problem however, you should contact your...

  • Page 35: Lubricants - Health And Safety

    Hygiene c Use special hand cleansers to help clean dirty hands. JCB lubricants are not a health risk when used properly for d Never use petrol, diesel fuel, or paraffin for washing. their intended purposes. e Avoid skin contact with oil soaked clothing.

  • Page 36: Service Schedules

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 3 - 1 Service Schedules 3 - 1 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.
  • Page 37 Section 3 Routine Maintenance Section 3 www.maskinisten.net 3 - 2 Service Schedules 3 - 2 Pre-start Cold Checks Operation †100 1000 2000 Service Points and Fluid Levels HYDRAULICS Oil Filter - Change " " " " Oil Level - Check "...
  • Page 38 " " † Note: First 100 Hours Service only or following major repair, to be completed by your JCB Distributor. Note: Check for leaks every 50 hours, check level if leaking. Note: Check the hydraulic fluid level with the loader and backhoe in the travel position.

  • Page 39: Loader Arm Safety Strut

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 4 - 1 Loader Arm Safety Strut 4 - 1 ! WARNING ! WARNING You could be killed or injured if the loader control is Raised loader arms can drop suddenly and cause accidentally operated.

  • Page 40: Checking For Damage

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 5 - 1 Checking for Damage 5 - 1 Inspect steelwork for damage. Note damaged paintwork for Check all bucket teeth for damage and security. future repair. Check all lamp lenses for damage. Make sure all pivot pins are correctly in place and secured by their locking devices.

  • Page 41: Seat Belt

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 6 - 1 Seat Belt 6 - 1 Checking the Seat Belt Condition and Security ! WARNING When a seat belt is fitted to your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident.

  • Page 42: Rops/Fops Structure

    ROPS/FOPS certification. INT-2-1-9/3 For assistance, contact your JCB distributor. Failure to take these precautions could result in death or injury to the operator. Check the structure for damage. Check that the mounting bolts are installed and undamaged.

  • Page 43: Engine Panels

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 8 - 1 Engine Panels 8 - 1 Removing and Fitting a Side Panel Opening and Closing the Bonnet ! WARNING To release the bonnet, insert key A into the bonnet lock and turn 90°...

  • Page 44: Grease (Daily)

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 9 - 1 Grease (Daily) 9 - 1 ! WARNING You must grease the machine regularly to keep it working efficiently. Regular greasing will also lengthen the machine's You will be working close into the machine for these working life.

  • Page 45: Loader Arms - Standard

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 9 - 2 Grease (Daily) 9 - 2 Loader Arms - Standard For each grease point shown there is another on the other side of the machine. Total 10 grease points 391610 Loader Arms - High Specification For each grease point shown there is another on the other side of the machine.

  • Page 46: Backhoe

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 9 - 3 Grease (Daily) 9 - 3 Backhoe 17 Grease Points. Note: Do not grease the kingpost mounting rails. 393820 9803/7130 Issue 1...

  • Page 47: 6-In-1 Clamshovel (If Fitted)

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 9 - 4 Grease (Daily) 9 - 4 6-in-1 Clamshovel (if fitted) Backhoe Quick-Hitch (Hydraulic) ! CAUTION For each grease point shown there is another at the other end of the bucket. Waxoyl contains turpentine substitute, which is inflammable.

  • Page 48: Greasing

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 10 - 1 Greasing 10 - 1 Axles Front Axle Note: When greasing, raise the wheels and swing them from lock to lock. This will ensure full penetration. Total 9 Grease Points. 391620 391610 Rear Axle Total 8 Grease Points.

  • Page 49: Propshafts

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 10 - 2 Greasing 10 - 2 Propshafts Airmaster Driveshaft 6 Grease Points. 2 Grease Points. Read Greasing (Daily) for general information about Read Greasing (Daily) for general information about greasing. greasing. ! WARNING You will be working close into the machine for these jobs.

  • Page 50: Stabiliser Legs

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 10 - 3 Greasing 10 - 3 Stabiliser Legs Extending Dipper ! CAUTION ! CAUTION Waxoyl contains turpentine substitute, which is Waxoyl contains turpentine substitute, which is inflammable. Keep flames away when applying Waxoyl. inflammable.

  • Page 51: Lubrication

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 11 - 1 Lubrication 11 - 1 The following points should be lightly oiled with engine oil. ! WARNING Make the machine safe before getting beneath it. Lower the attachments to the ground; engage the parking brake;...

  • Page 52: Tyres And Wheels

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 12 - 1 Tyres and Wheels 12 - 1 ! WARNING Checking the Roadwheel Tightness An exploding tyre can kill, inflated tyres can explode if On new machines, and whenever a wheel has been overheated.

  • Page 53: Engine Air Filter

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 13 - 1 Engine Air Filter 13 - 1 Cleaning the Pre-Cleaner Note: Do not run the engine with the filter pre-cleaner or the rain cap removed. If the pre-cleaner is more than a third full of dust, empty it.

  • Page 54: Changing The Elements

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 13 - 2 Engine Air Filter 13 - 2 Changing the Elements Depress clips B and lift off cover C. Remove outer ! CAUTION element D. Take care not to tap or knock the element. If The outer element must be renewed immediately if the the inner element is to be changed, lift up pulls E and warning light on the instrument panel illuminates.

  • Page 55: Engine Oil And Filter

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 14 - 1 Engine Oil and Filter 14 - 1 Checking the Oil Level Changing the Oil and Filter ! WARNING Prepare the Machine Park the machine on level ground. Lower the backhoe Hot oil and engine components can burn you.

  • Page 56: Engine Cooling System

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 15 - 1 Engine Cooling System 15 - 1 Adjusting the Fan Belt Checking the Coolant Level ! WARNING Raise and Lock the Loader Arms The cooling system is pressurised when the coolant is Remove the Right Hand Side Panel hot.

  • Page 57: Changing The Coolant

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 15 - 2 Engine Cooling System 15 - 2 Fill the System with the Correct Coolant Mixture. Changing the Coolant See Coolant Mixtures. ! WARNING Use the necessary mix of clean, soft water and anti- freeze.

  • Page 58: Fuel System

    Sulphur:0.5% of mass (maximum) present. Distillation: 85% at 350 °C (662 °F) Consult your JCB distributor for advice about the use of Cetane Number Fatty Acid Methyl Ester fuels, as improper application may Indicates ignition performance. Fuel with a low cetane impair engine performance.

  • Page 59: Draining The Filter

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 16 - 2 Fuel System 16 - 2 Draining the Filter Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine.

  • Page 60: Draining The Sediment Bowl

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 16 - 3 Fuel System 16 - 3 Draining the Sediment Bowl Bleed the System ! CAUTION Park the machine on firm level ground, engage the parking brake and set the transmission to neutral. Raise Running the engine with air in the system could damage and block the loader arms.

  • Page 61: Syncro Shuttle Transmission

    D. Pull out the strainer E and its gasket F. Clean the strainer with a suitable solvent. Follow the solvent manufacturer's instructions on safety. Fit the strainer and a new gasket F. Apply JCB S175870 Threadlocker and Sealer to bolts D before fitting and tightening them.

  • Page 62: Brakes

    Turn handle grip E clockwise, half a turn. reservoir regularly get the brake system checked by your JCB Dealer. Do not use the machine until the fault has Test the parking brake, refer to Section G Service been put right.

  • Page 63: Axles

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 19- 1 Axles 19 - 1 Checking the Differential Oil Level Changing the Differential Oil Prepare the Machine Prepare the Machine Park the machine on level ground. Engage the parking Park the machine on level ground. Engage the parking brake.

  • Page 64: Checking The Hub Oil Levels

    Engage the parking brake. Set the transmission to neutral. Lower the attachments to the ground. Stop the Consult your JCB distributor for advice if necessary. engine and remove the starter key. Set the machine level, with the tyres just clear of the Clean the area around the fill/level plug C.

  • Page 65: Hydraulic System

    (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. Add Oil If necessary, remove filler cap B and add recommended oil.

  • Page 66: Changing The Filter Element

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 20 - 2 Hydraulic System 20 - 2 Changing the Filter Element ! WARNING Remove the element from its canister. Fine jets of hydraulic fluid at high pressure can penetrate a Hold canister F. the skin.

  • Page 67: Electrical System

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 21 - 1 Electrical System 21 - 1 Fuses Relays ! CAUTION Indicators Front working lights Always replace fuses with ones of correct ampere rating Rear working lights to avoid electrical system damage. Starter 1 8-3-3-5 Starter 2...

  • Page 68: Link Box Fuses

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 21 - 2 Electrical System 21 - 2 Link Box Fuses Bulbs Rating (Watts) To further protect the machine wiring harnesses and Headlights - main 45 W electrical circuits, a fuse link box is fitted to the battery, as Headlights - dip 37.5 W shown at B.

  • Page 69: Battery

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 22 - 1 Battery 22 - 1 ! CAUTION Warning Symbols The following warning symbols may be found on the battery. Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged.

  • Page 70: First Aid - Electrolyte

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 22 - 2 Battery 22 - 2 ! WARNING Checking the Electrolyte Level Batteries give off an explosive gas. Do not smoke when Maintenance free batteries used in normal temperate climate handling or working on the battery. Keep the battery away applications should not need topping up.

  • Page 71: Cab Heater

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 23 - 1 Cab Heater 23 - 1 Changing the Recirculation Filter Renew the Filter Remove screws A, filter cover B and filter C. Insert a new filter into the filter cover and refit the filter cover. Note: The recirculation filter may be washed and re-used if in good condition.

  • Page 72: Windscreen Washer

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 24 - 1 Windscreen Washer 24 - 1 Fill the windscreen washer reservoir, through filler cap D, with a suitable liquid. The liquid should contain a de-icing fluid to prevent freezing. Do not use engine coolant antifreeze.

  • Page 73: Stabiliser Legs

    To adjust the clearance, screw pad B fully in until it just (contact your JCB Distributor). touches the inner leg and then back the pad off by one quarter of a turn.

  • Page 74: Align Road Wheels

    Section 3 Routine Maintenance Section 3 www.maskinisten.net 26 - 1 Align Road Wheels 26 - 1 ! WARNING At the start of each working period, and at least once a day, or if having difficulty in steering, check and, if necessary, re-align the road wheels.

  • Page 75: Fluids, Lubricants, Capacities And Specifications

    Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart.

  • Page 76: Coolant Mixtures

    7-3-4-4 The protection provided by JCB Four Seasons Antifreeze is shown below. If any other anti-freeze is used, refer to the manufacturers' 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.
  • Page 77 Section A Attachments Section A www.maskinisten.net Contents Page No. Service Tools 1 - 1 Hydraulic Tool Circuit (H.T.C.) Attachment Schematic Circuit 2 - 1 Circuit Description 2 - 2 Flow Diverter Valve Removal and Replacement 2 - 3 Dismantling and Assembly 2 - 4 Flow Testing 2 - 5...
  • Page 78 Section A Attachments Section A www.maskinisten.net Contents Page No. Airmaster Compressor Attachment - Continued Air/Oil Separator Removal and Replacement 30 - 1 Pressure Regulator Off-load Air Pressure Regulation 31 - 1 Checking Safety Valve Setting 31 - 1 Suction Unloader Dismantling 32 - 1 Assembly...

  • Page 79: Service Tools

    Section A Attachments Section A www.maskinisten.net 1 - 1 Service Tools 1 - 1 892/00878 Airmaster, Diaphram Assembly Tool - 892/00877 Airmaster, Air Test Silencer - safety Suction Unloader, tool shown in position device, attach to air delivery cocks when cocks are to be opened with no hose attached.

  • Page 80: Hydraulic Tool Circuit (H.t.c.) Attachment

    Section A Attachments Section A www.maskinisten.net 2 - 1 Hydraulic Tool Circuit (H.T.C.) 2 - 1 Schematic Hydraulic Circuit Component Key Hydraulic Tank Pump Loader Valve Block Filter Excavator Valve Block B.H.T.M.A. Class 'C' Quick Release Couplings Auxiliary Tool Switch Priority Flow Divider Hi-flow Return Line A173420...

  • Page 81: Circuit Description

    Section A Attachments Section A www.maskinisten.net 2 - 2 Hydraulic Tool Circuit (H.T.C.) 2 - 2 Circuit Description Oil from the hydraulic pump 2 enters the loader valve 3 (brake and steer circuits not shown). From the loader valve, the oil passes to flow diverter valve 8.

  • Page 82: Flow Diverter Valve

    Section A Attachments Section A www.maskinisten.net 2 - 3 Hydraulic Tool Circuit (H.T.C.) 2 - 3 Flow Diverter Valve Replacement Removal and Replacement Replacement is a reversal of the removal sequence. ! WARNING ! WARNING Make the machine safe before working underneath it. Park the machine on level ground, lower the arms.

  • Page 83: Dismantling And Assembly

    The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. When Assembling Renew all seals and 'O' rings. Lubricate with JCB Special Hydraulic Fluid. Torque Settings Item kgf m lbf ft 20.4...
  • Page 84 Section A Attachments Section A www.maskinisten.net 2 - 5 Hydraulic Tool Circuit (H.T.C.) 2 - 5 Flow Testing & Pressure Testing S198330 S205200 S205190 9803/7130 Issue 1...

  • Page 85: Flow Testing

    Section A Attachments Section A www.maskinisten.net 2 - 6 Hydraulic Tool Circuit (H.T.C.) 2 - 6 Flow Testing & Pressure Testing ! WARNING Pressure Testing Hydraulic Fluid Use the flow restrictor valve to pressurise the Fine jets of hydraulic fluid at high pressure can penetrate circuit.

  • Page 86: Airmaster Compressor Attachment

    Section A Attachments Section A www.maskinisten.net 5 - 1 Airmaster Compressor 5 - 1 Care and Safety It is expected that users will employ safe working practices and will observe any related legal requirements when operating or overhauling this machine. The following notes augment instructions given elsewhere in this publication and they are intended as a guide to the safe use of this machine and its associated compressed air supply under normal...
  • Page 87 Section A Attachments Section A www.maskinisten.net 5 - 2 Airmaster Compressor 5 - 2 Care and Safety (continued) ! Never apply compressed air to your skin or direct it at Using the Compressor Unit and Site Safety another person. Never use compressed air to blow dust and debris from your clothing.

  • Page 88: Unit Identification

    Section A Attachments Section A www.maskinisten.net 5 - 3 Airmaster Compressor 5 - 3 Unit Identification The air receiver serial number can be viewed through the access hole A located in the control console. The controls are located behind panel Y, use the key X provided with your machine to open the panel S212320 9803/7130...

  • Page 89: Safety Decals

    Section A Attachments Section A www.maskinisten.net 5 - 4 Airmaster Compressor 5 - 4 Safety Decals ! CAUTION ! WARNING Keep all decals clean and readable. Replace lost or RELEASE PARKBRAKE damaged decals. Each decal has a part number printed BEFORE on it, use this to order a new decal.

  • Page 90: Routine Maintenance

    Ambient Temperature Limitations Manufacturer -20 to +5 -10 to +25 -5 to Maximum Permissible JCB Hydraulic Fluid HP46 JCB Hydraulic Fluid HP46 JCB Hydraulic Fluid 68 Service Schedules Note: Operating hours refer to compressor hours NOT the Every 250 Operating Hours (or every 3 months -...

  • Page 91: Compressed Air Filter - Changing The Elements

    Section A Attachments Section A www.maskinisten.net 5 - 6 Airmaster Compressor 5 - 6 Routine Maintenance (continued) Compressor Air Filter - Changing the Elements ! CAUTION Clean inside the canister C and dust valve D. Do not run the compressor when the outer element has Test the seating of seals B and J: been removed.

  • Page 92: Compressor Oil And Filter - Draining Air Receiver Condensate

    Section A Attachments Section A www.maskinisten.net 5 - 7 Airmaster Compressor 5 - 7 Routine Maintenance (continued) Compressor Oil and Filter - Draining Air Receiver Compressor Oil and Filter - Checking Air Receiver Condensate Oil Level ! WARNING ! WARNING Oil is toxic.

  • Page 93: Changing Oil And Filter

    Section A Attachments Section A www.maskinisten.net 5 - 8 Airmaster Compressor 5 - 8 Routine Maintenance (continued) Compressor Oil and Filter - Changing Oil and Filter ! WARNING Oil 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.
  • Page 94 Section A Attachments Section A www.maskinisten.net 5 - 9 Airmaster Compressor 5 - 9 Routine Maintenance (continued) Compressor Oil and Filter - Drying the Separator Element The air/oil receiver separates the oil from the air/oil mixture after compression has taken place. In extreme conditions it is possible for the separator element (A) to become saturated.

  • Page 95: Safety Valve

    Section A Attachments Section A www.maskinisten.net 5 - 10 Airmaster Compressor 5 - 10 Routine Maintenance (continued) Safety Valve ! WARNING Fine jets of air/oil at high pressure can cause injury. Do not use your fingers to check for leaks. When checking the safety valve operation/setting always beware of escaping air/oil mixture.
  • Page 96 Section A Attachments Section A www.maskinisten.net 5 - 11 Airmaster Compressor 5 - 11 Routine Maintenance (continued) Cleaning the Oil Cooler Park the machine on firm level ground. Engage the parking brake and set the transmission to neutral. Stop the engine and remove the starter key. Remove the rear grille A to gain access to the cooler matrix.

  • Page 97: Oil Cooler

    Section A Attachments Section A www.maskinisten.net 7 - 1 Airmaster Compressor 7 - 1 Technical Data Performance Maximum working pressure 6.9 bar (100 Ibf/in Rated F.A.D. at full output to ISO 1217 73.2 Itr/sec (4.4 m /min, 155 ft /min) Maximum air delivery temperature at full output - at compressor unit discharge 120°C (248°F)
  • Page 98 Section A Attachments Section A www.maskinisten.net 9 - 1 Airmaster Compressor 9 - 1 S212090A S212090B S212090C S212090D 9803/7130 Issue 1...

  • Page 99: Basic Operation

    Section A Attachments Section A www.maskinisten.net 9 - 2 Airmaster Compressor 9 - 2 Basic Operation General Description Compression Cycle As the rotors revolve, air enters the compressor unit by way The compressor is an oil flooded, positive displacement, of the air cleaner unloader and the inlet port, filling the space single stage, rotary screw compressor driven by a power between the lobes of the male rotor and the flutes of the take-off from the transmission gearbox.

  • Page 100: Lubrication System

    Section A Attachments Section A www.maskinisten.net 15 - 1 Airmaster Compressor 15 - 1 Descriptions Lubrication System Cooling System When the compressor is running, the entire system is Heat is continuously extracted from the air being pressurised and oil is forced from the air/oil receiver 1, via compressed by the injection of a controlled flow of cool oil hose 2 to the oil cooler 3.

  • Page 101: Oil Separation And Recovery

    Section A Attachments Section A www.maskinisten.net 15 - 2 Airmaster Compressor 15 - 2 Descriptions (cont'd) Oil Separation and Recovery The air/oil receiver separates the oil from the air/oil mixture after compression has taken place and acts as an oil reservoir.
  • Page 102 Section A Attachments Section A www.maskinisten.net 15 - 3 Airmaster Compressor 15 - 3 A213020 9803/7130 Issue 1...

  • Page 103: Unloading And Speed Control

    Section A Attachments Section A www.maskinisten.net 15 - 4 Airmaster Compressor 15 - 4 Descriptions (cont'd) Unloading and Speed Control System The compressor air output is controlled by the unloader valve 4 which regulates the amount of air admitted to the compressor unit, in conjunction with variation of engine speed via control cylinder 7.

  • Page 104: Blow Down Valve

    Section A Attachments Section A www.maskinisten.net 15 - 5 Airmaster Compressor 15 - 5 Descriptions (cont'd) Blow Down Valve The blow down valve is situated on top of the receiver. It operates automatically to release all air pressure within the system on shut-down, thus ensuring that the plant is not started against delivery pressure.

  • Page 105: Transmission

    Section A Attachments Section A www.maskinisten.net 15 - 6 Airmaster Compressor 15 - 6 Descriptions (cont'd) Transmission The Airmaster compressor is driven by a propshaft connected to a P.T.O. on the syncro shuttle gearbox. For descriptions and procedures relating to the P.T.O. and propshaft systems and components see Section F, Transmission.

  • Page 106: Fault Finding

    Section A Attachments Section A www.maskinisten.net 20 - 1 Airmaster Compressor 20 - 1 Fault Finding FAULT POSSIBLE CAUSE REMEDY Compressor fails to build up a Choked air intake filter a Change air intake filter element to working pressure b Suction unloader valve stuck on seat b Inspect and release valve through unloader air intake c Faulty blow down valve...
  • Page 107 Section A Attachments Section A www.maskinisten.net 25 - 1 Airmaster Compressor 25 - 1 S254300 9803/7130 Issue 1...

  • Page 108: Commissioning The Compressor

    Section A Attachments Section A www.maskinisten.net 25 - 2 Airmaster Compressor 25 - 2 Commissioning the Compressor ! WARNING If for any reason the compressor settings are disturbed, for example if the throttle cable is replaced, or after major Keep clear of rotating parts. The compressor cooling fan servicing, the compressor should be set correctly using the will be rotating.

  • Page 109: Air/Oil Separator Removal And Replacement

    Section A Attachments Section A www.maskinisten.net 30 - 1 Airmaster Compressor 30 - 1 Air/Oil Separator Removal and Replacement Providing the compressor oil has been changed at the prescribed intervals and is free from contamination, the separator should require only infrequent attention. If, however, the oil consumption of the compressor rises or oil mist is discharged with the delivered air, then it may be necessary to change the air/oil separator.

  • Page 110: Pressure Regulator

    Section A Attachments Section A www.maskinisten.net 31 - 1 Airmaster Compressor 31 - 1 Pressure Regulator Off-load Air Pressure Regulation The pressure control system fitted to these machines operates over a range of approximately 1 bar (15 Ibf/in ), so that the off-load air pressure (unloader valve shut, engine idling) is approximately 1 bar higher than the full-load pressure (unloader valve wide open, engine at maximum...

  • Page 111: Suction Unloader Dismantling

    Section A Attachments Section A www.maskinisten.net 32 - 1 Airmaster Compressor 32 - 1 Suction Unloader Dismantling Unscrew the six screws 11 and remove the diaphragm body assembly 10 from the unloader body 4. Withdraw the valve and spring 7 from the piston 8. Secure the diaphragm body in a vice with the end cover 15 uppermost.
  • Page 112 Section A Attachments Section A www.maskinisten.net 32 - 2 Airmaster Compressor 32 - 2 9803/7130 Issue 1...
  • Page 113 Assemble the diaphragm, retaining plate and bolt, using JCB Lock & Seal (part number 4101/0202) on the threads (views 1- 4). Note: When fitting a new diaphragm, it is essential to first turn it inside out.
  • Page 114 Section A Attachments Section A www.maskinisten.net 33 - 1 Airmaster Compressor 33 - 1 S212000 9803/7130 Issue 1...

  • Page 115: Assembly

    (6, 24). Withdraw the spigot spacer equipment to prevent damage to parts. Contact JCB Special (21), oil thrower (19) and thrower spacer (18) from the Products for information on these special tools. The tools female rotor shaft.
  • Page 116 Section A Attachments Section A www.maskinisten.net 33 - 3 Airmaster Compressor 33 - 3 S211990 9803/7130 Issue 1...

  • Page 117: Assembly

    Using a new joint, and JCB Lock & Seal on the Place the delivery end casing in position over the rotor capscrews, refit the male bearing end cap, torquing the shafts and place the selected shims on their respective capscrews to 27 Nm (20 Ibf/ft).
  • Page 118 (Fig. 2 (8)) with JCB Super Clean Solvent. Use JCB Lock & Seal to make a seal between shaft and spacer by applying a complete run around the shaft about 20 mm from the bearing. Assemble the spacer and rotate a full circle to ensure a complete seal of sealant.
  • Page 119 Section B Body & Framework Section B www.maskinisten.net Contents Page No. Service Tools 1 - 1 Basic Operation Air Conditioning - R-134a Refrigerant 3 - 1 - System Operation 3 - 1 - System Control 3 - 2 Fault Finding Air Conditioning - General Fault Indications 10 - 1...

  • Page 120: Service Tools

    2 required to handle large panes of glass. No plug supplied. Note: 110V models available upon Ensure suction cups are protected from damage request - contact JCB Technical Service. during storage. JCB part number: JCB part number - 892/00842...
  • Page 121 'L' Blades - 25 mm (1 in) cut - replacement blades for cut-out knife (above). JCB part number - 992/12801 (unit quantity = 5 off) Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass.
  • Page 122 Service Tools 1 - 3 1 - 3 Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame. JCB part number - 926/15500 Nylon Spatula (unit quantity = 500 off) general tool used...

  • Page 123: Basic Operation

    This control enables refrigerant R-134a, which does not cause ozone depletion. air conditioned air to be heated to supply warm, de- The refrigerant used in the 2CX air conditioning system humidified air to the cab in cool, humid climates. is R-134a.

  • Page 124: System Control

    Section B Body & Framework Section B www.maskinisten.net 3 - 2 Basic Operation 3 - 2 Safety Procedures Air Conditioning (cont'd) The air conditioning system uses refrigerant under pressure The high temperature, high pressure refrigerant is forced by in a closed circuit. Any service procedure which breaks into compressor action into the expansion valve D, which meters the closed circuit and therefore requires discharging of the the amount of refrigerant entering the evaporator.

  • Page 125: Fault Finding

    Section B Body & Framework Section B www.maskinisten.net 10 - 1 Fault Finding 10 - 1 Air Conditioning Procedures that require charging or discharging the system are not given in this manual as they require special equipment that is usually held only by trained refrigeration engineers. The system will not function in very low ambient temperatures, therefore tests should be carried out in a warm environment.
  • Page 126 Section B Body & Framework Section B www.maskinisten.net 10 - 2 Fault Finding 10 - 2 Air Conditioning (cont’d) No Air Conditioning CHECK ACTION Are the controls set correctly, i.e. air conditioning YES: Check 2 selected, thermostat switch set to coldest position Reset controls and retest.

  • Page 127: Wiring Continuity Checks

    Section B Body & Framework Section B www.maskinisten.net 10 - 3 Fault Finding 10 - 3 Air Conditioning (cont'd) Wiring Continuity Checks Use the harness illustration below to complete continuity checks on the air conditioning harness wires.The harness connects to the mainframe harness via connector A, located behind the side console panel. ITEM DESCRIPTION Air Conditioning Power (from fuse C9)

  • Page 128: Service Procedures

    Section B Body & Framework Section B www.maskinisten.net 20 - 1 20 - 1 Service Procedures Air Conditioning Checking Refrigerant Charge Level The pressure in the system, i.e. the refrigerant charge level Leak Testing can be determined by checking the state of refrigerant at the receiver drier sight glass.

  • Page 129: Pressure Switch Testing

    Section B Body & Framework Section B www.maskinisten.net 20 - 2 Service Procedures 20 - 2 Air Conditioning Pressure Switches Removal and Replacement The 12V supply is fed from the thermostat to the ! WARNING compressor clutch via the low and high pressure switches which are wired in series.

  • Page 130: Condenser Coil Cleaning

    Section B Body & Framework Section B www.maskinisten.net 20 - 3 Service Procedures 20 - 3 Air Conditioning Condenser Coil Remove the starter key. It is likely that over a period of time, because of the Remove the front grille. machine's working environment, the airflow around the condenser coil will become restricted due to a build up of Remove both side panels.

  • Page 131: Filters - Changing And Cleaning

    Section B Body & Framework Section B www.maskinisten.net 20 - 4 Service Procedures 20 - 4 Air Conditioning Filters - Changing and Cleaning Recirculation Filter - Change/Clean Air Intake Filter - Clean Remove screws A, filter cover B and filter C. Insert a Stop the engine and remove the starter key.

  • Page 132: Compressor Drive Belt - Adjusting

    Section B Body & Framework Section B www.maskinisten.net 20 - 5 Service Procedures 20 - 5 Air Conditioning Compressor Drive Belt - Adjusting Park the machine on firm level ground. Raise and block the loader arms. Lower the backhoe to the ground and stop the engine.

  • Page 133: Glazing

    Reference is made to the tools in the text. The majority of these tools can Always wear safety glasses during both removal and be obtained locally and the remainder from JCB Service, replacement. refer to Service Tools.
  • Page 134 Section B Body & Framework Section B www.maskinisten.net 21 - 2 Service Procedures 21 - 2 Direct Glazing (cont'd) Removing the Broken Glass and Old Sealant (cont'd) 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 laminated...
  • Page 135 Section B Body & Framework Section B www.maskinisten.net 21 - 3 Service Procedures 21 - 3 Direct Glazing (cont'd) Removing the Broken Glass and Old Sealant (cont'd) Preparing the Cab Frame Aperture d Craft Knife H. The blades are replaceable. If damp or wet, dry the aperture area using a hot air gun (sourced locally).
  • Page 136 Section B Body & Framework Section B www.maskinisten.net 21 - 4 Service Procedures 21 - 4 Direct Glazing (cont'd) b If the glass does not have a black ceramic ink band, Preparing the New Glass (cont'd) paint a band on the glass using 'Black Primer 206J'. The band should be approximately 25mm (1in) wide, After checking for size, remove the new glass and place and the edge should be a neat straight line as shown...
  • Page 137 Section B Body & Framework Section B www.maskinisten.net 21 - 5 Service Procedures 21 - 5 Direct Glazing (cont'd) c Make sure that the glass is correctly positioned, then gently press around the edges of the glass and Preparing the New Glass (cont'd) ensure full adhesive contact is achieved.

  • Page 138: Cab Rops/Fops Structure - Checks

    Section B Body & Framework Section B www.maskinisten.net 22 - 1 Service Procedures 22 - 1 Cab ROPS/FOPS Structure - Checks ! WARNING The machine is fitted with a Roll Over Protection Structure (ROPS) and a Falling Objects Protection Structure (FOPS). You could be killed or seriously injured if you operate the machine with a damaged or missing ROPS/FOPS.

  • Page 139: Stabiliser Leg - Wear Pad Adjustment

    Section B Body & Framework Section B www.maskinisten.net 23 - 1 Service Procedures 23 - 1 Stabiliser Leg Wear Pad Adjustment Instructions for adjusting the wear pads are described in the maintenance section, refer to Section 3 Stabiliser Legs - Wear Pad Adjustment.

  • Page 140: Air Conditioning

    Section B Body & Framework Section B www.maskinisten.net 30 - 1 Air Conditioning 30 - 1 Blower Motor Thermostat Removal Removal Remove the four screws and the front panel 1 of air Disconnect the electrical connections from the conditioning unit. thermostat 4.
  • Page 141 Section B Body & Framework Section B www.maskinisten.net 40 - 1 Stabiliser Leg 40 - 1 S271851 9803/7130 Issue 1...
  • Page 142 When the inner leg is in position adjust the bottom pads, refer to Section 3 Stabiliser Legs - Wear Pad Adjustment. Apply a high pressure grease such as JCB HP Grease (part number 4003/2000) to the threads of pad B.
  • Page 143 Section C Electrics Section C www.maskinisten.net Contents Page No. Service Tools 1 - 1 Technical Data System Type 2 - 1 Fuses & Relays 2 - 2 Fuse Link Box 2 - 3 Basic System Operation Circuit Schematics 4 - 1 Service Procedures Battery - Maintenance...
  • Page 144 Section C Electrics Section C www.maskinisten.net 1 - 1 Service Tools 1 - 1 993/85700 Battery Tester Wiring Harness Repair Tools 892/00350 Butane Heater Assembly 892/00349 Crimp Tool 892/00351 Splice 0.5 - 1.5mm (Red) 892/00352 Splice 1.5 - 2.5mm (Blue) 892/00353 Splice 3.0 - 6.0mm (Yellow) AVO Test Kit 892/00283...
  • Page 145 Section C Electrics Section C www.maskinisten.net 2 - 1 Technical Data 2 - 1 System Type 12 Volt, negative earth Battery Cranking Performance at -18 °C (0 °F) 410 Amps to 1.4 V.P.C. Reserve Capacity (minutes) for 25 amp load Alternator A127, 55 Amp max.
  • Page 146 Section C Electrics Section C www.maskinisten.net 2 - 2 Technical Data 2 - 2 Fuses Relays ! CAUTION Indicators Front working lights Always replace fuses with ones of correct ampere rating Rear working lights to avoid electrical system damage. Starter 1 8-3-3-5 Starter 2 Buzzer...
  • Page 147 Section C Electrics Section C www.maskinisten.net 2 - 3 Technical Data 2 - 3 Fuse Link Box To further protect the machine wiring harnesses and electrical circuits, a fuse link box is fitted to the battery, as shown at A. Remember to check the main circuit fuses as well as the link box fuses shown on this page.
  • Page 148 Section C Electrics Section C www.maskinisten.net 4 - 1 Basic System Operation 4 - 1 FUSE P3 FUSE P3 BATTERY FEED TTERY FEED FUSE P2 FUSE P2 200M 200M FUSE P1 FUSE P1 200G/200L 200G/200L FUSE P4 FUSE P4 200E/200R 200E/200R A395410 9803/7130...
  • Page 149 Section C Electrics Section C www.maskinisten.net 4 - 2 Basic System Operation 4 - 2 Circuit Schematics Front Instrument Console Warning Lights Front Instrument Console Warning Lights Front Instrument Console Warning Lights Front Instrument Console Warning Lights 2 Wheel Steer Selected Warning Light Component Key: Turn Signal Indicator Warning Light Thermostart...
  • Page 150 Section C Electrics Section C www.maskinisten.net 4 - 3 Basic System Operation 4 - 3 69 71 73 75 77 105 106 110 111 SIDE CONSOLE FRONT CONSOLE INSTRUMENTS INSTRUMENTS BATTERY FEED TTERY FEED 200M 200G/200L 200E/200R A395370 9803/7130 Issue 1...
  • Page 151 Section C Electrics Section C www.maskinisten.net 4 - 4 Basic System Operation 4 - 4 FUSE P3 FUSE P3 BATTERY FEED FUSE P2 FUSE P2 200M FUSE P1 FUSE P1 200G/200L FUSE P4 FUSE P4 200E/200R A395380 9803/7130 Issue 1...
  • Page 152 Section C Electrics Section C www.maskinisten.net 4 - 5 Basic System Operation 4 - 5 Circuit Schematics Turn Signal Indicator Warning Light Hazard Warning Light Main Beam Warning Light 212SU Utility Front Instrument Console Warning Lights Front Instrument Console Warning Lights Component Key: Alternator No Charge Warning Light Thermostart...
  • Page 153 Section C Electrics Section C www.maskinisten.net 4 - 6 Basic System Operation 4 - 6 66 68 70 72 74 98 99 79 82 84 87 FRONT CONSOLE INSTRUMENTS BATTERY FEED 200D/200M 200G 200E/200R A395390 9803/7130 Issue 1...
  • Page 154 Section C Electrics Section C www.maskinisten.net 4 - 7 Basic System Operation 4 - 7 22 23 24 HAND HELD HYDRACLAMP HEATER/AIR CON. HAMMER RADIO AIRMASTER HEATER TOOLS COMPRESSOR A395400 9803/7130 Issue 1...
  • Page 155 Electrics Section C www.maskinisten.net 4 - 8 Basic System Operation 4 - 8 Circuit Schematics 2CX, 212SU Utillity Options Hand Held Hydraulic Tools Circuit Cab Heater Circuit Component Key: Component Key: Auxillary Feed Socket Cab Heater Fan Motor Hand Held Tools Solenoid...
  • Page 156 Section C Electrics Section C www.maskinisten.net 20 - 1 Service Procedures 20 - 1 Battery Maintenance Safety ! WARNING To ensure that the battery provides optimum performance Batteries give off an explosive gas. Do not smoke when the following steps should be observed: handling or working on the battery.
  • Page 157 Section C Electrics Section C www.maskinisten.net 20 - 2 Service Procedures 20 - 2 Battery (cont’d) Testing This test is to determine the electrical condition of the Set the CHECK/LOAD switch A to LOAD and hold down battery and to give an indication of the remaining useful for 5 - 10 seconds until the meter reading stabilises.
  • Page 158 Section C Electrics Section C www.maskinisten.net 21 - 1 Sevice Procedures 21 - 1 Alternator Connect the leads to the meter and set the meter to the relevant range as follows. General Description AVO 2002 Red lead to volts (middle) socket on meter. Black lead to negative on meter.
  • Page 159 Section C Electrics Section C www.maskinisten.net 22 - 1 Sevice Procedures 22 - 1 Starter Motor Starting Circuit Test Test 3 Before carrying out the voltmeter tests, check the battery Connect the voltmeter between the solenoid terminal C and condition (see Battery Testing) and ensure that all a good earth.
  • Page 160 Section C Electrics Section C www.maskinisten.net 22 - 2 Sevice Procedures 22 - 2 Starter Motor (cont’d) Starting Circuit Test (cont'd) Test 5 Test 3b Connect the voltmeter between battery positive and the starter main terminal A. With the starter switch 'off', the If the reading between terminal D and earth is below 8.0V, voltmeter should indicate battery voltage, but it should fall to connect the voltmeter between terminal E and earth.
  • Page 161 Cut the wire and remove the protective insulation for a Note that JCB harnesses have an International Protection suitable distance dependent upon the size of wire and rating of 67 (I.P.67).
  • Page 162 Section C Electrics Section C www.maskinisten.net 23 - 2 Service Procedures 23 - 2 Wiring Harness - Repair Procedure (cont'd) With the Butane Heater assembly 892/00350, seal the connection using the following procedure. Remove the cap A from the end of the disposable gas cartridge B.
  • Page 163 Section C Electrics Section C www.maskinisten.net 23 - 3 Service Procedures 23 - 3 Wiring Harness - Repair Procedure (cont'd) Turn the red ring D to the right (in the direction of the plus sign) in order to turn on the gas. IMPORTANT: Before turning the heater on, make sure that the cartridge is not hotter than the reflector element.
  • Page 164 Section C Electrics Section C www.maskinisten.net 30 - 1 Alternator 30 - 1 Removal and Replacement Disconnect the battery. Remove the fan guard, if fitted. Disconnect cables from rear of alternator, remove bolts A, B and C and withdraw unit from machine. Replace by reversing the removal sequence.

  • Page 165: Removal And Replacement

    Section C Electrics Section C www.maskinisten.net 40 - 1 Starter Motor 40 - 1 Removal and Replacement Disconnect cables and remove battery. Remove cables from main starter terminal A and solenoid terminal B. Using special tool 825/00410 (and adapter 825/99833 if required) unscrew three securing nuts C and remove starter motor.
  • Page 166 Section D Controls Section D www.maskinisten.net Contents Page No. Steering Column Removal and Replacement 30 - 1 Dismantling and Assembly 30 - 1 Loader Control Knob Dismantling and Assembly 32 - 1 9803/7130 Issue 1...
  • Page 167 Section D Controls Section D www.maskinisten.net 30 - 1 Steering Column 30 - 1 A390880 A390860 9803/7130 Issue 1...

  • Page 168: Removal And Replacement

    Section D Controls Section D www.maskinisten.net 30 - 2 Steering Column 30 - 2 Removal and Replacement Dismantling and Assembly The illustration on the adjacent page is intended as a guide The illustration on the adjacent page is intended as a guide to removal and replacement.
  • Page 169 Microswitch 4, adapter 5, and rubber cover 6 may now be withdrawn through the knob. Assembly Apply JCB Threadlocker and Sealer to microswitch adapter 5 prior to assembly. Note: Microswitch 4 is a non-service item, and must be replaced as an assembly.
  • Page 170 Section E Hydraulics Section E www.maskinisten.net Contents Page No. Service Tools 1 - 1 Technical Data System Type 2 - 1 Hydraulic Pumps 2 - 1 Relief Valve Pressures 2 - 1 Smooth Ride System 2 - 2 Basic System Operation Component Location 3 - 1 Neutral Circuit Description...
  • Page 171 62 - 1 - Hydraclamp Valve 63 - 1 Hydraulic Rams - Dismantling and Assembly Typical Ram 80 - 1 JCB Ram Sealing Procedure 85 - 1 Smooth Ride System Accumulator - Removal and Replacement 101 - 1 - Dismantling and Assembly...
  • Page 172 Section E Hydraulics Section E www.maskinisten.net 1 - 1 Service Tools 1 - 1 Hydraulic Circuit Pressure Test Kit 892/00253 Pressure Test Kit 892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in 892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in 892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in 892/00254 Replacement Hose 892/00347 Gauge Connector S188120...
  • Page 173 Section E Hydraulics Section E www.maskinisten.net 1 - 2 Service Tools 1 - 2 Tool Components for Hamworthy A.R.V. testing 892/00252 Test Block for A.R.V. 992/02400 Tee-piece 1606/0003 Adapter 3/8 in. x 1/4 in. BSP 1406/0011 Bonded Washer 2401/0103 ‘O’ Ring 1406/0018 Bonded Washer 992/01003...
  • Page 174 Section E Hydraulics Section E www.maskinisten.net 1 - 3 Service Tools 1 - 3 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 BSP 816/00193 1 in BSP S193880 S216250 892/003334 Ram Seal Fitting Tool...
  • Page 175 Section E Hydraulics Section E www.maskinisten.net 1 - 4 Service Tools 1 - 4 892/01027 Piston Seal Assembly Tool S338410 11 o Ram Seal Protection Sleeves 10mm 20mm 892/01016 For 25 mm Rod Diameter 892/01017 For 30 mm Rod Diameter 892/01018 For 40 mm Rod Diameter 892/01019...
  • Page 176 Section E Hydraulics Section E www.maskinisten.net 2 - 1 Technical Data 2 - 1 System Type An engine driven gear pump provides a fixed flow output to supply the steering, loader and excavator hydraulic circuits. This is supplemented by an auxiliary gear pump on some machine configurations where additional flow is required.
  • Page 177 Section E Hydraulics Section E www.maskinisten.net 2 - 2 Technical Data 2 - 2 Smooth Ride System System Type A piston type accumulator operates as a liquid spring absorbing displaced fluid from the lift rams. Selectable from a switch in the cab. Charging Gas Air Free Dry Nitrogen Accumulator Capacity...
  • Page 178 Section E Hydraulics Section E www.maskinisten.net 3 - 1 Basic System Operation 3 - 1 9803/7130 Issue 1...
  • Page 179 Section E Hydraulics Section E www.maskinisten.net 3 - 2 Basic System Operation 3 - 2 9803/7130 Issue 1...

  • Page 180: Introduction To Hydraulic Schematic Symbols

    Section E Hydraulics Section E www.maskinisten.net 3 - 5 Basic System Operation 3 - 5 Introduction to Hydraulic Schematic Pumps & Motors Symbols Complex hydraulic components and circuits can be Variable capacity pump described to the engineer by using graphical symbols. The two directions of flow following pages illustrate and give a brief description for some of the more common symbols used.
  • Page 181 Section E Hydraulics Section E www.maskinisten.net 3 - 6 Basic System Operation 3 - 6 Introduction to Hydraulic Schematic Symbols (cont'd) Control Valves 3-Position, 4-Port High pressure selector spring centred pilot (shuttle valve) operated valve 3-Position, 6-Port spring centred hand Throttling orifice - operated valve normally closed...
  • Page 182 Section E Hydraulics Section E www.maskinisten.net 3 - 7 Basic System Operation 3 - 7 Introduction to Hydraulic Schematic Symbols (cont'd) Energy Transmissions and Conditioning Working line, return or feed Reservoir - return line above fluid level Pilot control Reservoir - return line below fluid level Drain lines Flexible pipe...
  • Page 183 Section E Hydraulics Section E www.maskinisten.net 3 - 8 Basic System Operation 3 - 8 Introduction to Hydraulic Schematic Symbols (cont'd) Control Mechanisms Rotating shaft-one direction Solenoid one winding Rotating shaft-two directions Solenoid two winding Detent Electric motor operated Locking device Internal pressure pilot operated Over centre device...
  • Page 184 Port 2 the flow arrows take in their respective operating squares. Port 4 Three typical JCB style spools are known as 'D' spools, 'F' spools and 'N' spools. The 'D' spools generally control rams because when in the FIG 4 neutral position the outlet ports are blocked, preventing ram movement.
  • Page 185 Section E Hydraulics Section E www.maskinisten.net 3 - 10 Basic System Operation 3 - 10 Introduction to Hydraulic Schematic Symbols (cont'd) Example of Schematic Circuit Some of the symbols described on the preceding pages Example Circuit Key have been arranged into a simple schematic circuit shown below.
  • Page 186 3G Auxiliary /Quick Hitch ram head side A.R.V. Rockbreaker 3H Auxiliary /Quick Hitch ram rod side A.R.V. Load hold check valves Note: Excavator services shown here are to the JCB 'X' Excavator valve block control pattern. For ISO '+' control pattern, components 4B, 4A Slew spool...

  • Page 187: Circuit Schematic

    Section E Hydraulics Section E www.maskinisten.net 3 - 16 Circuit Schematic 3 - 16 A390550 Issue 1 9803/7130...
  • Page 188 Section E Hydraulics Section E www.maskinisten.net 3 - 17 Circuit Schematic 3 - 17 A390770 Issue 1 9803/7130...
  • Page 189 Hydraulics Section E www.maskinisten.net 3 - 18 Basic System Operation 3 - 18 Hydraulic System Schematic 2CX Airmaster Component Key Tank 1A Tank cap 1B Filter with bypass 1C Suction strainer Main pump Loader valve block (2 or 3 spool)
  • Page 190 Hydraulics Section E www.maskinisten.net 3 - 19 Basic System Operation 3 - 19 Hydraulic System Schematic 2CX Farm Master Component Key Tank 1A Tank cap 1B Filter with bypass 1C Suction strainer Main pump Loader valve block (2 or 3 spool)
  • Page 191 Section C Hydraulics Section C www.maskinisten.net 3 - 20 Circuit Schematic 3 - 20 A390710 Issue 1 9803/7130...
  • Page 192 Section E Hydraulics Section E www.maskinisten.net 3 - 21 Circuit Schematic 3 - 21 A390720 A390720 Issue 1 9803/7130...
  • Page 193 Section E Hydraulics Section E www.maskinisten.net 3 - 22 Basic System Operation 3 - 22 Hydraulic System Schematic 2CXU, 212SU Utility Component Key Tank 1A Tank cap 1B Filter with bypass 1C Suction strainer Main pump Loader valve block (2 or 3 spool) 3A Loader shovel spool 3B Loader lift spool with float 3C Auxiliary /Quick Hitch spool...

  • Page 194: Circuit Descriptions

    Section E Hydraulics Section E www.maskinisten.net 4 - 1 Circuit Descriptions 4 - 1 Hydraulic Pump Operation (Typical) The hydraulic pump is a gear type. The basic principle of the Component Key: pump depends on the meshing of the two spur gears A and B, one of which is engine-driven whilst the other is an idler.
  • Page 195 Section E Hydraulics Section E www.maskinisten.net 4 - 2 Circuit Descriptions 4 - 2 Key to Oil Flow & Pressure Full Pressure Pressure A390330 Servo Neutral Exhaust Cavitation Lock Up A390630 9803/7130 Issue 1...
  • Page 196 Section E Hydraulics Section E www.maskinisten.net 5 - 1 Circuit Descriptions 5 - 1 3B 3A Key to Oil Flow & Pressure A390340 Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 9803/7130 Issue 1...
  • Page 197 Section E Hydraulics Section E www.maskinisten.net 5 - 2 Circuit Descriptions 5 - 2 Loader Valve Neutral Circuit The loader valve is mounted on the chassis frame, right Component Key: hand side (when viewed from the rear). Tank Port It includes the shovel ram spool 3A, lift ram spool 3B and Parallel gallery auxiliary spool 3C.
  • Page 198 Section E Hydraulics Section E www.maskinisten.net 5 - 3 Circuit Descriptions 5 - 3 Loader Valve - Load Hold Check Valves Component Key: Operation 1 Parallel Gallery The illustration shows 'arms raise' being selected by the lift Service Line ram spool 3B. 1A Pump Inlet 3B Lift Ram Spool The weight of the loaded shovel, as indicated by the arrows,...
  • Page 199 Section E Hydraulics Section E www.maskinisten.net 5 - 4 Circuit Descriptions 5 - 4 A390350 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A390360 9803/7130 Issue 1...
  • Page 200 Section E Hydraulics Section E www.maskinisten.net 5 - 5 Circuit Descriptions 5 - 5 A390370 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A390380 9803/7130 Issue 1...

  • Page 201: Loader Valve

    Section E Hydraulics Section E www.maskinisten.net 5 - 6 Circuit Descriptions 5 - 6 Loader Valve Arms Lower Component Key: When a spool is selected as shown at 3B, the central lands Spool Waist of the spool C block the neutral circuit. Oil from the pump, Spool Lands entering at 1A, is diverted into the parallel gallery X, flows Spool Waist...
  • Page 202 Section E Hydraulics Section E www.maskinisten.net 5 - 7 Circuit Descriptions 5 - 7 Loader Valve - A.R.V. Operation Component Key: Under normal operating conditions, with the shovel in the 'carry' position, the mechanical linkage keeps the shovel Tank Port level as the arms are raised, to prevent spillage of the load.
  • Page 203 Section E Hydraulics Section E www.maskinisten.net 5 - 8 Circuit Descriptions 5 - 8 A390390 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 9803/7130 Issue 1...
  • Page 204 Section E Hydraulics Section E www.maskinisten.net 6 - 1 Circuit Descriptions 6 - 1 A390400 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 9803/7130 Issue 1...
  • Page 205 Section E Hydraulics Section E www.maskinisten.net 6 - 2 Circuit Descriptions 6 - 2 Main Relief Valve - Operation The main relief valve (M.R.V.) 3D, situated in the loader valve Component Key: block, provides control of both loader and excavator pressures.

  • Page 206: Excavator Valve Neutral Circuit

    7 - 1 Circuit Descriptions 7 - 1 Excavator Valve Neutral Circuit Component Key: (JCB 'X' Control Pattern) Oil from the loader valve enters the excavator valve at A and flows through the neutral gallery and around the waists Inlet of the solid spools.
  • Page 207 Section E Hydraulics Section E www.maskinisten.net 7 - 2 Circuit Descriptions 7 - 2 Key to Oil Flow & Pressure Full Pressure Pressure Servo A390410 Neutral Exhaust Cavitation Lock Up A390630 9803/7130 Issue 1...
  • Page 208 Section E Hydraulics Section E www.maskinisten.net 7 - 3 Circuit Descriptions 7 - 3 A390420 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A390430 9803/7130 Issue 1...
  • Page 209 Section E Hydraulics Section E www.maskinisten.net 7 - 4 Circuit Descriptions 7 - 4 Excavator Valve - Load Hold Check Valves Component Key: Operation 1 Parallel Gallery Flow to the service via a typical solid spool 4B is controlled Service Line by the load hold check valve 4S which is a spring-loaded 4B Spool non-return valve operating across the pressure feed from the...
  • Page 210 Section E Hydraulics Section E www.maskinisten.net 7 - 5 Circuit Descriptions 7 - 5 Excavator Valve - Bi-Restrictor Operation Componet Key: Because of its weight, the excavator end could take over control when boom lower was selected. The falling boom Lower Service Port would tend to push oil out of the ram faster than the head Upper Service Port...
  • Page 211 Section E Hydraulics Section E www.maskinisten.net 7 - 6 Circuit Descriptions 7 - 6 A390440 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A390460 9803/7130 Issue 1...
  • Page 212 Section E Hydraulics Section E www.maskinisten.net 7 - 7 Circuit Descriptions 7 - 7 Key to Oil Flow & Pressure A390470 Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 A390450 9803/7130 Issue 1...
  • Page 213 Section E Hydraulics Section E www.maskinisten.net 7 - 8 Circuit Descriptions 7 - 8 Excavator Valve - Slew A.R.V. and Anti- Cavitation Operation The spool 4A is in neutral but the momentum of the slewing Componet Key: excavator end creates back pressure in the head side of the R.H.

  • Page 214: Pilot Operated Pressure Relief Valve Operation

    Section E Hydraulics Section E www.maskinisten.net 7 - 9 Circuit Descriptions 7 - 9 Pilot-Operated Pressure Relief Valve Operation Component Key: Valve at Rest A Service Pressure A.R.V's are positioned in the excavator valve block in order B Poppet to relieve excessive pressure in the services as shown on C Piston page E-7- 7.
  • Page 215 Section E Hydraulics Section E www.maskinisten.net 7 - 10 Circuit Descriptions 7 - 10 A390480 Key to Oil Flow & Pressure Full Pressure Pressure Servo Neutral Exhaust Cavitation Lock Up A390630 9803/7130 Issue 1...
  • Page 216 Section E Hydraulics Section E www.maskinisten.net 8 - 1 Circuit Descriptions 8 - 1 Key to Oil Flow & Pressure Full Pressure Pressure Servo A390544 Neutral Exhaust Cavitation Lock Up A390630 9803/7130 Issue 1...
  • Page 217 Section E Hydraulics Section E www.maskinisten.net 8 - 2 Circuit Descriptions 8 - 2 Ram Operation and End Damping The illustration shows pressurised oil fed to the head side of Component Key: the ram via port A. As the pressurised oil causes the ram to move up the cylinder bore, exhaust oil is vented from the rod Head Side Port side of the rem via port B.
  • Page 218 Section E Hydraulics Section E www.maskinisten.net 10 - 1 Circuit Descriptions 10 - 1 9803/7130 Issue 1...
  • Page 219 Section E Hydraulics Section E www.maskinisten.net 10 - 2 Circuit Descriptions 10 - 2 9803/7130 Issue 1...

  • Page 220: Smooth Ride System

    Section E Hydraulics Section E www.maskinisten.net 15 - 1 Fault Finding 15 - 1 Fault Finding Contents Introduction Page No. The purpose of this section is to help you trace hydraulic faults to a faulty unit (valve, actuator, ram etc). Once you have traced the faulty unit, refer to the appropriate Introduction 15 - 1...
  • Page 221 Section E Hydraulics Section E www.maskinisten.net 15 - 2 Fault Finding 15 - 2 Fault Probable Cause Action All hydraulic rams slow to operate. Neutral circuit or low pressure Check pipe lines and replace as required. lines leaking, damaged, trapped or kinked.
  • Page 222 Section E Hydraulics Section E www.maskinisten.net 15 - 3 Fault Finding 15 - 3 Fault Probable Cause Action A spool is sticking. Oil temperature abnormally high. Check for correct fluid, see Lubricants and Capacities. Check oil cooler and grille for blockage. The hydraulic fluid is dirty.
  • Page 223 Section E Hydraulics Section E www.maskinisten.net 15 - 4 Fault Finding 15 - 4 Fault Probable Cause Action Hydraulic oil becomes too hot Oil cooler obstructed Remove debris from cooler matrix fins. Restriction in neutral circuit Check hoses, replace as necessary lines Hydraulic filter clogged and Change hydraulic filter.

  • Page 224: Smooth Ride System

    Section E Hydraulics Section E www.maskinisten.net 15 - 5 Fault Finding 15 - 5 Smooth Ride System Fault Probable Cause Action Unable to power down loader arms Rod side solenoid valve open. Check if solenoid operating, replace with system switched OFF. solenoid or selector valve as required.

  • Page 225: Service Procedures

    Section E Hydraulics Section E www.maskinisten.net 20 - 1 Service Procedures 20 - 1 Hydraulic Contamination Hydraulic Fluid Quality Contaminant Standards Construction machinery uses a large volume of fluid in the Dirt that damages your system is in many cases too small to hydraulic system for power transmission, equipment be seen with the eye.

  • Page 226: Flow And Pressure Testing

    Section E Hydraulics Section E www.maskinisten.net 21 - 1 Service Procedures 21 - 1 Flow and Pressure Testing Main Pump If the flow is less than that specified replace the pump The main hydraulic pump is mounted on the left side of the engine and driven from the power take off point below the complete.
  • Page 227 Section E Hydraulics Section E www.maskinisten.net 21 - 2 Service Procedures 21 - 2 Flow and Pressure Testing Auxiliary Pump On some machines a second pump is mounted on the right side of the engine and driven by an auxiliary power take off. The unit supplies additional flow to the excavator valve.

  • Page 228: Pressure Testing

    Section E Hydraulics Section E www.maskinisten.net 22 - 1 Service Procedures 22 - 1 Pressure Testing Main Relief Valve (M.R.V.) - In situ The MRV is housed in the loader valve block. 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;...
  • Page 229 Section E Hydraulics Section E www.maskinisten.net 22 - 2 Service Procedures 22 - 2 Pressure Testing Auxiliary Relief Valves (A.R.V's) - Using Hand Pump Insert the A.R.V. into the test block (service tool 892/00252). Connect hand pump (service tool 892/00223) and a 0-400 bar (0-6000 lbf/in ) pressure gauge.

  • Page 230: Quick Release Couplings

    Section E Hydraulics Section E www.maskinisten.net 23 - 1 Service Procedures 23 - 1 Quick Release Couplings - Connecting and Disconnecting ! WARNING Flat face quick release couplings allow the operator to Hydraulic fluid at pressure can injure you. Make the remove and install attachments swiftly and efficiently.

  • Page 231: Smooth Ride System

    Section E Hydraulics Section E www.maskinisten.net 25 - 1 Service Procedures 25 - 1 Smooth Ride System Charging/Discharging the Accumulator Discharging Charging Park the machine on level ground, lower the loader Park the machine on level ground, lower the loader arms, switch off the engine and chock all four wheels.

  • Page 232: Main Pump

    Section E Hydraulics Section E www.maskinisten.net 30 - 1 Main Pump 30 - 1 Removal and Replacement Before removing and dismantling the pump, check flow and pressure. If either of these are low and cannot be corrected at the relief valve, the pump must be renewed completely. Renewal of components such as gears, bearings and housing will not effect a permanent cure.
  • Page 233 Section E Hydraulics Section E www.maskinisten.net 31 - 1 Main Pump 31 - 1 9803/7130 Issue 1...
  • Page 234 Section E Hydraulics Section E www.maskinisten.net 31 - 2 Main Pump 31 - 2 Dismantling and Assembly Inspecting Before removing and dismantling the pump, check flow and pressure. If either of these are low the pump must be changed. Renewal of components such as gears, bearings Remove and discard all seals.
  • Page 235 Section E Hydraulics Section E www.maskinisten.net 31 - 3 Main Pump 31 - 3 9803/7130 Issue 1...
  • Page 236 Fit circlip 16 and outer shaft seal 15 with garter spring Item Kgf. m Ibf. ft C facing away from the pump. Coat seal lips with JCB HP grease. Fit seal 26 and back up seal 27 to balance plate 25, locate assembly into main body 5.

  • Page 237: Removal And Replacement

    Section E Hydraulics Section E www.maskinisten.net 40 - 1 Auxiliary Pump 40 - 1 Removal and Replacement Before removing and dismantling the pump, check flow and pressure. If either of these are low and cannot be corrected at the relief valve, the pump must be renewed completely. Renewal of components such as gears, bearings and housing will not effect a permanent cure.
  • Page 238 Section E Hydraulics Section E www.maskinisten.net 41 - 1 Auxiliary Pump 41 - 1 S230540 9803/7130 Issue 1...
  • Page 239 12 and cover 8 to ensure their correct positioning during assembly. Renew all seals and 'O' rings. Lubricate using JCB Special Hydraulic Fluid. Dismantle in the numerical order shown on the illustration opposite, bearing in mind the following...

  • Page 240: Removal And Replacement

    INT-3-1-11/1 Note: All hydraulic adapters that are installed together with a bonded sealing washer must also have JCB Threadseal Removal applied to the threads of the adapter. Operate the valve block levers back and forth to vent residual pressure.

  • Page 241: Dismantling And Assembly

    Renew all 'O' rings and back-up rings. For assembly the sequence should be reversed. Lubricate parts with JCB Hydraulic Fluid before assembling. Great care should be taken when dismantling and Make sure that all the parts move freely.
  • Page 242 Section E Hydraulics Section E www.maskinisten.net 52 - 2 Loader Valve 52 - 2 A262860 S262720 9803/7130 Issue 1...
  • Page 243 Section E Hydraulics Section E www.maskinisten.net 52 - 3 Loader Valve 52 - 3 A262850 S248470 9803/7130 Issue 1...
  • Page 244 Renew all 'O' rings and back-up rings. For assembly the sequence should be reversed. Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely. Great care should be taken when dismantling and assembling a valve to avoid the following:- Make sure that the ‘O’...

  • Page 245: Standard Spool

    Section E Hydraulics Section E www.maskinisten.net 54 - 1 Loader Valve 54 - 1 Dismantling and Assembly Standard Spool The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. Great care should be taken when dismantling and assembling a valve to avoid the following:- Contamination...
  • Page 246 Section E Hydraulics Section E www.maskinisten.net 54 - 2 Loader Valve 54 - 2 9803/7130 Issue 1...

  • Page 247: Float Spool

    Section E Hydraulics Section E www.maskinisten.net 55 - 1 Loader Valve 55 - 1 Dismantling and Assembly Float Spool The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. Great care should be taken when dismantling and assembling a valve to avoid the following:- Contamination...
  • Page 248 Section E Hydraulics Section E www.maskinisten.net 55 - 2 Loader Valve 55 - 2 9803/7130 Issue 1...

  • Page 249: Excavator Valve

    Remove clevis pins A to disconnect the control levers from the valve block spools. Note: All hydraulic adapters that are installed together with a bonded sealing washer must also have JCB Threadseal Disconnect all hydraulic hoses from the valve block and applied to the threads of the adapter.
  • Page 250 Section E Hydraulics Section E www.maskinisten.net 60 - 2 Excavator Valve 60 - 2 A390780 9803/7130 Issue 1...
  • Page 251 Section E Hydraulics Section E www.maskinisten.net 61 - 1 Excavator Valve 61 - 1 9803/7130 Issue 1...

  • Page 252: Dismantling And Assembly

    Inspect the valve components for scratches, nicks or any other type of damage, replace with new if required. Assembly Renew all 'O' rings. Lubricate new seals with JCB Hydraulic Fluid and take care to prevent them from being damaged by the sharp edges of S205350 the spool.
  • Page 253 Section E Hydraulics Section E www.maskinisten.net 62 - 1 Excavator Valve 62 - 1 9803/7130 Issue 1...
  • Page 254 Seven A.R.V's are fitted to the excavator valve block. The following procedure covers the dismantling and assembly of Renew all seals, using JCB Hydraulic Fluid as a lubricant. A.R.V's 4L, 4M and 4P. A.R.V's 4H, 4J, 4K and 4N are identical in design to those fitted in the loader valve, refer to Fit shims 7 to the same total thickness as those removed.
  • Page 255 Section E Hydraulics Section E www.maskinisten.net 63 - 1 Excavator Valve 63 - 1 9803/7130 Issue 1...

  • Page 256: Hydraclamp Valve

    Ensure that orifice X is clear. Great care should be taken when dismantling and assembling a valve to avoid the following:- Lubricate new seals with JCB Hydraulic Fluid. Contamination Damage to spools Ensure that plug 7 locates in groove Y of rotary spool 9.
  • Page 257 Section E Hydraulics Section E www.maskinisten.net 80 - 1 Hydraulic Rams 80 - 1 s263650 A263680 9803/7130 Issue 1...

  • Page 258: Typical Ram

    When Assembling - Typical Ram Clean threads of piston rod, piston head, end cap and cylinder using a wire brush. Use JCB Cleaner & Degreaser to When Dismantling ensure that all threads are free from grease, hydraulic oil and The numerical sequence shown on the illustration is intended old sealant.
  • Page 259 Position cylinder on bench and install rod assembly into cylinder. Apply JCB Threadlocker to first three threads of cylinder, torque tighten the end cap to 678 Nm (500 lbf ft). A263750 Note: If hydraulic oil contacts uncured Threadlocker a weakening of the bond will result.

  • Page 260: Jcb Ram Sealing Procedure

    Hydraulics 85 - 1 Hydraulic Rams 85 - 1 JCB Ram Sealing Procedure To fit new rod seal: Use seal fitting tool (892/00334) to fit rod seals, the size (diameter) and position of pins A is determined by the diameter and radial width of the rod seal being fitted.
  • Page 261 85 - 2 Hydraulic Rams 85 - 2 JCB Ram Sealing Procedure (continued) Fit new piston head seals: Use a blunt instrument (892/01027) shown at F, lever the inner seal G into the piston head seal groove, do not let the seal twist.

  • Page 262: Smooth Ride System

    Section E Hydraulics Section E www.maskinisten.net 101 - 1 Smooth Ride System 101 - 1 Accumulator Removal and Replacement Removal Replacement Park the machine on level ground, lower the loader Replacement is a reverse of removal. arms, switch off the engine and chock all four wheels. Release all hydraulic pressure in the accumulator by Charge the accumulator, refer to Service Procedures, selecting the SRS ON and operating the loader arm...
  • Page 263 Section E Hydraulics Section E www.maskinisten.net 101 - 2 Smooth Ride System 101 - 2 S308280 9803/7130 Issue 1...
  • Page 264 Section E Hydraulics Section E www.maskinisten.net 101 - 3 Smooth Ride System 101 - 3 Accumulator Dismantling and Assembly Dismantling Assembly ! DANGER Coat all internal components with clean hydraulic oil. Before disconnecting or dismantling the accumulator Fit piston seal 9, teflon back up rings 10 and seals 11. discharge all gas pressure.
  • Page 265 Section F Transmission Section F www.maskinisten.net Contents Page No. Service Tools Axles 1 - 1 Syncro Shuttle Gearbox 1 - 4 Technical Data Wheels and Tyres 2 - 1 Front and Rear Axle 2 - 2 Syncro Shuttle Gearbox 2 - 2 Torque Converter 2 - 3 Basic Operation...
  • Page 266 Section F Transmission Section F www.maskinisten.net Contents Page No. Drive Head with Limited Slip Differential - Dismantling and Assembly 42 - 1 Axle Hub and Driveshaft - Dismantling and Assembly 43 - 1 Rear Axle Removal and Replacement 50 - 1 Drive Head Maxtrac - Dismantling and Assembly 51 - 1...

  • Page 267: Service Tools

    Section F Transmission Section F www.maskinisten.net 1 - 1 Service Tools 1 - 1 Axles 892/00179 Bearing Press (use with appropriate adapters) 892/00812 Drive Coupling Spanner for front and rear axle yoke couplings and for 4WD output coupling on Syncro Shuttle S107750 S188200 892/00225...
  • Page 268 Section F Transmission Section F www.maskinisten.net 1 - 2 Service Tools 1 - 2 Axles (cont'd) 992/04000 Torque Multiplier (use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts) S197030 992/00800 Extractor for removing front axle pivot pin 892/00174 Measuring Cup - Pinion Head Bearing S190770...
  • Page 269 Section F Transmission Section F www.maskinisten.net 1 - 3 Service Tools 1 - 3 Axles (cont'd) Solid Spacer Setting Kit 892/00918 Setting Tool Kit 993/70111 Breakback Torque Wrench 921/52600 Spacer Kit 921/52627 Spacer 14.20 Service use Comprises of: 921/52601 Spacer 12.75 921/52602 Spacer 12.80 921/52603...

  • Page 270: Syncro Shuttle Gearbox

    Section F Transmission Section F www.maskinisten.net 1 - 4 Service Tools 1 - 4 Syncro Shuttle Gearbox 993/59400 End Float Setting Tool for gearbox: 993/59401 Base Plate 892/00304 Flow Test Adapter 993/59402 Setting Yoke 892/00301 Flow Test Adapter 993/59403 Mainshaft Adapter (long) 892/00302 Flow Test Adapter 993/59404 Mainshaft Adapter (short) 993/59405 Ouput Yoke Adapter Plate...

  • Page 271: Technical Data

    †† These tyre pressures are recommended when handling heavy or palletised loads. ††† These tyre pressures are recommended when using a rock breaker or patch planer. Note: If the tyres fitted to your machine are not listed, then contact your JCB Distributor for advice, DO NOT guess tyre pressures.
  • Page 272 Section F www.maskinisten.net 2 - 2 Technical Data 2 - 2 Front Axle (SD55) Type JCB spiral bevel input with epicyclic hub reduction Designation SD55 (without brakes) Installation Centre pivot Weight (dry, with no steer rams and without wheels) 354 kg (780 lb) approx Overall Gear Ratio (20’’...
  • Page 273 Section F Transmission Section F www.maskinisten.net 2 - 3 Technical Data 2 - 3 Syncro Shuttle (cont'd) Converter Pressures (in neutral) kgf/cm lbf/in 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...
  • Page 274 Colour Coded Dots 3 Brown 1 Pink & 1 Yellow 2 Orange & 1 Green Designation SSL11 SSS11 WH11 Stall Figures Airmaster Farm 2CX - 20 kph 2CXU 210S Master 210SU Engine Stall Speed 1 Converter only max r.p.m. 2127 2127 1790...

  • Page 275: Basic Operation

    Section F Transmission Section F www.maskinisten.net 3 - 1 Basic Operation 3 - 1 9803/7130 Issue 1...
  • Page 276 Section F Transmission Section F www.maskinisten.net 3 - 2 Basic Operation 3 - 2 9803/7130 Issue 1...
  • Page 277 Section F Transmission Section F www.maskinisten.net 3 - 3 Basic Operation 3 - 3 9803/7130 Issue 1...
  • Page 278 Section F Transmission Section F www.maskinisten.net 3 - 4 Basic Operation 3 - 4 9803/7130 Issue 1...
  • Page 279 Section F Transmission Section F www.maskinisten.net 3 - 5 Basic Operation 3 - 5 9803/7130 Issue 1...
  • Page 280 Section F Transmission Section F www.maskinisten.net 3 - 6 Basic Operation 3 - 6 9803/7130 Issue 1...

  • Page 281: Systems Description

    Section F Transmission Section F www.maskinisten.net 6 - 1 Systems Description 6 - 1 9803/7130 Issue 1...

  • Page 282: Synchromesh - Operation

    Section F Transmission Section F www.maskinisten.net 6 - 2 Systems Description 6 - 2 Syncro Shuttle Gearbox As the speeds are synchronised the radial load on the Synchromesh - Operation blocker pin and the syncro hub is reduced. This allows the syncro hub to slide freely along the blocker pin and engage The gearbox is fitted with 'Blocking Pin' synchromesh, its dog teeth with second gear, see diagram J.
  • Page 283 Section F Transmission Section F www.maskinisten.net 6 - 3 Systems Description 6 - 3 9803/7130 Issue 1...
  • Page 284 Section F Transmission Section F www.maskinisten.net 6 - 4 Systems Description 6 - 4 9803/7130 Issue 1...

  • Page 285: Fault Finding

    Section F Transmission Section F www.maskinisten.net 10 - 1 Fault Finding 10 - 1 Syncro-Shuttle Gearbox - Hydraulic Before commencing with the fault finding procedure make sure that the correct type of transmission fluid has been used. LACK OF POWER Possible Cause Remedy Poor engine condition.

  • Page 286: Mechanical

    Section F Transmission Section F www.maskinisten.net 10 - 2 Fault Finding 10 - 2 Syncro-Shuttle Gearbox - Hydraulic (cont'd) HIGH CONVERTER OUT PRESSURE Possible Cause Remedy Oil cooler/lines blocked. Clean cooler, free blockage. Converter in pressure incorrect Check converter in pressure correct Converter relief valve faulty.
  • Page 287 Section F Transmission Section F www.maskinisten.net 10 - 3 Fault Finding 10 - 3 Syncro Shuttle Gearbox - Mechanical 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.
  • Page 288 Section F Transmission Section F www.maskinisten.net 10 - 4 Fault Finding 10 - 4 Syncro Shuttle Gearbox - Mechanical (cont'd) CHECK ACTION Is 'converter in' pressure as specified? YES: Check 15 NO: Inspect converter relief valve for damage. Check cooler bypass relief valve pressure setting. Is pump being driven by converter? YES: Check pump pressure.
  • Page 289 Section F Transmission Section F www.maskinisten.net 10 - 5 Fault Finding 10 - 5 Syncro Shuttle Gearbox - Mechanical (cont'd) CHECK ACTION Are the selector rods worn or damaged? YES: Renew. NO: Check 34 Are the selector fork pads out of position? YES: Reposition or renew (check interlock).

  • Page 290: Pto

    Section F Transmission Section F www.maskinisten.net 10 - 6 Fault Finding 10 - 6 Power Take-Off Clutch FAULT POSSIBLE CAUSE ACTION PTO shaft does not turn. Solenoid valve faulty. Dismantle solenoid valve and check component parts, renew valve if necessary. Solenoid not energising.

  • Page 291: Service Procedures

    Section F Transmission Section F www.maskinisten.net 20 - 1 Service Procedures 20 - 1 Front and Rear Axle - Renewing the Pinion Oil Seal The pinion oil seal 4 may be renewed without removing the axle from the machine. ! WARNING A raised and badly supported machine can fall on you.

  • Page 292: Brakes - Testing For Piston Seal Leakage

    Section F Transmission Section F www.maskinisten.net 20 - 2 Service Procedures 20 - 2 Brakes Testing for Piston Seal Leakage Instructions for piston seal leakage tests are described in the brakes section, refer to Section G Service Procedures, Service Brakes - Brake Piston Seal Leakage Test. 9803/7130 Issue 1...
  • Page 293 Section F Transmission Section F www.maskinisten.net 21 - 1 Service Procedures 21 - 1 9803/7130 Issue 1...

  • Page 294: Pressure And Flow Tests

    Section F Transmission Section F www.maskinisten.net 21 - 2 Service Procedures 21 - 2 Pressure and Flow Tests If testing the complete transmission, the following procedures are listed in a logical sequence and should therefore be completed in the same sequence. Also, refer to the Fault Finding procedures at the beginning of the Before completing any of the transmission pressure/flow transmission section for reference to specific tests.
  • Page 295 Section F Transmission Section F www.maskinisten.net 21 - 3 Service Procedures 21 - 3 Pressure and Flow Tests (continued) Converter Relief (Safety) Valve Pressure Connect a 0-10 bar (0-145 lbf/in ) pressure gauge to test point D. Pump Flow Fit a load valve J into the converter out line. Stop engine, remove transmission filter F, and screw adapter X (service tool 892/00304) on to the threaded CAUTION: Make sure the load valve is in the OPEN position...

  • Page 296: Solenoid Valve

    Lightly lubricate all parts with clean transmission fluid before assembling. Check that the flying leads are secure and that the connectors are intact. Apply a small quantity of JCB Threadlocker & Sealer to the threads in the knurled nut 2 before fitting. 161590 9803/7130...

  • Page 297: Torque Converter Stall Test

    Section F Transmission Section F www.maskinisten.net 22 - 1 Service Procedures 22 - 1 Torque Converter Stall Test If engine speeds are higher than the stated figures Note: Before completing the torque converter stall test, check the transmission for clutch slippage or internal make sure that the mainline and clutch pressures are leakage.

  • Page 298: Removing And Replacing

    Retaining straps C stretch with use, therefore these straps must always be replaced with new ones. Apply JCB Threadlocker and Sealer to threads of all flange bolts. Note: Propshafts should be installed with their main shaft sections fitted to the axle end, and their sliding sections fitted to the transmission 4 wheel drive unit.

  • Page 299: Front Axle

    Section F Transmission Section F www.maskinisten.net 40 - 1 Front Axle 40 - 1 A390500 9803/7130 Issue 1...

  • Page 300: Removal And Replacement

    ! WARNING Replacing is the reverse of the removal sequence. Raised loader arms can drop suddenly and cause Apply JCB Threadlocker & Sealer to the threads of serious injury. Before working under raised loader arms, bolts B. fit the loader arm safety strut.
  • Page 301 Section F Transmission Section F www.maskinisten.net 41 - 1 Front Axle 41 - 1 Drive Head Maxtrac - Dismantling S385640 9803/7130 Issue 1...
  • Page 302 Section F Transmission Section F www.maskinisten.net 41 - 2 Front Axle 41 - 2 Drive Head Maxtrac - Dismantling The numerical sequence shown on the illustration is intended as a guide to dismantling. Drain the oil from the drive head. Remove the propshaft, refer to Propshafts - Removing and Replacing.
  • Page 303 Section F Transmission Section F www.maskinisten.net 41 - 3 Front Axle 41 - 3 Drive Head Maxtrac - Assembly S385640 9803/7130 Issue 1...
  • Page 304 Section F Transmission Section F www.maskinisten.net 41 - 4 Front Axle 41 - 4 Drive Head Maxtrac - Assembly The outline procedure below refers also to the following Fit special bracket D to the drive-head housing using aspects of the drivehead assembly, which are covered two M10 x 30 nuts and bolts.

  • Page 305: Drive Head Maxtrac

    Section F Transmission Section F www.maskinisten.net 41 - 5 Front Axle 41 - 5 Drive Head Maxtrac - Assembly (cont’d) S385640 9803/7130 Issue 1...
  • Page 306 Note: If the pinion is not free to rotate check the correct size Meshing. spacer has been fitted. Apply JCB Multigasket to the mating faces of drive head carrier 2 and the axle casing. Fit the drive head If rolling torque measured at step 10 is too high, fit the carrier to the axle casing with the crownwheel towards next larger size spacer.

  • Page 307: Pinion Depth Setting

    Section F Transmission Section F www.maskinisten.net 41 - 7 Front Axle 41 - 7 Pinion Depth Setting Place new pinion head bearing assembly on a flat surface and position service tool 892/00174 over the bearing. Measure gap A (e.g. 0.20 mm) and add this to the cup depth stamped on the tool (e.g.

  • Page 308: Collapsible Spacer Assembly

    Smear output shaft inner bearing 27 with JCB HP Grease before refitting. Fit bearing cup 28 over pinion shaft 23 and assemble into drive head casing.

  • Page 309: Crownwheel And Pinion Meshing

    Section F Transmission Section F www.maskinisten.net 41 - 9 Front Axle 41 - 9 Crownwheel and Pinion Meshing Meshing of the gears should be checked by marking three of the pinion teeth with engineers marking compound and rotating the pinion. The marking will then be transferred to the crown wheel teeth.
  • Page 310 Section F Transmission Section F www.maskinisten.net 42 - 1 Front Axle 42 - 1 Drive Head Limited Slip Differential - Dismantling S380240 9803/7130 Issue 1...
  • Page 311 Section F Transmission Section F www.maskinisten.net 42 - 2 Front Axle 42 - 2 Drive Head Limited Slip Differential - Dismantling The numerical sequence shown on the illustration is intended as a guide to dismantling. For assembly the sequence should be reversed. ! WARNING A raised and badly supported machine can fall on you.
  • Page 312 Section F Transmission Section F www.maskinisten.net 42 - 3 Front Axle 42 - 3 Drive Head Limited Slip Differential - Assembly S380240 9803/7130 Issue 1...
  • Page 313 Repeat steps 2, 3, and 4. If the end float is correct. Pinion Depth Setting Remove bolt 11 apply JCB Threadlock and Sealer to Collapsible Spacer Assembly threads of bolt then fit and tighten to 28 Nm (20 lbf ft).
  • Page 314 Section F Transmission Section F www.maskinisten.net 42 - 5 Front Axle 42 - 5 Drive Head Limited Slip Differential - Assembly S380240 9803/7130 Issue 1...
  • Page 315 Section F Transmission Section F www.maskinisten.net 42 - 6 Front Axle 42 - 6 Drive Head Limited Slip Differential - Fit sleeve B. Tighten adapter C to no more than 50 Nm to protect against bearing damage while spacer Assembly (cont’d) selection is verified making sure the pinion is free to rotate.
  • Page 316 Check tooth marking to verify crown and pinion are set correctly, refer to Crownwheel and Pinion Meshing. Apply JCB Multigasket to the mating faces of the drive head carrier 2 and the axle casing. Fit securing bolts 1 and tighten to 98 Nm (72 lbf ft, 10 kgf m).
  • Page 317 Section F Transmission Section F www.maskinisten.net 43 - 1 Front Axle 43 - 1 A313631 9803/7130 Issue 1...
  • Page 318 Section F Transmission Section F www.maskinisten.net 43 - 2 Front Axle 43 - 2 Axle Hub and Driveshaft - Dismantling ! WARNING A raised and badly supported machine can fall on you. Remove and discard combination oil seal 18. Position the machine on a firm, level surface before raising one end.
  • Page 319 Section F Transmission Section F www.maskinisten.net 43 - 3 Front Axle 43 - 3 A313631 9803/7130 Issue 1...
  • Page 320 Section F Transmission Section F www.maskinisten.net 43 - 4 Front Axle 43 - 4 Axle Hub and Driveshaft - Assembly Measure seal drag rolling force as follows: Refit the planet gear carrier 2 - DO NOT FIT THE Fit drive shaft 26 inner end into splines of differential SUN GEAR 8.
  • Page 321 Section F Transmission Section F www.maskinisten.net 50 - 1 Rear Axle 50 - 1 A390490 9803/7130 Issue 1...
  • Page 322 Replacing is the reverse of the removal sequence. Engage the parking brake and block the front wheels. Use the stabiliser legs to raise the rear end of the Apply JCB Threadlocker & Sealer to the threads of machine. bolts A.
  • Page 323 Section F Transmission Section F www.maskinisten.net 51 - 1 Rear Axle 51 - 1 Drive Head Maxtrac - Dismantling As the drivehead cannot be dismantled whilst fitted on the machine, we recommend that the complete axle is removed, refer to Rear Axle - Removal and Replacement. Note: The crownwheel and pinion are matched and should be renewed as a pair if either one is damaged or excessively worn.
  • Page 324 Section F Transmission Section F www.maskinisten.net 51 - 2 Rear Axle 51 - 2 Drive Head Maxtrac - Dismantling (cont'd) Remove and discard the pinion spacer. Pull off the bearing cone. S256080 To dismantle the differential assembly, first remove bolts. Lift off the top half housing.
  • Page 325 (see Note above). Apply S256100 JCB Threadlocker & Sealer to the threads of bolts, then fit and torque - tighten to 56 Nm (42 lbf ft, 6 kgf m). Check the gears for free rotation.
  • Page 326 Section F Transmission Section F www.maskinisten.net 51 - 4 Rear Axle 51 - 4 Drive Head Maxtrac - Assembly (cont'd) To select the right size solid spacer, subtract the end float obtained at step 17 from the solid spacer size (14.20 mm).
  • Page 327 Step 16. Then install the crownwheel /differential assembly into the drive head. S256070 Apply JCB Multigasket to the drive head mating face, then fit the brake piston housing. Ensure that the match - marks made during dismantling are aligned. Fit capscrews.
  • Page 328 Section F Transmission Section F www.maskinisten.net 51 - 6 Rear Axle 51 - 6 Drive Head Maxtrac - Assembly (cont'd) Measure the crownwheel backlash, which should be 0.17 - 0.28 mm (0.006 - 0.010 in). Adjust the differential side nuts by equal amounts when altering backlash. When backlash and preload are both correct, fit the sidenut locking pins, see step 27.
  • Page 329 Section F Transmission Section F www.maskinisten.net 52 - 1 Rear Axle 52 - 1 Limited Slip Differential S212800 S171530 S212790 9803/7130 Issue 1...
  • Page 330 Section F Transmission Section F www.maskinisten.net 52 - 2 52 - 2 Rear Axle Limited Slip Differential (Optional) Dismantling Friction Plate Wear Limits Measure and note the thickness of the friction plate, the The numerical sequence shown on the illustration is result must not be less than 1.25 mm (0.049 in).
  • Page 331 Section F Transmission Section F www.maskinisten.net 53 - 1 Rear Axle 53 - 1 Axle Hub and Driveshaft - Dismantling and Assembly The rear axle hub and driveshaft dismantling and assembly procedure is identical to the front axle, refer to Front Axle - Axle Hub and Driveshaft - Dismantling and Assembly.
  • Page 332 Section F Transmission Section F www.maskinisten.net 54 - 1 54 - 1 Rear Axle 378121 9803/7130 Issue 1...
  • Page 333 Section F Transmission Section F www.maskinisten.net 54 - 2 54 - 2 Rear Axle Brakes Match mark the brake piston housing 7 and the drive Dismantling head. Undo four capscrews 9 and remove the brake housing and piston assembly. Axles are fitted with brake controlled back off to maintain a constant clearance of 0.6mm (0.02in) within the brake pack.
  • Page 334 Section F Transmission Section F www.maskinisten.net 54 - 3 54 - 3 Rear Axle 378121 9803/7130 Issue 1...
  • Page 335 Rear Axle Brakes Assembly Apply JCB Multigasket to the mating face of the drive Remove all traces of old sealant from the mating faces head, and JCB Threadlocker and Sealer to the threads of the drive head and the brake piston housing.

  • Page 336: Syncro Shuttle Gearbox

    Section F Transmission Section F www.maskinisten.net 60 - 1 Syncro Shuttle Gearbox 60 - 1 Removal and Replacement A390530 9803/7130 Issue 1...
  • Page 337 Section F Transmission Section F www.maskinisten.net 60 - 2 Syncro Shuttle Gearbox 60 - 2 Removal and Replacement Remove front and rear axle drive shaft bolts J. Park the machine on firm level ground. ! WARNING For machines fitted with the power take off option, remove the PTO drive shaft bolts X, and the PTO A raised and badly supported machine can fall on you.
  • Page 338 Section F Transmission Section F www.maskinisten.net 60 - 3 Syncro Shuttle Gearbox 60 - 3 Removal and Replacement A390530 9803/7130 Issue 1...
  • Page 339 Set the torque converter as described in Torque Converter. retaining bolts N. Fill the transmission with the specified amount of JCB Support the transmission with a trolley jack as shown at Special Transmission Fluid (refer to Section 3 Lubricants P, see note 3.
  • Page 340 Section F Transmission Section F www.maskinisten.net 61 - 1 Syncro Shuttle Gearbox 61 - 1 9803/7130 Issue 1...
  • Page 341 Section F Transmission Section F www.maskinisten.net 61 - 2 Syncro Shuttle Gearbox 61 - 2 Dismantling Drain the oil from the casing into a suitable container by Remove the adaptor block assembly retaining removing the drain plug 1 and sealing washer 2. setscrews 10 (4 off) and remove the block 11.
  • Page 342 Section F Transmission Section F www.maskinisten.net 61 - 3 Syncro Shuttle Gearbox 61 - 3 9803/7130 Issue 1...
  • Page 343 Section F Transmission Section F www.maskinisten.net 61 - 4 Syncro Shuttle Gearbox 61 - 4 Dismantling (Cont'd) Assembly Remove the output shaft assembly 41. Note: All bearings must be lightly oiled before assembly. Make sure all components are thoroughly clean and renew Remove locking screws 42 (2 off) from selector forks 44 all 'O' rings.

  • Page 344: Shaft End Float Measurements

    Section F Transmission Section F www.maskinisten.net 61 - 5 Syncro Shuttle Gearbox 61 - 5 Assembly (Cont'd) Calculate the required shim thickness. Shaft End Float Measurements Example: Clean the layshaft end cover mating face. End Float Tolerance : 0.03 to 0.08 mm. (Identical Using service tool kit 993/59400, fit base plate A onto clearance for all shafts.) the layshaft end cover mating face and secure with...
  • Page 345 Section F Transmission Section F www.maskinisten.net 61 - 6 Syncro Shuttle Gearbox 61 - 6 Assembly (Cont'd) Clean the mounting face of the flywheel housing. Mount Temporarily refit taper plug 67. the DTI on the face with the probe resting on the end of the reverser unit shaft.
  • Page 346 Section F Transmission Section F www.maskinisten.net 61 - 7 Syncro Shuttle Gearbox 61 - 7 Assembly (Cont'd) Using a bearing puller, remove the layshaft bearing cup If any measurement is outside the tolerance, remove from the rear casing. Referring to the shim thickness rear casing, see step 45.
  • Page 347 6 (4 off). Torque tighten to 5.8 Nm (4.3 lbf ft). Fit a new gasket 5 to a clean suction strainer 4 and insert into the casing. Apply JCB Threadlocker and Sealer to the threads of setscrews 3 (2 off) and torque tighten to 10 Nm (7.4 lbf ft).

  • Page 348: Reverser Unit

    Section F Transmission Section F www.maskinisten.net 62 - 1 Reverser Unit 62 - 1 Dismantling Carefully remove the piston ring seals 1 (3 off). Note: If the piston ring seals are excessively worn then check for burrs or damage on the shaft grooves. If necessary remove burrs with a fine grade abrasion paper and oil.
  • Page 349 Section F Transmission Section F www.maskinisten.net 62 - 2 Reverser Unit 62 - 2 Dismantling (Cont'd) Remove the clutch friction/counter plate retaining circlip 11. Remove the thick pressure end plate (6mm thick) 13. Note: If the reverser unit has been previously dismantled, shims 12 may also be fitted.
  • Page 350 Section F Transmission Section F www.maskinisten.net 62 - 3 Reverser Unit 62 - 3 Dismantling (Cont'd) Position clutch assembly in a suitable press to compress the piston spring then remove circlip 17. S145000 Lift off spring retaining plate 18. Remove spring 19 and oil baffle plate 20. Turn the assembly over and knock the clutch shaft on a wooden block to loosen the piston 21.
  • Page 351 Reverser Unit 62 - 4 Assembly The assembly procedure is the reverse of the dismantling Pack the clutch end bearing with JCB MPL Grease and procedure. press the bearing onto clutch shaft. Make sure all components are thoroughly clean prior to Fit a new stake nut 1A and torque tighten to 200 Nm assembly.
  • Page 352 Section F Transmission Section F www.maskinisten.net 63 - 1 Syncro Shuttle Gearbox 63 - 1 S212380-1 9803/7130 Issue 1...

  • Page 353: Power Take Off Clutch (If Applicable)

    Section F Transmission Section F www.maskinisten.net 63 - 2 Syncro Shuttle Gearbox 63 - 2 Power Take Off Clutch Removal and Replacement Removal Note: If the PTO clutch is to be dismantled, the drive yoke stake nut 4 should be loosened before the clutch is removed from the gearbox.
  • Page 354 Section F Transmission Section F www.maskinisten.net 63 - 3 Syncro Shuttle Gearbox 63 - 3 S212380-1 9803/7130 Issue 1...
  • Page 355 Section F Transmission Section F www.maskinisten.net 63 - 4 Syncro Shuttle Gearbox 63 - 4 Power Take Off Clutch Inspection Thoroughly clean all components. Ensure that all oil ways Dismantling and Assembly are clear. Idler Assembly Inspect generally for damage. Check for scoring inside the piston housing and at the oil feed end of the shaft.
  • Page 356 Section F Transmission Section F www.maskinisten.net 63 - 5 Syncro Shuttle Gearbox 63 - 5 Power Take Off Clutch Dismantling and Assembly (cont’d) Brake Operation With the assembly mounted on the gearbox, check the operation of the clutch brake as follows: With no electrical power or pressure connected, check that the coupling 6 is free to rotate.

  • Page 357: Piston Ring Seals - Fitting Procedure

    Section F Transmission Section F www.maskinisten.net 65 - 1 Syncro Shuttle Gearbox 65 - 1 Piston Ring Seals - Fitting Procedure Wind the PTFE piston ring seal around your finger as shown, so that the seal forms a 'coil'. 157250 Smear the seal with grease and then fit the seal to the shaft.

  • Page 358: Torque Converter

    Section F Transmission Section F www.maskinisten.net 70 - 1 Torque Converter 70 - 1 Removal and Replacement The torque converter must be removed together with the syncro shuttle gearbox, refer to Syncro Shuttle Gearbox - Removal and Replacement. Replacement Ensure that flywheel face, drive plate, and hardware are clean free from...
  • Page 359 Section G Brakes Section G www.maskinisten.net Contents Page No. Technical Data System type 2 - 1 Basic System Operation Compensating Master Cylinder - Description 3 - 1 Pedals Locked - Normal Operation 3 - 1 Pedals Locked - Compensating Operation 3 - 1 Pedals Unlocked - Normal Operation 3 - 1...
  • Page 360 Hydraulic service brakes in rear axle only, operated from seperate pedals. No servo assistance. Independant cable operated parking brake on output to front wheels. Service Brakes Type JCB Oil-Immersed Multi-Plate Discs Actuation Hydraulic Location Rear Axle Centre Casing (2 brake packs)

  • Page 361: Basic System Operation

    Section G Brakes Section G www.maskinisten.net 3 - 1 Basic System Operation 3 - 1 Compensating Master Cylinder Pedals Locked - Compensating Operation When the brake pedals are pushed down (the brake pedals are mechanically locked together), actuation of the brake Description packs H and H1 is as described in Pedals Locked - Normal Operation.

  • Page 362: Fault Finding

    Section G Brakes Section G www.maskinisten.net 10 - 1 Fault Finding 10 - 1 Brake System Note: The brakes generate a high temperature when operating, this means that the casing will be hot to touch, this condition is normal. FAULT POSSIBLE CAUSE ACTION One or both brakes do not apply.
  • Page 363 Section G Brakes Section G www.maskinisten.net 10 - 2 Fault Finding 10 - 2 FAULT POSSIBLE CAUSE ACTION Pulling to one side when pedals Braking system inoperative on Unlatch pedals to test circuits locked together (cont'd). one side. individually. Friction plates worn beyond limits Renew friction/counter plates - or distorted on one side.
  • Page 364 Section G Brakes Section G www.maskinisten.net 10 - 3 Fault Finding 10 - 3 FAULT POSSIBLE CAUSE ACTION Poor braking when hot. Moisture in system vapourizing Strip axle and clean annular piston to when axle is hot. remove moisture. Remove master cylinders and check for corrosion, service as required.

  • Page 365: Service Procedures

    BRAK 2-1 1 Remove and cap brake piston feed pipe A. 2 Fill the brake piston housing with JCB Light Hydraulic Fluid. 3 Check for severe piston seal damage: Install a hand pump fitted with a 0 - 40 bar (0 - 600 lbf/in ) pressure gauge to port B, as shown at X.

  • Page 366: Parking Brake

    Parking Brake - Testing If you have any queries concerning this test procedure or SAFETY NOTICE: Ensure all routine health and safety parking brake adjustment, consult your local JCB distributor. precautions are observed before operating machines. ! WARNING ! WARNING Do not use a machine with a faulty parking brake.

  • Page 367: Testing

    Section G Brakes Section G www.maskinisten.net 20 - 4 Service Procedures 20 - 4 Parking Brake - Adjustment Cable Adjustment ! CAUTION Adjust the cable at the calliper if there is insufficient The parking brake must not be used to slow the machine adjustment at the parking brake lever.
  • Page 368 Section G Brakes Section G www.maskinisten.net 20 - 6 Service Procedures 20 - 6 Parking Brake - Renewing the Brake Pads Pad Replacement Fit the pad 2 to the lever side of the calliper. Position ! WARNING the pad inside housing 15. Locate the plastic clip in the This is a safety critical installation.

  • Page 369: Compensating Master Cylinder

    Section G Brakes Section G www.maskinisten.net 30 - 1 Compensating Master Cylinder 30 - 1 A390750 A390740 A390840 A390740 S390760 9803/7130 Issue 1...

  • Page 370: Removal And Replacement

    BRAK 1-4 BRAK 1-1 Removal Fill the brake system with JCB Light Hydraulic Fluid and bleed the system. Refer to Service Brakes - Bleeding. Gain access the the brake pedal box assembly. On completion bleed the brake system and check the Remove the steering wheel, column switches and brakes operate correctly.

  • Page 371: Dismantling And Assembly

    6. Take care not to damage the piston assembly, or the bore of the cylinder body 5. Clean and lubricate all components, with JCB Special Hydraulic Fluid. DO NOT USE CONVENTIONAL BRAKE Examine the working surfaces of piston and cylinder. If FLUID OR SERIOUS DAMAGE WILL BE CAUSED.

  • Page 372: Service Brakes

    Section G Brakes Section G www.maskinisten.net 40 - 1 Service Brakes 40 - 1 Dismantling and Assembly The service brakes are located in the rear axle, as shown at A. Instructions for dismantling and assembly of the brake are described in Section F - Rear Axle Brakes. A388340 9803/7130 Issue 1...

  • Page 373: Bleeding

    Section G Brakes Section G www.maskinisten.net 40 - 2 Service Brakes 40 - 2 Bleeding ! WARNING Before proceeding with the bleeding procedure it is important to ensure that the parking brake is engaged and that one pair of wheels is blocked on both sides. BRAK 1-2 ! WARNING Use of incorrect fluid will cause serious damage to the...

  • Page 374: Parking Brake

    Section G Brakes Section G www.maskinisten.net 50 - 1 Parking Brake 50 - 1 Torque Figures The illustration shows a typical installation. Where appropriate, the grade of bolt is indicated in parenthesis eg. (10.9). Refer also to relevant dismantling and assembly procedures.

  • Page 375: Calliper Removal And Replacement

    Section G Brakes Section G www.maskinisten.net 50 - 2 Parking Brake 50 - 2 Calliper Removal and Replacement Replacement ! WARNING This is a safety critical installation. Do not attempt to do Replacement is the reverse of the removal sequence. this procedure unless you are skilled and competent to do so.
  • Page 376 Section G Brakes Section G www.maskinisten.net 50 - 3 Parking Brake 50 - 3 Component Listing: Carrier Side Pad Lever Side Pad Bolt Anti-rotation Clip Washer Washer Lever Spring Rotor Ball Spacer Ball Bearings Mounting Bush O-ring Shaft Seal Housing 228362 9803/7130 Issue 1...

  • Page 377: Calliper Dismantling And Assembly

    Section G Brakes Section G www.maskinisten.net 50 - 4 Parking Brake 50 - 4 Calliper Dismantling and Assembly Dismantling Inspection The numerical sequence shown on the illustration on the Clean and dry all parts. Check all parts are free from adjacent page is intended as a guide to dismantling.
  • Page 378 Section G Brakes Section G www.maskinisten.net 50 - 5 Parking Brake 50 - 5 228362 9803/7130 Issue 1...
  • Page 379 Section G Brakes Section G www.maskinisten.net 50 - 6 Parking Brake 50 - 6 Dismantling and Assembly (cont’d) Assembly Before assembly make sure all parts are clean and serviceable. Fit a new shaft seal 14 if removed. Install the seal as shown.
  • Page 380 Section H Steering Section H www.maskinisten.net Contents Page No. Service Tools 1 - 1 Technical Data System Type 2 - 1 Basic System Operation Steer System Schematics 3 - 1 Hydraulic Operation 3 - 2 Circuit Description Steer Unit Operation 4 - 1 Priority Valve Operation 5 - 1...

  • Page 381: Service Tools

    Section H Steering Section H www.maskinisten.net 1 - 1 Service Tools 1 - 1 S191750 892/0018 Seal Fitting Tool for fitting 'O' ring and kin ring to Hydraulic Steer Unit 9803/7130 Issue 1...

  • Page 382: System Type

    Section H Steering Section H www.maskinisten.net 2 - 1 Technical Data 2 - 1 System Type Full Power Hydrostatic permanent 4-wheel steer. Oil supply from Main Hydraulic Pump via Priority Valve to Steer Unit Valve complete with Load Sensing and Integral Relief Valve.

  • Page 383: Basic System Operation

    Section H Steering Section H www.maskinisten.net 3 - 1 Basic System Operation 3 - 1 Steer System Schematics Component Key: Pump Tank Priority Valve Front Steer Ram Rear Steer Ram Steer Unit Steer Setting Valve Note: Hydraulic component port identification letters are shown in parenthesis, e.g.

  • Page 384: Hydraulic Operation

    Section H Steering Section H www.maskinisten.net 3 - 2 Basic System Operation 3 - 2 Hydraulic Operation The main components of the steering system are the priority valve A, load sensing steer unit B, hydraulic tank C, front steer ram D and rear steer ram E and steer setting valve F. When the steering wheel is turned, a pressure demand is sensed at the priority valve A via load sensing line LS.

  • Page 385: Circuit Description

    Section H Steering Section H www.maskinisten.net 4 - 1 Circuit Description 4 - 1 9803/7130 Issue 1...
  • Page 386 Section H Steering Section H www.maskinisten.net 4 - 2 Circuit Description 4 - 2 9803/7130 Issue 1...
  • Page 387 Section H Steering Section H www.maskinisten.net 4 - 3 Circuit Description 4 - 3 9803/7130 Issue 1...
  • Page 388 Section H Steering Section H www.maskinisten.net 4 - 4 Circuit Description 4 - 4 9803/7130 Issue 1...
  • Page 389 Section H Steering Section H www.maskinisten.net 4 - 5 Circuit Description 4 - 5 9803/7130 Issue 1...
  • Page 390 Section H Steering Section H www.maskinisten.net 4 - 6 Circuit Description 4 - 6 9803/7130 Issue 1...
  • Page 391 Section H Steering Section H www.maskinisten.net 4 - 7 Circuit Description 4 - 7 9803/7130 Issue 1...
  • Page 392 Section H Steering Section H www.maskinisten.net 4 - 8 Circuit Description 4 - 8 9803/7130 Issue 1...
  • Page 393 Section H Steering Section H www.maskinisten.net 4 - 9 Circuit Description 4 - 9 9803/7130 Issue 1...
  • Page 394 Section H Steering Section H www.maskinisten.net 4 - 10 Circuit Description 4 - 10 9803/7130 Issue 1...
  • Page 395 Section H Steering Section H www.maskinisten.net 5 - 1 Circuit Description 5 - 1 9803/7130 Issue 1...
  • Page 396 Section H Steering Section H www.maskinisten.net 5 - 2 Circuit Description 5 - 2 9803/7130 Issue 1...
  • Page 397 Section H Steering Section H www.maskinisten.net 5 - 3 Circuit Description 5 - 3 9803/7130 Issue 1...
  • Page 398 Section H Steering Section H www.maskinisten.net 5 - 4 Circuit Description 5 - 4 9803/7130 Issue 1...

  • Page 399: Fault Finding

    Section H Steering Section H www.maskinisten.net 10 - 1 Fault Finding 10 - 1 Fault Finding Contents Introduction Page No. The purpose of this section is to help you trace hydraulic faults to a faulty unit (E.g. valve, actuator, ram etc). Once you have traced the faulty unit, refer to the appropriate Introduction 10 - 1...
  • Page 400 Section H Steering Section H www.maskinisten.net 10 - 2 Fault Finding 10 - 2 Fault Probable Cause Action Steering wheel difficult to turn. Priority valve not operating Check if the priority valve (continued) correctly. is sticking, rectify as required. Check the load sense line from the steer unit to the priority valve for signs of leaking or poor...
  • Page 401 Section H Steering Section H www.maskinisten.net 10 - 3 Fault Finding 10 - 3 Fault Probable Cause Action Machine will not turn when the steering wheel is turned (continued). Mechanical failure. Check for damaged axle components, such as rams, trackrods, linkages etc.

  • Page 402: Service Procedures

    Section H Steering Section H www.maskinisten.net 20 - 1 Service Procedures 20 - 1 Initial System Bleeding If a steering system component has been replaced, e.g., a steer ram, or after a steering hose burst the following procedure must be followed: Start the engine.
  • Page 403 Section H Steering Section H www.maskinisten.net 20 - 2 Service Procedures 20 - 2 Steering System Pressure Testing Park the machine on level ground, engage the parking brake and set the transmission to neutral. Lower the attachments to the ground. Stop the engine and remove the starter key.

  • Page 404: Re-Aligning The Road Wheels

    Section H Steering Section H www.maskinisten.net 20 - 3 Service Procedures 20 - 3 Re-Aligning the Road Wheels ! WARNING At the start of each working period, and at least once a day, or if having difficulty in steering, check and, if necessary, re-align the road wheels.

  • Page 405: Steer Rams

    Section H Steering Section H www.maskinisten.net 30 - 1 Steer Rams 30 - 1 Removal Replacement Replacement is the reverse of removal. ! WARNING Torque Settings Make the machine safe before getting beneath it. Lower the attachments to the ground; engage the parking Item kgf m lbf ft...

  • Page 406: Removal And Replacement

    Lubricate all parts with hydraulic fluid. Renew aluminium washers 8 and 10. Note: All hydraulic adapters that are installed together with a bonded sealing washer must also have JCB Threadseal applied to the threads of the adapter. Torque Settings Item...

  • Page 407: Hydraulic Steer Unit

    Note: All hydraulic adapters that are installed together with a Get an assistant to hold of the steering unit, and, bonded sealing washer must also have JCB Threadseal working inside the cab, loosen and remove 4 bolts B. applied to the threads of the adapter.
  • Page 408 Section H Steering Section H www.maskinisten.net 50 - 2 Hydraulic Steer Unit 50 - 2 S10221A 9803/7130 Issue 1...

  • Page 409: Dismantling And Assembly

    Section H Steering Section H www.maskinisten.net 50 - 3 Hydraulic Steer Unit 50 - 3 Dismantling and Assembly The numerical sequence shown on the illustration is intended as a guide to dismantling. Note: 1 During manufacture, a small mark X will have been made on sleeve 12 and spool 15, close to one of the slots for the centring springs 13.
  • Page 410 If the shock valves have been dismantled, clean the threads of adjusting screw 31 and the threads in the bore of the steering unit body using JCB Cleaner/Degreaser, allow to dry. Assemble seat 35, ball 34, cap 33 and spring 32 then coat threads of screw 31 with JCB Threadlocker and Sealer.
  • Page 411 Section K Engine Section K www.maskinisten.net Contents Page No. Service Tools 1 - 1 Technical Data 2 - 1 9803/7130 Issue 1...
  • Page 412 Section K Engine Section K www.maskinisten.net 1 - 1 Service Tools 1 - 1 892/00041 De-glazing Tool for Cylinder Bores (to assist bedding-in of new piston rings) Note: For other engine tools refer to the Engine Service Manual. S192390 A314530 892/00956 Timing pin for fuel injection pump (AK, AM, AR)
  • Page 413 Section K Engine Section K www.maskinisten.net 2 - 1 Technical Data 2 - 1 67 BHP 75 BHP Type 1004-40AJ, naturally aspirated 1004-42AR, naturally aspirated Build Number AJ50686 AR50696 Number of cylinders Bore 100 mm (3.937 in) 103 mm (4.055 in) Stroke 127.0 mm (5.00 in) 127.0 mm (5.00 in)
  • Page 414 Section K Engine Section K www.maskinisten.net 2 - 2 Technical Data 2 - 2 75 BHP Type 1000 Series, naturally aspirated Build Number AA50525 Number of cylinders Bore and Stroke 100 mm (3.937 in) x 127.0 mm (5.00 in) Swept Volume 4 litres (243 in Compression Ratio 16.5:1...

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