General Information 1

Care & Safety 2

Routine Maintenance 3
R

Attachments A
Body & Framework B
Service
Electrics C
Manual
2CX, 2DX, 210, 212
Controls D
& VARIANTS
Hydraulics E
Backhoe
Loader
Transmission F
From M/c No. 657001 TO
763230
Brakes G
&
481196 Onwards

PUBLISHED BY THE
Steering H
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; © WORLD PARTS CENTRE,
CHEADLE ROAD, UTTOXETER, ST14 7BS
ENGLAND
Tel. ROCESTER (01889) 590312
Engine K
PRINTED IN ENGLAND

Publication No. 9803/7110

 Introduction
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training
by JCB Technical Training Department.

These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated
with the maintenance and repair of hydraulic earthmoving equipment.

Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of
course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe
connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all
else SAFETY MUST COME FIRST!

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

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

2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for all the
machine.

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

A = Attachments
B = Body & Framework ...etc.

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

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

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

Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry
threads, hence for lubricated threads may be reduced by one third.

With the exception of slewing operations 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing
forwards.
*
Machine Nomenclature
In this Service Manual, reference is made to machine models, e.g. 2CX, 2DX, 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.

European North American

2CX = 210S
2DX = 213S

9803/7110 Issue 2*
Section 1 General Information Section 1
i i

Contents Page No.

Machine Identification Plate 1-1

Typical Machine Identification Number 1-1

Typical Engine Identification Number 1-1

Unit Identification 1-2

Torque Settings 2-1

Service Tools Numerical List 3-1

Service Tools
Electrics 4-1
Hydraulics 4-2
Transmission 4-5
Engine 4-7

Sealing and Retaining Compounds 5-1

9803/7110 Issue 1
Section 1 General Information Section 1
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 SLP 2DX T S R E 123456
door. The serial numbers of the machine and its major units
are stamped on the plate. A B C D E F G

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

unit itself. If a major unit is replaced by a new one, the serial
A World Manufacturer Identification
number on the identification plate will be wrong. Either
stamp the new number of the unit on the identification plate,
or simply stamp out the old number. This will prevent the B Machine Model
wrong unit number being quoted when replacement parts
are ordered.
C Steer Type (T= 2WS, F=4WS)
The machine and engine serial numbers can help identify
exactly the type of equipment you have. D Build Type (S=Sideshift, C=Centremount, L=Loader)

E Year of Manufacture:
R = 1994 1 = 2001
S = 1995 2 = 2002
T = 1996 3 = 2003
V = 1997 4 = 2004
W = 1998 5 = 2005
X = 1999 6 = 2006
Y = 2000 7 = 2007

F Manufacturer Location (E = England)

G Machine Serial Number:

*
Typical Engine
Identification Number
AB 50262 U 500405 P
A B C D E

A Engine Type
AB = 4 cylinder turbo

B Build Number

C Country of Origin

D Engine Sequence Number

E Year of Manufacture

S227230

9803/7110 Issue 3*
Section 1 General Information Section 1
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.
front of the machine).

175510

The Syncro Shuttle serial number is stamped on a label The front axle serial number is stamped on a plate mounted
which is mounted to the rear face of the unit. to the rear face of the axle, as shown below.

175520

9803/7110 Issue 1
Section 1 General Information Section 1
2-1 2-1

Torque Settings
Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the
figures stated. For lubricated threads the values should be REDUCED by one third.

UNF Grade 'S' Bolts

Bolt Size Hexagon (A/F) Torque Settings

in (mm) in Nm kgf m lbf ft

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

5/16 (7.9) 1/2 28 2.8 20
3/8 (9.5) 9/16 49 5.0 36
7/16 (11.1) 5/8 78 8.0 58
1/2 (12.7) 3/4 117 12.0 87
9/16 (14.3) 13/16 170 17.3 125
5/8 (15.9) 15/16 238 24.3 175
3/4 (19.0) 11/8 407 41.5 300
7/8 (22.2) 15/16 650 66.3 480
1 (25.4) 11/2 970 99.0 715
11/4 (31.7) 17/8 1940 198.0 1430
11/2 (38.1) 21/4 3390 345.0 2500

Metric Grade 8.8 Bolts

Bolt Size Hexagon (A/F) Torque Settings

(mm) mm Nm kgf m lbf ft

M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105

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

9803/7110 Issue 1
 Section 1 General Information Section 1
3-1 3-1

Service Tools Numerical List

Page No. Page No.
816/00189 Blanking Cap 4-6 892/00301 Flow Test Adapter 4-7
816/00190 Blanking Ca 4-6 892/00302 Flow Test Adapter 4-7
816/00193 Blanking Cap 4-6 892/00304 Flow Test Adapter 4-7
816/00196 Blanking Cap 4-6 * 892/00334 Ram Seal Fitting Tool 4-6
816/00197 Blanking Cap 4-6 892/00347 Gauge Connector 4-4
816/00294 Blanking Cap 4-6 892/00706 Test Probe 4-5
816/15118 Pressure Test Adapter 4-4 892/00812 Drive Coupling Spanner 4-7
816/20008 Adapter 4-4 892/00822 Splined Bolt Socket 4-8
816/50043 'T' Adapter 4-6 892/00833 Annulus Removal Tool 4-8
816/55038 Pressure Test 'T' Adapter 4-4 892/00843 Folding Stand 4-1
816/55040 Pressure Test 'T' Adapter 4-4 892/00844 Long Knife 4-2
816/60096 'T' Adapter 4-6 892/00845 Cartridge Gun 4-1
892/00041 De-glazing Tool 4-9 892/00846 Glass Extractor Handles 4-2
892/00047 'T' Adapter 4-6 892/00847 Nylon Spatula 4-3
892/00048 'T' Adapter 4-6 892/00848 Wire Starter 4-2
892/00055 Blanking Plug 4-6 892/00849 Braided Cutting Wire 4-2
892/00056 Blanking Plug 4-6 * 892/00956 Timing Pin 4-9
892/00057 Blanking Plug 4-6 * 892/01016 Ram Seal Protection Sleeve 25 mm 4 - 6A
892/00059 Blanking Plug 4-6 * 892/01017 Ram Seal Protection Sleeve 30 mm 4 - 6A
892/00060 Blanking Plug 4-6 * 892/01018 Ram Seal Protection Sleeve 40 mm 4 - 6A
892/00074 Female Connector 4-6 * 892/01019 Ram Seal Protection Sleeve 50 mm 4 - 6A
892/00075 Female Connector 4-6 * 892/01020 Ram Seal Protection Sleeve 50 mm 4 - 6A
892/00077 Female Connector 4-6 * 892/01021 Ram Seal Protection Sleeve 60 mm 4 - 6A
892/00137 Hose 4-5 * 892/01022 Ram Seal Protection Sleeve 60 mm 4 - 6A
892/00153 Test Block for Excavator A.R.V. 4-5 * 892/01023 Ram Seal Protection Sleeve 65 mm 4 - 6A
* 892/00167 Ram Seal Protection Sleeve 90mm 4 - 6A * 892/01024 Ram Seal Protection Sleeve 70 mm 4 - 6A
892/00174 Measuring Cup 4-8 * 892/01025 Ram Seal Protection Sleeve 75 mm 4 - 6A
892/00179 Bearing Press 4-7 * 892/01026 Ram Seal Protection Sleeve 80 mm 4 - 6A
892/00180 Seal Fitting Tool 4-6 * 892/01027 Piston Seal Assembly Tool 4 - 6A
892/00223 Hand Pump 4-5 926/15500 Rubber Spacer Blocks 4-3
892/00224 Extractor 4-8 992/00800 Extractor 4-8
892/00225 Adapter - Impulse Extractor 4-7 992/01003 Plug 4-5
892/00252 Test Block 4-5 992/10200 Body for Hamworthy A.R.V. 4-5
892/00253 Pressure Test Kit 4-4 992/02400 Tee-piece 4-5
892/00255 Pressure Test Adapter 4-4 992/04000 Torque Multiplier 4-8
892/00256 Pressure Test Adapter 4-4 992/07609 Bearing Adapter 4-8
892/00257 Pressure Test Adapter 4-4 992/09300 Spanner 4-5
892/00258 Pressure Test Adapter 4-4 992/09400 Spanner 4-5
892/00259 Pressure Test Adapter 4-4 992/10800 Spanner 4-5
892/00260 Pressure Test Adapter 4-4 992/12300 12v Mobile Oven 4-1
892/00261 Pressure Test Adapter 4-4 992/12400 Static Oven - 2 Cartridge 4-1
892/00262 Pressure Test 'T' Adapter 4 - 4/4 - 5 992/12600 Static Oven - 6 Cartridge 4-1
892/00263 Pressure Test 'T' Adapter 4-4 992/12800 Cut-out Knife 4-2
892/00264 Pressure Test 'T' Adapter 4-4 992/12801 'L' Blades 4-2
892/00265 Pressure Test 'T' Adapter 4-4 993/59400 End Float Setting Tool 4-8
892/00268 Flow Monitoring Unit 4-4 993/59500 Bearing Extractor 4-7
892/00269 Sensor Head 4-4 993/68100 Slide Hammer Kit 4 - 2A
892/00270 Load Valve 4-4 993/85700 Battery Tester 4-3
892/00271 Adapter 4-4 1406/0011 Bonded Washer 4-5
892/00272 Adapter 4-4 1406/0018 Bonded Washer 4-5
892/00274 Adapter 4-5 1406/0021 Bonded Washer 4-5
892/00275 Adapter 4-4 1406/0029 Bonded Washer 4-5
892/00276 Adapter 4-4 1604/0003 Adapter 4-5
892/00277 Adapter 4-4 1604/0004 Adapter 4-5
892/00278 Gauge 4-5 1604/0006 Adapter 4-5
892/00279 Gauge 4-5 1606/0003 Adapter 4-5
892/00282 Shunt 4-3 1606/0004 Adapter 4-5
892/00283 Tool Kit Case 4-3 1606/0007 Adapter 4-5
892/00284 Tachometer 4-3 1606/0008 Adapter 4-5
892/00285 Hydraulic Oil Temperature Probe 4-3 1606/0009 Adapter 4-5
892/00286 Surface Temperature Probe 4-3 1612/0006 Adapter 4-4
892/00298 Fluke Meter 85 4-3 2401/0103 ‘O’ Ring 4-5

9803/7110 Issue 7*
 Section 1 General Information Section 1
3-2 3-2

Service Tools Numerical List (cont'd)

Page No.
4104/1310 Hand Cleaner 4-1
The following parts are replacement items for kits and would
normally be included in the kit numbers quoted on page 1/3-
1.

Replacement item for kit no. 892/00180

892/00181 Replacement Plastic Boss 4-6

Replacement items for kit no. 892/00253

892/00201 Replacement Gauge 4-4
892/00202 Replacement Gauge 4-4
892/00203 Replacement Gauge 4-4
892/00254 Replacement Hose 4-4

Replacement items for kit no. 993/59400

993/59401 Base Plate 4-8
993/59402 Setting Yoke 4-8
993/59403 Mainshaft Adapter (long) 4-8
993/59404 Mainshaft Adapter (short) 4-8
993/59405 Ouput Yoke Adapter Plate 4-8
* 993/59406 Setting Yoke Support Pillars 4-8

Replacement items for kit no. 993/68100

993/68101 Slide Hammer 4 - 2A
993/68102 End Stops 4 - 2A
993/68103 Adaptor - M20 x 5/8" UNF 4 - 2A
993/68104 Adaptor - M20 x 1" UNF 4 - 2A
993/68105 Adaptor - M20 x M20 4 - 2A
993/68106 Adaptor - M20 x M24 4 - 2A
993/68107 Bar - M20 x M20 X 800MM 4 - 2A
993/68108 Adaptor - M20 x 7/8" UNF 4 - 2A
993/68109 Adaptor - M20 x M12 4 - 2A
993/68110 Adaptor - M20 x 5/8" UNF (Shoulder) 4 - 2A
993/68111 Adaptor - M20 x 1/2" UNF 4 - 2A

9803/7110 Issue 2*
Section 1 General Information Section 1
4-1 4-1

Service Tools
Section B - Body & Framework

Cartridge Gun - hand operated - essential for the

application of sealants, polyurethane materials etc.

JCB part number -

892/00845

Hand Cleaner - special blend for the removal of

polyurethane adhesives.

JCB part number - 4104/1310

(454g; 1 lb tub)
S186240 S186270

Folding Stand for

Holding Glass -
essential for preparing
new glass prior to
installation.

12V Mobile Oven - 1 cartridge capacity - required to JCB part number -

pre-heat adhesive prior to use. It is fitted with a male 892/00843
plug (703/23201) which fits into a female socket
(715/04300).

JCB part number - 992/12300

S186250 S186280

240V Static Oven - available with 2 or 6 cartridge Glass Lifter - minimum 2 off - essential for glass
capacity - required to pre-heat adhesive prior to use. installation, 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

992/12400 - 2 Cartridge x 240V
992/12600 - 6 Cartridge x 240V

S186260 S186300

9803/7110 Issue 2
Section 1 General Information Section 1
4-2 4-2

Service Tools (cont'd)

Section B - Body & Framework

Wire Starter - used to access

braided cutting wire (below)
through original polyurethane
seal.

Cut-Out Knife - used to remove

broken glass.

JCB part number - 992/12800

JCB part number - 892/00848

S186340
S186310

'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.

JCB part number - 892/00846

S186320 S186350

Long Knife - used to give extended reach for normally

Braided Cutting Wire - consumable heavy duty cut-out inaccessible areas.
wire used with the glass extraction tool (above).
JCB part number - 892/00844
JCB part number - 892/00849
(approx 25 m length)

S186330 S186360

9803/7110 Issue 2
Section 1 General Information Section 1
4-3 4-3

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 used for
smoothing sealants - also
used to re-install glass in rubber
glazing because metal tools will chip
the glass edge.

JCB part number - 892/00847

S186470 S186550

Section C - Electrics

AVO Test Kit

1 892/00283 Tool Kit Case

2 892/00298 Fluke Meter 85

3 892/00286 Surface Temperature Probe

4 892/00284 Venture Microtach Digital

Tachometer

5 892/00282 100 amp Shunt - open type

6 892/00285 Hydraulic Temperature Probe

S188230
S188230

*993/85700 Battery Tester

9803/7110 Issue 3*
Section 1 General Information Section 1
4-4 4-4

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/in2)

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

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

892/00254 Replacement Hose

892/00347 Gauge Connector

S188120

S188130

Pressure Test Adapters

Pressure Test 'T' Adapters 892/00255 1/4 in BSP x Test Point

892/00256 3/8 in BSP x Test Point S200140
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 892/00257 1/2 in BSP x Test Point
816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point 892/00258 5/8 in BSP x Test Point
816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point 816/15118 3/4 in BSP x Test Point
892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point 892/00259 1 in BSP x Test Point
892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point 892/00260 1.1/4 in BSP x Test Point
892/00265 1 in M BSP x 1 in F BSP x Test Point 892/00261 5/8 in UNF x Test Point

Flow Test Equipment

892/00268 Flow Monitoring Unit

892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)
892/00270 Load Valve
1406/0021 Bonded Washer
1604/0006 Adapter 3/4 in M x 3/4 in M BSP
1612/0006 Adapter 3/4 in F x 3/4 in M BSP
892/00271 Adapter 3/4 in F x 5/8 in M BSP
892/00272 Adapter 5/8 in F x 3/4 in M BSP
816/20008 Adapter 3/4 in F x 1/2 in M BSP
892/00275 Adapter 1/2 in F x 3/4 in M BSP
892/00276 Adapter 3/4 in F x 3/8 in M BSP S188150
892/00277 Adapter 3/8 in F x 3/4 in M BSP

9803/7110 Issue 2
Section 1 General Information Section 1
4-5 4-5

Service Tools (cont'd)

Section E - Hydraulics

* Tool Components for Hamworthy A.R.V. testing

892/00252 Test Block for A.R.V.

1 992/02400 Tee-piece
2 1606/0003 Adapter 3/8 in. x 1/4 in. BSP
3 1406/0011 Bonded Washer
4 2401/0103 ‘O’ Ring
5 1406/0018 Bonded Washer
6 992/01003 Plug
7 992/10200 Body for Hamworthy A.R.V.
8 892/00153 Test Block Excavator A.R.V.

S220840 S230730

Hand Pump Equipment

892/00223 Hand Pump

892/00137 Micro-bore Hose 1/4 in BSP x 5 metres
892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP
Taper
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
892/00706 Test Probe
892/00278 Gauge 0 - 40 bar (0 - S188140
600 lbf/in2) Bonded Washers
892/00279
Gauge 0 - 400 bar (0 - 1406/0011 1/4 in BSP
6000 lbf/in2) 1406/0018 1/2 in BSP
1406/0021 3/4 in BSP
1406/0029 1.1/4 in BSP
S193850

Male Adapters - BSP x BSP

S193930
1606/0003 3/8 in x 1/4 in
1604/0003 3/8 in x 3/8 in
1606/0004 1/2 in x 1/4 in
1606/0007 1/2 in x 3/8 in Hexagon Spanners for Ram Pistons and End Caps
1604/0004 1/2 in x 1/2 in
1606/0008 3/4 in x 3/8 in 992/10800 50 mm A/F
1606/0009 3/4 in x 1/2 in 992/09300 55 mm A/F
1604/0006 3/4 in x 3/4 in 992/09400 65 mm A/F

S193860

9803/7110 Issue 4*
Section 1 General Information Section 1
4-6 4-6

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 * 892/003334 Ram Seal Fitting Tool

Female Cone Blanking Plug Male Cone Blanking Cap

816/00294 1/4 in BSP

892/00055 1/4 in BSP 816/00189 3/8 in BSP
892/00056 3/8 in BSP 816/00190 1/2 in BSP
892/00057 1/2 in BSP 816/00197 5/8 in BSP
892/00059 3/4 in BSP 816/00196 3/4 in BSP
892/00060 1 in BSP 816/00193 1 in BSP S193880

S193870

'T' Adapters
892/00047 3/8 in BSP (A) x 1/4 in BSP (B)
892/00048 1/2 in BSP (A) x 1/4 in BSP (B)
816/50043 3/4 in BSP (A) x 1/4 in BSP (B)
816/60096 3/4 in BSP (A) x 3/4 in BSP (B)

Female Connectors
S193900

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

892/00075 1/2 in BSP x 1/2 in BSP
892/00077 3/4 in BSP x 3/4 in BSP

S193890

9803/7110 Issue 4*
Section 1 General Information Section 1
4 - 6A 4 - 6A

Service Tools (cont'd)

Section E - Hydraulics

7mm
11o
S338410
20mm 10mm

Ram Seal Protection Sleeves

5mm
892/01016 For 25 mm Rod Diameter m
892/01017 For 30 mm Rod Diameter 3m
R
892/01018 For 40 mm Rod Diameter
892/01019 For 50 mm Rod Diameter
892/01020 For 50 mm Rod Diameter (slew ram) 110mm
892/01021 For 60 mm Rod Diameter
175mm
892/01022 For 60 mm Rod Diameter (slew ram)
892/01023 For 65 mm Rod Diameter 3o
892/01024 For 70 mm Rod Diameter R
1.4
892/01025 For 75 mm Rod Diameter mm
892/01026 For 80 mm Rod Diameter
892/00167 For 90 mm Rod Diameter

892/01027 Piston Seal Assembly Tool

338500

9803/7110 Issue 1
Section 1 General Information Section 1
4-7 4-7

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

892/00225 Adapter - Impulse Extractor

A 892/00304 Flow Test Adapter Small 17mm to 25mm
B 892/00301 Flow Test Adapter Medium 25mm to 45mm
C 892/00302 Flow Test Adapter Large 45mm to 80mm

993/59500 Adapter - Impulse Extractor

S197080

S188210

9803/7110 Issue 2
Section 1 General Information Section 1
4-8 4-8

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 Measuring Cup - Pinion Head Bearing

S190770

S197050

892/00224 Impulse Extractor Set for Hub Bearing

Seals

892/00822 Splined Bolt Socket for driveshafts

S197070

S197060
993/59400 End Float Setting Tool for gearbox:
:993/59401 Base Plate
:993/59402 Setting Yoke
:993/59403 Mainshaft Adapter (long)
992/07609 Adapter - Steer/Drive Axle Pinion Bearing :993/59404 Mainshaft Adapter (short)
Cone :993/59405 Ouput Yoke Adapter Plate
:993/59406 Setting Yoke Support Pillars

S188160

892/00833 Annulus Removal Tool

S200170 S204180

9803/7110 Issue 1
Section 1 General Information Section 1
4-9 4-9

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.

S192390

S216250
A314530

* 892/00956 Timing pin for fuel injection pump

(AK, AM, AR)

9803/7110 Issue 2*
 Section 1 General Information Section 1
5-1 5-1

Sealing and Retaining Compounds

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. 4101/0651

* JCB Threadlocker and Sealer A high strength locking fluid for sealing
and retaining nuts, bolts, and screws up to
50mm diameter, and for hydraulic fittings up
to 25mm diameter. 4101/0252

* Threadseal A medium strength thread sealing compound. 4102/1951

* Threadlocker A locking fluid for use on threads larger than

50mm dia. 4101/0451

* Activator A cleaning primer which speeds the curing rate 4104/0251 150ml
of anaerobic products. 4104/0253 1 litre

* Cleaner / Degreaser For degreasing components prior to use of

anaerobic adhesives and sealants. 4104/1557 400ml

Direct Glazing Kit For one pane of glass, comprises items

marked † below plus applicator nozzle etc. 993/55700

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

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

4104/1203 250 g

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

Clear Silicone Sealant To seal butt jointed glass 4102/0933

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

JCB Cleaner & Degreaser For degreasing components prior to use of anaerobic
adhesives and sealants. 4104/1538 Aerosol

9803/7110 Issue 3*
Section 2 Care & Safety Section 2
1-1 1-1

Contents Page No.

Safety Notices 1-1

General Safety 2-1

Operating Safety 3-1

Maintenance Safety 4-1

Safety Decals 5-1

9803/7110 Issue 1
Section 2 Care & Safety Section 2
1-1 1-1

Safety Notices

In this publication and on the machine, there are safety notices. Each notice starts with a signal
word. The signal word meanings are given below.

! DANGER
Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable
that the operator (or others) could be killed or seriously injured.
INT-1-2-1

! WARNING
Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could
be killed or seriously injured.
INT-1-2-2

! CAUTION
Denotes a reminder of safety practices. Failure to follow these safety practices could result
in injury to the operator (or others) and possible damage to the machine.
INT-1-2-3

9803/7110 Issue 1
Section 2 Care & Safety Section 2
2-1 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.

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

Do not start any job until you are sure that you and those
around you will be safe.

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

ask someone who knows. Do not assume anything.

Remember

BE CAREFUL
BE ALERT
BE SAFE
GEN-1-6

General Safety

! WARNING ! WARNING
Decals Lifting Equipment
You can be injured if you do not obey the decal safety You can be injured if you use faulty lifting equipment. Make
instructions. Keep decals clean. Replace unreadable or sure that lifting equipment is in good condition. Make sure
missing decals with new ones before operating the machine. that lifting tackle complies with all local regulations and is
Make sure replacement parts include warning decals where suitable for the job. Make sure that lifting equipment is
necessary. strong enough for the job.
INT-1-3-4 INT-1-3-7

! WARNING
Care and Alertness
All the time you are working with or on the machine, take ! WARNING
care and stay alert. Always be careful. Always be alert for Raised Attachments
hazards. Raised attachments can fall and injure you. Do not walk or
INT-1-3-5 work under raised attachments unless they are safely
blocked.
INT-1-3-8
! WARNING
Clothing
You can be injured if you do not wear the proper clothing.
Loose clothing can get caught in the machinery. Wear
protective clothing to suit the job. Examples of protective
clothing are: a hard hat, safety shoes, safety glasses, a well
fitting overall, ear-protectors and industrial gloves. Keep
cuffs fastened. Do not wear a necktie or scarf. Keep long
hair restrained.
INT-1-3-6

9803/7110 Issue 1
Section 2 Care & Safety Section 2
3-1 3-1

Operating Safety

! WARNING ! WARNING
Machine Condition ROPS/FOPS Structure
A defective machine can injure you or others. Do not operate The machine is fitted with a Roll Over Protection Structure
a machine which is defective or has missing parts. Make (ROPS) and a Falling Objects Protection Structure (FOPS).
sure the maintenance procedures in this manual are You could be killed or seriously injured if you operate the
completed before using the machine. machine with a damaged or missing ROPS/FOPS. If the
INT-2-1-2 ROPS/FOPS has been in an accident, do not use the
machine until the structure has been renewed. Modifications
! WARNING and repairs that are not approved by the manufacturer may
be dangerous and will invalidate the ROPS/FOPS
Controls
certification.
You or others can be killed or seriously injured if you operate INT-2-1-9/3
the control levers from outside the cab. Operate the control
levers only when you are correctly seated inside the cab.
! WARNING
INT-2-1-3

Exhaust Gases
! WARNING Breathing the machine exhaust gases can harm and
possibly kill you. Do not operate the machine in closed
Machine Limits
spaces without making sure there is good ventilation. If
Operating the machine beyond its design limits can damage
possible, fit an exhaust extension. If you begin to feel
the machine, it can also be dangerous. Do not operate the
drowsy, stop the machine at once. Get out of the cab into
machine outside its limits. Do not try to upgrade the
fresh air.
machine performance with unapproved modifications. INT-2-1-10
INT-2-1-4

! WARNING ! WARNING
Communications
Engine/Steering Failure
Bad communications can cause accidents. Keep people
If the engine or steering fails, stop the machine as quickly as
around you informed of what you will be doing. If you will be
possible. Do not operate the machine until the fault has been
working with other people, make sure any hand signals that
corrected.
INT-2-1-5 may be used are understood by everybody. Work sites can
be noisy, do not rely on spoken commands.
! WARNING INT-2-2-3

Engine
The engine has rotating parts. Do not open the engine cover ! WARNING
while the engine is running. Do not use the machine with the
Ramps and Trailers
cover open.
INT-2-1-6 Water, mud, ice, grease and oil on ramps or trailers can
cause serious accidents. Make sure ramps and trailers are
clean before driving onto them. Use extreme caution when
! WARNING driving onto ramps and trailers.
INT-2-2-6
Entering/Leaving
Entering the cab or canopy must only be made where steps
and handrails are provided. Always face the machine when
entering and leaving. Make sure the step(s), handrails and
! DANGER
your boot soles are clean and dry. Do not jump from the Sparks
machine. Do not use the machine controls as handholds, Explosions and fire can be caused by sparks from the
use the handrails. exhaust or the electrical system. Do not use the machine in
INT-2-1-7/1 closed areas where there is flammable material, vapour or
dust.
INT-2-2-10

9803/7110 Issue 1
Section 2 Care & Safety Section 2
4-1 4-1

Maintenance Safety

! WARNING ! WARNING
Repairs Battery
Do not try to do repairs or any other type of maintenance A battery with frozen electrolyte can explode if it is used or
work you do not understand. To avoid injury and/or damage charged. Do not use a machine with a frozen battery. To
get the work done by a specialist engineer. help prevent the battery from freezing, keep the battery fully
GEN-1-5 charged.
INT-3-1-7

! WARNING
! WARNING
Modifications and Welding
Non-approved modifications can cause injury and damage. Battery Gases
Parts of the machine are made from cast iron; welds on cast Batteries give off explosive gases. Keep flames and sparks
iron can weaken the structure and break. Do not weld cast away from the battery. Do not smoke close to the battery.
iron. Contact your JCB dealer for advice before modifying Make sure there is good ventilation in closed areas where
the machine. batteries are being used or charged. Do not check the
INT-3-1-2/1 battery charge by shorting the terminals with metal; use a
hydrometer or voltmeter.
INT-3-1-8

! WARNING
Metal Splinters
! WARNING
You can be injured by flying metal splinters when driving
metal pins in or out. Use a soft faced hammer or drift to Battery Terminals
remove and fit metal pins. Always wear safety glasses. The machine is negatively earthed. Always connect the
INT-3-1-3 negative pole of the battery to earth.

When connecting the battery, connect the earth (-) lead last.
! WARNING
When disconnecting the battery, disconnect the earth (-)
Electrical Circuits
lead first.
Understand the electrical circuit before connecting or INT-3-1-9
disconnecting an electrical component. A wrong connection
can cause injury and/or damage.
! WARNING
INT-3-1-4

Hydraulic Fluid
! WARNING Fine jets of hydraulic fluid at high pressure can penetrate the
skin. Do not use your fingers to check for hydraulic fluid
Communications
leaks. Do not put your face close to suspected leaks. Hold a
Bad communications can cause accidents. If two or more
piece of cardboard close to suspected leaks and then
people are working on the machine, make sure each is
inspect the cardboard for signs of hydraulic fluid. If hydraulic
aware of what the others are doing. Before starting the
fluid penetrates your skin, get medical help immediately.
engine make sure the others are clear of the danger areas; INT-3-1-10/1
examples of danger areas are: the rotating blades and belt
on the engine, the attachments and linkages, and anywhere
beneath or behind the machine. People can be killed or
injured if these precautions are not taken.
! DANGER
INT-3-1-5 Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
! WARNING engine and operate the controls to release pressure trapped
Petrol in the hoses. Make sure the engine cannot be started while
Do not use petrol in this machine. Do not mix petrol with the the hoses are open.
INT-3-1-11/1
diesel fuel; in storage tanks the petrol will rise to the top and
form flammable vapours.
INT-3-1-6

9803/7110 Issue 1
Section 2 Care & Safety Section 2
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. Do not smoke while refuelling the machine or sure it is checked regularly. Keep it in the operator's cab
working on the engine. Do not refuel with the engine until you need to use it.
running. There could be a fire and injury if you do not follow
these precautions. Do not use water to put out a machine fire, you could spread
INT-3-2-2 an oil fire or get a shock from an electrical fire. Use carbon
dioxide, dry chemical or foam extinguishers. Contact your
nearest fire department as quickly as possible. Firefighters
! WARNING should use self-contained breathing apparatus.
INT-3-2-7/1
Oil
Oil is toxic. If you swallow any oil, do not induce vomiting,
seek medical advice. Used engine oil contains harmful
! CAUTION
contaminants which can cause skin cancer. Do not handle
used engine oil more than necessary. Always use barrier Rams
cream or wear gloves to prevent skin contact. Wash skin The efficiency of the rams will be affected if they are not
contaminated with oil thoroughly in warm soapy water. Do kept free of solidified dirt. Clean dirt from around the rams
not use petrol, diesel fuel or paraffin to clean your skin. regularly. When leaving or parking the machine, close all
INT-3-2-3 rams if possible to reduce the risk of weather corrosion.
INT-3-2-10

! WARNING
! CAUTION
Soft Ground
A machine can sink into soft ground. Never work under a Cleaning
machine on soft ground. Cleaning metal parts with incorrect solvents can cause
INT-3-2-4 corrosion. Use only recommended cleaning agents and
solvents.
INT-3-2-11

! WARNING
Counterweights
! CAUTION
Your machine may be fitted with counterweights. They are
extremely heavy. Do not attempt to remove them. 'O' rings, Seals and Gaskets
INT-3-2-5 Badly fitted, damaged or rotted 'O' rings, seals and gaskets
can cause leakages and possible accidents. Renew
whenever disturbed unless otherwise instructed. Do not use
! WARNING Trichloroethane or paint thinners near 'O' rings and seals.
INT-3-2-12
Tyres and Rims
Over-inflated or over-heated tyres can explode. Follow the
instructions in this manual for inflating the tyres. Do not weld
! WARNING
or cut rims. Get a tyre/wheel specialist to do any repair work.
INT-3-2-6 Jacking
A machine can roll off jacks and crush you unless the wheels
have been chocked. Always chock the wheels at the
! WARNING opposite end of the machine that is to be jacked. Do not
work underneath a machine supported only by jacks. Always
Hot Coolant
support a jacked-up machine on axle stands before working
The cooling system is pressurised when the engine is hot.
underneath it.
Hot coolant can spray out when you remove the radiator INT-3-2-8
cap. Let the system cool before removing the radiator cap.
To remove the cap, turn it to the first notch and let the
! WARNING
system pressure escape, then remove the cap.
INT-3-2-9 Safety Strut
Raised loader arms can drop suddenly and cause serious
injury. Before working under raised loader arms, fit the
loader arm safety strut.
2-1-1-6

9803/7110 Issue 1
Section 2 Care & Safety Section 2
4-3 4-3

Maintenance Safety (cont'd)

! WARNING
Hydraulic Hoses ! WARNING
Damaged hoses can cause fatal accidents. Inspect the Waxoyl contains turpentine substitute, which is flammable.
hoses regularly for: Keep flames away when applying Waxoyl. Waxoyl can take
- Damaged end fittings a few weeks to dry completely. Keep flames away during the
- Chafed outer covers drying period.
- Ballooned outer covers
- Kinked or crushed hoses Do not weld near the affected area during the drying period.
- Embedded armouring in outer covers Take the same precautions as for oil to keep Waxoyl off your
- Displaced end fittings. skin. Do not breathe the fumes. Apply in a well-ventilated
INT-3-3-2 area.
5-3-1-
9

! WARNING
To avoid burning, wear protective gloves when handling hot
! WARNING
components. To protect your eyes, wear goggles when
using a wire brush to clean components. Fluoroelastomeric Materials
HYD 1-3 Certain seals and gaskets (e.g. crankshaft oil seal) on JCB
machines contain fluoroelastomeric materials such as Viton,
Fluorel and Technoflon. Fluoroelastomeric materials
subjected to high temperatures can produce highly corrosive
! WARNING hydrofluoric acid. THIS ACID CAN SEVERELY BURN.
A raised and badly supported machine can fall on you.
New fluoroelastomeric components at ambient temperature
Position the machine on a firm, level surface before raising
require no special safety precautions.
one end. Ensure the other end is securely chocked. Do not
rely solely on the machine hydraulics or jacks to support the
Used fluoroelastomeric components whose temperatures
machine when working under it.
have not exceeded 300°C require no special safety
precautions. If evidence of decomposition (e.g. charring) is
Disconnect the battery, to prevent the engine being started
found, refer to the next paragraph for safety instructions. DO
while you are beneath the machine.
GEN-1-1 NOT TOUCH COMPONENT OR SURROUNDING AREA.

Used fluoroelastomeric components subjected to

! WARNING temperatures greater than 300°C (e.g. engine fire) must be
treated using the following safety procedure. Make sure that
Make the machine safe before working underneath it. Park
heavy duty gloves and special safety glasses are worn:
the machine on level ground, lower the arms. Apply the
parking brake, put the transmission in neutral and stop the
1 Ensure that components have cooled then remove and
engine. Chock both sides of all four wheels.
place material into plastic bags.
Disconnect the battery, to prevent the engine being started
2 Thoroughly wash contaminated area with 10% calcium
while you are beneath the machine.
GEN-1-2
hydroxide or other suitable alkali solution, if necessary
use wire wool to remove burnt remains.

! WARNING 3 Thoroughly wash contaminated area with detergent and

water.
JCB Extradig Dipper Lubricant
JCB Extradig dipper lubricant contains 1.53% lead. The 4 Contain all removed material, gloves etc. used in this
repeated swallowing of very small quantities can cause operation in sealed plastic bags and dispose of in
chronic lead poisoning. Do not smoke or touch food while accordance with Local Authority Regulations.
handling this lubricant. Dispose of waste (rags etc.) in
accordance with local regulations. DO NOT BURN FLUOROELASTOMERIC MATERIALS.
2-1-1-8

If contamination of skin or eyes occurs, wash affected area

with a continuous supply of clean water or with calcium
hydroxide solution for 15-60 minutes. Get medical attention
immediately.
INT-3-3-5/1

9803/7110 Issue 1
Section 2 Care & Safety Section 2
5-1 5-1

Safety Decals
Decals on the machine warn you of particular hazards. Each
decal is attached close to a part of the machine where there
is a possible hazard. Read and make sure you understand
the safety message before you work with or on that part of
the machine.

Keep all decals clean and readable. Replace lost or

damaged decals. The decals and their attachment points are
shown on the following page. Each decal has a part number
printed on it, use this number to order a new decal from your
JCB dealer.

! WARNING
If you need eye-glasses for reading, make sure you wear
them when reading the safety decals. Decals are
strategically placed around the machine to remind you of
possible hazards. Do not over-stretch or place yourself
in dangerous positions to read the decals.
INT-3-3-4

9803/7110 Issue 1
Section 2 Care & Safety Section 2
5-2 5-2

Safety Decals (cont'd)

2CX

S198220

9803/7110 Issue 3
Section 2 Care & Safety Section 2
5-3 5-3

Safety Decals (cont'd)

210S

187740/1

9803/7110 Issue 1
Section 2 Care & Safety Section 2
5-4 5-4

Safety Decals (cont'd)

210S

187740 (2)

9803/7110 Issue 1
Section 2 Care & Safety Section 2
5-5 5-5

Safety Decals (cont'd)

* 2CXU (212SU North America Only)

S297470

9803/7110 Issue 2*
Section 3 Routine Maintenance Section 3
i i

Contents Page No.

Lubricants & Capacities
* - 2CX Machines up to serial No. 659598 1-1
* - 2DX & 2CX Machines from serial No. 659599
including North American machines up to serial No. 762079 1 - 2
* - North American machines from serial No. 762080 1-3

Service Schedules 2-1

Greasing
- Loader Arms 3-1
- 6-in-1 clamshovel 3-2
- Backhoe Quickhitch 3-2
- Hydraulic Backhoe Quickhitch 3-2
- Backhoe (2CX Machines) 3-3
- Backhoe (2DX Machines) 3-4
- Axles 3-5
- Driveshafts 3-6
- Extending Dipper 3-6
- Stabiliser Legs (2DX Machines Only) 3-7

Oiling
- Control Levers 4-1

Loader Arm Safety Strut

- Fitting and Removing 5-1

Boom and Slew Locks

- Fitting and Removing Boom Lock 6-1
- Fitting and Removing Slew Lock 6-1

Hydraulic Fluid
- Check Level 7-1

Hydraulic Filter
- Renew Element 7-1

Syncro Shuttle Transmission

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

Axle Oil Level

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

Engine Oil and Filter

- Check Level 10 - 1
- Change Oil & Filter 10 - 1

Fuel Filter
- Drain 11 - 1
- Renew Element 11 - 1

Fuel Sediment Bowl

- Drain 11 - 1
- Clean 11 - 1

Fuel System
- Bleeding 11 - 2
9803/7110 Issue 4*
Section 3 Routine Maintenance Section 3
ii ii

Contents Page No.

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

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

Air Filter Pre-Cleaner

- Empty 14 - 1

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

Brakes
- Parking Brake Testing 15 - 1

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

* Road Wheels
- Re-alignment 17 - 1
- Fault Finding 17 - 1

Cleaning the Machine 18 - 1

9803/7110 Issue 3*
 Section 3 Routine Maintenance Section 3
1-1 1-1

* Lubricants and Capacities (2CX up to machine serial No. 659598)

Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load).
Engines of new machines are 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. JCB 10W/30
Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the
machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.

ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL

Litres UK Gal USA Gal SPECIFICATION

Fuel Tank 83.2 18.3 22.0 Diesel Oil ASTM D975-66T Nos. 1D, 2D

Engine (Oil) 10.7 2.4 2.9 JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B,
-10 °C to 50 °C (14 °F to 122 °F) API CE/SF, MIL-L-2104D

JCB Super Universal Agricultural SAE10W/30, MIL-L-2105,

-15 °C to 30 °C (5 °F to 86 °F) API CD/SE, MIL-L-2104C
MIL-L-46152

JCB Torque Converter Fluid SAE10W, MIL-L-46152,

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

Engine (Coolant) 11 2.4 2.9 JCB Universal Antifreeze/water ASTM D3306-74

(See Coolant Mixtures)

Syncro Shuttle 17.5 3.8 4.6 JCB Special Transmission Fluid ESP-M2C 33G

Axles (2CX, 210S)

Housing 4 0.88 1.1 JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x4) 1 0.22 0.26 JCB Special Gear Oil

Axles (2CXL, 2CX Farm Master, 210SL)

Housing 8.8 1.94 2.33 JCB Special Gear Oil ESEN-M2C 86A/B
Hubs (x4) 1.8 0.4 0.48 JCB Special Gear Oil

Hydraulic System † 77 17 20.4 JCB High Performance Hydraulic Oil ISO VG46
(including tank) (Above 38 °C, 100 °F)

JCB Special Hydraulic Fluid ISO VG32

(Below 38 °C, 100 °F)

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

consistency.

--- JCB HP Grease (High Performance) Lithium based, No. 2

consistency.

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

9803/7110 Issue 5*
Section 3 Routine Maintenance Section 3
1-2 1-2

* Lubricants
and Capacities (2DX machines and 2CX machines from Serial No. 659599)
Including North American Machines up to serial No. 762079
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load).
Engines of new machines are 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. JCB 10W/30
Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the
machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.

ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL

Litres UK Gal USA Gal SPECIFICATION

Fuel Tank 83.2 18.3 22 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D

Engine (Oil) 11.1 2.5 2.9 JCB 15W/40 Multigrade SAE15W/40, MIL-L-46152B,
-10 °C to 50 °C (14 °F to 122 °F) API CD/SE, MIL-L-2104D
JCB Super Universal Agricultural SAE10W/30, MIL-L-2105,
-15 °C to 30 °C (5 °F to 86 °F) API CD/SE, MIL-L-2104C
MIL-L-46152
JCB Torque Converter Fluid SAE10W, MIL-L-46152,
-18 °C to 0 °C (0 °F to 32 °F) API CD/SE, MIL-L-2104D

Engine (Coolant) 12.0 2.6 3.2 JCB Universal Antifreeze/water ASTM D3306-74
(See Coolant Mixtures)

Syncro Shuttle 17.5 3.8 4.6 JCB Special Transmission Fluid ESP-M2C 33G

Axles
Housing (SD55) 8.8 1.94 2.3 JCB Special Gear Oil API-GL4
Housing (SD40) 4.0 0.88 1.0 JCB Special Gear Oil API-GL4

Hubs (x4 - SD55) 1.8 0.4 0.5 JCB Special Gear Oil API-GL4
Hubs (x4 - SD40) 1.0 0.22 0.25 JCB Special Gear Oil API-GL4

Hydraulic System† 82 18.04 21.7 JCB High Performance Hydraulic Oil ISO VG46
(including tank) (Above 38 °C, 100 °F)
JCB Special Hydraulic Fluid ISO VG32
(Below 38 °C, 100 °F)

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

consistency.
--- JCB HP Grease (High Performance) Lithium based, No. 2
consistency.

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

9803/7110 Issue 3*
Section 3 Routine Maintenance Section 3
1-3 1-3

Lubricants and Capacities - North American Machines from serial No. 762080
Note: New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle
immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently
run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g., warming up without load).
Engines of new machines are 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. JCB 10W/30
Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the
machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended
below.

ITEM CAPACITY FLUID/LUBRICANT INTERNATIONAL

USA Gal Litres SPECIFICATION

Fuel Tank 22 83.2 Diesel Oil (See Types of Fuel) ASTM D975-66T Nos. 1D, 2D

Engine (Oil) 2.9 11.1 JCB 15W/40 Engine Oil CF-4/SG, SAE15W/40
-10 °C to 50 °C (14 °F to 122 °F)

JCB Engine Oil 10W CF-4/SG, SAE10W

-20 °C to 10 °C (-4 °F to 50 °F)
Engine (Coolant) 3.2 12.0 JCB Universal Antifreeze/water ASTM D3306-74
(See Coolant Mixtures)

Syncro Shuttle 4.6 17.5 JCB Special Transmission Fluid ESP-M2C 33G

Axles
Housing (SD55) 2.3 8.8 JCB Special Gear Oil API-GL4

Hubs (x4 - SD55) 0.5 1.8 JCB Special Gear Oil API-GL4

Hydraulic System† 21.7 82 JCB High Performance Hydraulic Oil ISO VG46
(including tank) (Above 38 °C, 100 °F)
JCB Special Hydraulic Fluid ISO VG32
(Below 38 °C, 100 °F)

Grease Points --- JCB Moly EP#2 Grease Lithium based, No. 2

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

9803/7110 Issue 1
Section 3 Routine Maintenance Section 3
2-1 2-1

Service Schedules
A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular
maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working
condition.

! WARNING
Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the
loader arm safety strut.
GEN 3-2

Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings
to correctly gauge service intervals. Do not use a machine which is due for a service. Make sure any defects found during the
regular maintenance checks are rectified immediately.

Calendar equivalents:
10 Hours = Daily 50 Hours = Weekly 500 Hours = Six Months
1000 Hours = Yearly 2000 Hours = 2 Years

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

Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr

ENGINE
Engine Mount Security ! - Check " " " "

Oil Level - Check " "

Oil and Filter # - Change " " " "

Fuel Filter - Change " " " "

Air Cleaner Dust Valve - Clean " " "

Air Cleaner Outer Element $ - Change " " "

Air Cleaner Inner Element - Change "

Valve Clearances ! - Check and Adjust "

External Oil Leaks - Check " " " " " "

Fan Belt Tension/Condition - Check " " " " "

Fuel Sedimenter and Filter - Drain " " " " "

Coolant Level and Antifreeze Strength - Check " " " " " "

Pre-cleaner - Clean (if fitted) " " " " " "

Radiator Hose - Condition - Check " " " "

TRANSMISSION AND AXLES

Drive/Steer Axle Oil Level % - Check "

Drive/Steer Axle Oil - Change " " "

Steer Hub Oil Level % - Check "

Steer Hub Oil - Change " " "

Drive Shaft - Security/Grease " " " "

Oil Filter - Change " " " "

Steering Swivels - Grease " " "

Transmission Oil Level - Check " " " "

Transmission Oil - Change " "

Axles/Hubs/Transmission for Leaks % - Check " " " " "

Steer Axle Pivots and Linkages - Grease/Check " " " " " "

Propshafts - Grease " " "

Tyre Pressures/Condition - Check " " " " " "

Wheel Nut Security & - Check " " " " " "

9803/7110 Issue 4
Section 3 Routine Maintenance Section 3
2-2 2-2

Service Schedules (continued)

Pre-start Cold Checks Operation 10 50 †100 500 1000 2000
Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr

HYDRAULICS
Oil Filter - Change " " " "

Oil Level ' - Check " " " " "

Oil - Sample/Change "

Suction Strainer - Clean "

Hydraulic System for Leaks (Hoses etc.) - Check " " " "

Rod/Rams - Condition - Check " " "

ELECTRICS
Battery Electrolyte Level - Check " " " "

Wiring for Chafing - Check " " " " "

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

BRAKES
Accumulator Pressure ! - Check " " "

Brake System Pipes/Hoses for Routing and Leaks - Check " " " "

Brake Warning Light - Check " " " "

BODYWORK AND FRAMEWORK

All Pivot Points - Grease/Check " " " " " "

All Mounting Bolts for Tightness ! - Check " " " "

All Hinges - Lubricate " " " "

All Cables - Lubricate " " " "

All Slides/Control Levers - Lubricate " " " "

CAB
ROPS/FOPS - Check " "

Heater Filter - Clean (if fitted) " " "

Windscreen Washer Fluid Level - Check " " " " " "

ATTACHMENTS
Optional Equipment (as required) - Check " " " " "

Functional Test Operation 10 50 †100 500 1000 2000

and Final Inspection Hr Hr Hr Hr Hr Hr

ENGINE
Idle Speed ! - Check and Adjust " " " "

Stall Speed ! - Check Pull Down " " " "

Max. No Load Speed ! - Check and Adjust " " "

Exhaust System Security ! - Check " " " "

Air Inlet System Security - Check " " " "

Fuel System for Leaks and Contamination - Check " " " " "

Coolant System for Leaks and Contamination - Check " " " "

Throttle System and Control Cable ! - Check " " " "

Exhaust Smoke (excessive) - Check " " " " "

TRANSMISSION AND AXLES AND

STEERING
Torque Converter Mainline Pressure ! - Check " " " "

Clutch Pack Pressure ! - Check " " " "

Forward/Reverse - Selection/Operation - Check " " " "

Oil Cooler and Pipework - Check " " " "

9803/7110 Issue 5
Section 3 Routine Maintenance Section 3
2-3 2-3

Service Schedules (continued)

Functional Test Operation 10 50 †100 500 1000 2000
and Final Inspection Hr Hr Hr Hr Hr Hr

HYDRAULICS
MRV Pressure ! - Check and Adjust " " " "

Steer Circuit MRV ! - Check and Adjust " " " "

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

Operation All Services - Check " " " " " "

Road Wheel Alignment - Check " " " " "

Steer Circuit Operation - Check " " " " " "

ELECTRICS
Operate All Electrical Equipment - Check " " " " " "

Warning Lights - Check " " " " " "

Lights and Instruments - Check " " " " " "

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

Starter Motor - Check "

Alternator - Output - Check "

Wipers - Check " " "

Heater - Check " " "

BRAKES
Foot Brake - Operation - Check " " " " " "

Parking Brake - Operation - Check " " " " " "

Parking Brake ! - Check and Inspect " "

BODYWORK AND FRAMEWORK

Teeth and Side cutters - Security - Check "

CAB
Seat/Seat Belt - Check " " " " " "

Glazing for Correct Fit - Check "

Locks and Keys - Check "

Tool Kit and Handbooks - Check "

PAINTWORK
Condition - - Check "

ATTACHMENTS
Attachment Circuit Pressures ! - Check " " " "

Attachment Operation - Check " "

† Note: First 100 Hours Service only, 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.

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

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

& Note: Check tightness of wheel nuts every day for first week (when machine is new), thereafter every 50 hours.

$ Note: Change outer element if warning 'Air Filter Blocked' alarm sounds. A new inner element must be fitted at latest every
third time the outer element is changed.

9803/7110 Issue 4
Section 3 Routine Maintenance Section 3
3-1 3-1

Greasing
Loader Arms - for Interval see Servicing Schedule.

For each grease point shown there is another on the other

side of the machine.

9 grease points each side -

Total 18 grease points.

Grease point 8 on end of loader arm.

Grease point 9 on end of tipping link A.

2 1
5

4
6
3

7
8

175710

9803/7110 Issue 1
 Section 3 Routine Maintenance Section 3
3-2 3-2

Greasing (cont'd)
6-in-1 Clamshovel - for Interval see Servicing Schedule. * Hydraulic Backhoe Quick-Hitch (if fitted)
For each grease point shown there is another at the other ! CAUTION
end of the bucket. Waxoyl contains turpentine substitute, which is
inflammable. Keep flames away when applying Waxoyl.
* 4 grease points at each end - Waxoyl can take a few weeks to dry completely. Keep
Total 8 grease points. flames away during the drying period.

Do not weld near the affected area during the drying

period. Take the same precautions as for oil to keep
Waxoyl off your skin. Do not breathe the fumes. Apply in
a well-ventilated area.
1 5-3-1-9

Coat the slide A with Waxoyl .

4 Grease Points

2 3

4
S137070
3
1

Backhoe Quickhitch (if fitted) - for Interval see Servicing

Schedule. A
1 grease point

1 S211750

S231280

9803/7110 Issue 2*
 Section 3 Routine Maintenance Section 3
3-3 3-3

Greasing (cont'd)

* Backhoe (2CX Machines) - for Interval see Servicing

Schedule.

Total 22 grease points.

Note: Do not grease the kingpost mounting rails.

Access to point 13 is from above the boom.

Access to points 15 and 16 is from underneath.
Grease point 22 is on the top slew ram rod end.

S175720

9803/7110 Issue 2*
Section 3 Routine Maintenance Section 3
3-4 3-4

Greasing (cont'd)
Backhoe (2DX Machines) - for Interval see Servicing
Schedule.

26 Grease Points.

For grease points 1, 4 and 6 there is another on the other

side of the machine (2, 5 and 7).

Grease points 9 and 10 are located in the end of the pin.

Note: Do not grease the kingpost mounting rails.

^ %

!
3 12
( *
&
67
) ¼ 45
¤
›
‹ 90
8
½
¾

S228590

9803/7110 Issue 2
Section 3 Routine Maintenance Section 3
3-5 3-5

Greasing (cont'd)
Front Axle - for Interval see Servicing Schedule.

Total 9 grease points.

Note: When greasing, raise the wheels and swing them from
lock to lock. This will ensure full penetration.

1 3

2 4

175730

8
9 7
5
6

S175730

Rear Axle - for Interval see Servicing Schedule.

Total 8 grease points.

Note: The grease points for the rear axle are in the same
position as those for the front axle, except in this case there
is no remote pivot pin grease point.

9803/7110 Issue 3
Section 3 Routine Maintenance Section 3
3-6 3-6

Greasing (cont'd)
Propshafts - for Interval see Servicing Schedule.

6 Grease points.

3
2

4
S175740 5

Extending Dipper (if fitted)

! CAUTION
Waxoyl contains turpentine substitute, which is
inflammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep
flames away during the drying period.

Do not weld near the affected area during the drying

period. Take the same precautions as for oil to keep
Waxoyl off your skin. Do not breathe the fumes. Apply in
a well-ventilated area.
5-3-1-9

Extend the dipper. Coat the runners with Waxoyl as shown.

S207230

9803/7110 Issue 1
Section 3 Routine Maintenance Section 3
3-7 3-7

Greasing (cont'd)
Stabiliser Legs (2DX Machines Only) * 3 Point Hitch (2CXU & 212SU Machines) - for Interval see
Servicing Schedule.
! CAUTION Total 6 grease points.
Waxoyl contains turpentine substitute, which is
inflammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep
flames away during the drying period.

Do not weld near the affected area during the drying

period. Take the same precautions as for oil to keep 1
Waxoyl off your skin. Do not breathe the fumes. Apply in 2
a well-ventilated area.
5-3-1-9
3
Coat the stabiliser legs with Waxoyl .

6
5 S327810

S228580

9803/7110 Issue 2*
Section 3 Routine Maintenance Section 3
4-1 4-1

Oiling

Control Levers - for Interval see Servicing Schedule.

Oil the clevis at the bottom of every attachment control

lever.

Note: Remove the bolts securing the side moulding A to gain

access to the loader arm levers.

A 175750 175760

175770

9803/7110 Issue 1
Section 3 Routine Maintenance Section 3
5-1 5-1

Loader Arm Safety Strut

! WARNING
Raised loader arms can drop suddenly and cause
serious injury. Before working under raised loader arms,
fit the loader arm safety strut.
2-1-1-6

Installing

1 Empty the shovel and raise the loader arms fully.

2 Stop the engine. Remove the starter key.

! WARNING
You could be killed or injured if the loader control is
accidentally operated. Make sure no-one comes near
175800
the machine while you release the safety strut.
2-3-1-2

3 Open fastener A. Remove strut B.

4 Push strut B over the ram piston rod. Secure the strut
in position with strap C.

5 Lower the strut onto the ram.

To prevent any chance of the loader arms creeping

down and trapping your fingers, the loader arms should
be carefully lowered onto the safety strut as shown.

Start the engine and slowly lower the loader arms onto
the safety strut, stop the movement immediately the
weight of the loader arms is supported by the safety
strut.

Note: When lowering the loader, operate the control lever

carefully. 'Feather' the lever to lower the loader very slowly.

Removing

1 Fully raise the loader arms to take the weight off the 175820

safety strut.

2 Stop the engine. Remove the starter key.

3 Undo strap C. Remove strut B from the ram piston rod.

4 Stow strut B onto the loader arm and secure with

fastener A.

9803/7110 Issue 1
Section 3 Routine Maintenance Section 3
6-1 6-1

Boom and Slew Locks

There are two boom lock positions and three slew lock 4 Fit the Slew Lock
positions which allow the backhoe to be safely stowed for
road or site travel. It is recommended that when preparing The three slew lock positions are right, left and centre.
the machine for travel the boom lock is fitted first.
i Determine which lock position is required.
Fit the Boom Lock ii Move the kingpost either fully right, fully left or
central, ensuring that the hole in the kingpost is
The two boom lock positions are fully raised and part raised. aligned with the hole in the carriage when viewed
The part raised position allows the backhoe to be stowed from the cab.
within the profile of the machine. iii Stop the engine and exit the cab.
iv Remove the locking pin J from the stowed position K
and fit it into the appropriate aligned locking holes L,
! WARNING M or N.
You or others can be killed or seriously injured if you
operate the control levers from outside the cab. Operate 5 Remove the Slew Lock
the control levers only when you are correctly seated
inside the cab. i Remove the locking pin J and fit it in the stowed
INT-2-1-3
position K.
1 Fully Raised Position

i Fully raise the boom and stop the engine.

ii Exit the cab.
B A
iii Remove the locking pin A from the stowed position
B and lower the boom lock C to align the boom
H
locking hole D with the kingpost locking hole E.
iv Fit the locking pin A and insert the locking clip F.
F E
2 Part Raised Position C
Note : This job is easier done by two people - one to
operate the controls and one to line up and insert the
locking pin.

! WARNING
If two people are doing this job, make sure that the D
person working the controls is a competent operator. If
the wrong control lever is moved or the controls are 175780
moved violently, the other person could be killed or
injured.
2-2-6-5

i Raise or lower the boom to the part raised position.

Stop the engine.
ii Exit the cab unless a second person is assisting.
iii Remove the locking pin A from the stowed position
B and lower the boom lock C to align the boom
locking hole H with the kingpost locking hole E. The
boom may have to be repositioned to align the
locking pin holes. Make sure the second person is
well clear of the backhoe before operating the K
controls.
iv Fit the locking pin A and insert the locking clip F.

3 Remove the Boom Lock (both positions) J M

i Start the engine and take the weight of the boom by N L
raising the boom slightly. Stop the engine.
ii Exit the cab.
iii Withdraw the locking clip F and remove the locking
pin A.
iv Swing the boom lock C up to the stowed position, fit 175790
the locking pin A and secure with the locking clip F.

9803/7110 Issue 1
 Section 3 Routine Maintenance Section 3
7-1 7-1

Hydraulic Fluid Hydraulic Filter

Check the Fluid Level - for Interval see Servicing Schedule. Changing the Filter Element - for Interval see Servicing
Schedule.
! WARNING
1 Park the machine on level ground. Make sure the
Fine jets of hydraulic fluid at high pressure can penetrate
parking brake is engaged. Set the loader shovel on the
the skin. Do not use your fingers to check for hydraulic
ground. Raise the boom, swing in the dipper and close
fluid leaks. Do not put your face close to suspected
the bucket. Stop the engine. Put the transmission in
leaks. Hold a piece of cardboard close to suspected
neutral
leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates your skin, get
2 Gain access to the filter element by removing the
medical help quickly.
INT-3-1-10/1 battery cover. Unscrew the filter canister C - remember
that it will be full of oil.

1 Position the machine on level ground. Set the loader 3 Clean the mating faces of the new element and filter
shovel on the ground. Raise the boom, swing in the holder. Smear the seal D of the new filter element with
dipper and close the bucket. Stop the engine. Remove hydraulic oil. Screw the new filter element on clockwise
the starter key. into the filter head until the gasket makes contact.
Tighten the filter a further half a turn.
2 Look at the fluid level in the plastic glass A. The level
* 4 Top up the hydraulic tank with recommended fluid. See
should be at the red mark (or above). If the fluid is
cloudy, water or air has entered the system. Water or p. 1-1 for recommended oil.
air in the system could damage the hydraulic pump.
Make sure the filler cap is replaced and run the engine
Note: Earlier machines have a sight tube E, the level should for a few minutes. Make the machine safe and check
* be between the two marks on the tube. that there are no leaks at the filter.

3 If necessary, remove filler cap B and add

recommended oil. See p.1-1 for recommended oil.
Replace filler cap B when level is satisfactory.

A
C
E
D

S175831 S175840

9803/7110 Issue 2*
Section 3 Routine Maintenance Section 3
8-1 8-1

Syncro Shuttle Transmission

Checking the Oil Level - for Interval see Servicing 5 Renew the Filter
Schedule.
a Unscrew and remove the filter B.
Note: The dipstick marks are for cold oil. The engine must b On the new filter, smear seal C with transmission oil.
be cold when you check the oil level. Make sure the engine c Screw the new filter in place, hand-tight only.
is stopped. Remove the starter key.
6 Fill the System
Check that the oil is at the top mark on dipstick A. Add
recommended oil, if necessary. See p.1-1 for recommended Fill the system with new oil, as specified on page 1-1,
oil. Do not fill past the top mark on the dipstick. through the dipstick/filler A.

Changing the Oil and Filter - for Interval see Servicing Note: Do not fill past the top mark on the dipstick.
Schedule.

1 Prepare the Machine

Park the machine on level ground. Engage the parking

brake. Lower the attachments to the ground. Stop the
engine. Remove the starter key. Disconnect the battery.

2 Drain the Oil and Remove the Strainer

a Place a container that can hold at least 20.8 litres

(5.5 gal) beneath the machine. (To catch the oil).

! CAUTION
When the strainer is removed, oil will gush out. Keep to
one side when you remove the strainer.
2-3-4-2

b Remove bolts D. Pull out the strainer E and its

gasket F.

3 Clean the Strainer 175860

Clean the strainer with a suitable solvent. Follow the

solvent manufacturer's instructions on safety.

4 Refit the Strainer

Fit the strainer and a new gasket F. Apply JCB 'Lock

And Seal' to bolts D before fitting and tighten to 10 Nm
(7.4 lbf ft).

175850 175870

9803/7110 Issue 1
Section 3 Routine Maintenance Section 3
9-1 9-1

Axle Oil Level

Check Differential Oil Level - for Interval see Service Change Hub Oil - for Interval see Service Schedule
Schedule
1 Set the machine level, with the tyres just clear of the
1 Remove fill/level plug A and its bonded washer. Oil ground. Manually rotate the wheels to bring the OIL
should be level with the bottom of the fill/level hole. LEVEL mark on the hubs to the vertical position, with
the fill/level plugs C at the bottom.
2 If necessary, top up with JCB recommended axle oil as
specified on page 1 - 1. Clean and refit fill/level plug A
with new bonded washer.

Change Differential Oil - for Interval see Service Schedule

1 Remove fill/level plug A and drain plug B, together with

their bonded washers. Allow time for the oil to drain
out.

2 Clean and refit drain plug B with a new bonded washer.

Tighten to 79 Nm (58 lbf ft).

3 Fill the axle with JCB recommended axle oil through the
fill/level hole A. Oil should be level with the bottom of
the fill/level hole.

4 Clean and refit fill/level plug A with a new bonded

washer. 137570

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

out.

3 Set OIL LEVEL marks to the horizontal.

175880 137570

4 Fill the hubs with JCB recommended axle oil, as

specified on page 1 - 1, through the fill/level holes C.
Check Hub Oil Level - for Interval see Service Schedule Oil should be level with the bottom of the fill/level hole.

1 Make sure the OIL LEVEL mark on the hub is 5 Clean and refit fill/level plugs C.
horizontal.

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

bottom of the fill/level hole.

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

Clean and refit fill/level plug C.

9803/7110 Issue 1
Section 3 Routine Maintenance Section 3
10 - 1 10 - 1

Engine Oil and Filter

Check Level - for Interval see Service Schedule Change Oil & Filter - for Interval see Service Schedule

1 Park the machine on level ground. Lower the backhoe ! CAUTION

to the ground. Stop the engine and open the bonnet. Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil contains
2 Make sure that the oil level is between the two marks harmful contaminants which can cause skin cancer. Do
on the dipstick A. not handle used engine oil more than necessary. Always
use barrier cream or wear gloves to prevent skin
3 If necessary, top up with JCB recommended oil, as contact. Wash skin contaminated with oil thoroughly in
specified on page 1 - 1, through filler point B. warm soapy water. Do not use petrol, diesel fuel or
paraffin to clean your skin.
4 Replace dipstick and filler cap. Close the bonnet. INT-3-2-3

1 Remove drain plug C and its 'O' ring and drain the oil
into a suitable container. Renew the 'O' ring. Clean and
A refit the drain plug and new 'O' ring. Tighten to 34 Nm
(25 lbf ft).

2 Change the filter:

B a Unscrew oil filter canister D.

b Clean the filter head.
c Smear the new filter canister seal E with engine oil.
d Screw in the new filter canister - hand tight only.

3 Fill the engine with new oil, as specified on page 1 - 1.

Wipe off any spilt oil. Check the system for leaks.

4 Replace filler cap.

5 Make sure the engine will not start and turn the starter
175890 switch to operate the starter motor until the oil pressure
light is extinguished. (To make sure the engine will not
start, remove the engine shut-off solenoid fuse, housed
in the fuse box).

6 Run the engine at idling speed for a few seconds and

check for leaks. When the engine has cooled, check
the oil level.

175900

9803/7110 Issue 1
SXXXXXX
Section 3 Routine Maintenance Section 3
11 - 1 11 - 1

Fuel Filter
Drain - for Interval see Service Schedule

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

Renew Element - for Interval see Service Schedule

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

filter element D. Wash the bowl in clean fuel.

2 Inspect sealing rings E and F and 'O' ring seals G and

H. Renew if damaged.

3 Fit new element D, sealing rings E and F, 'O' rings G

and H and bowl B. Tighten bolt C. Check for leaks.

4 Bleed the fuel system as described on Page 11 - 2.

G M

H
E
L

D J
K

E
181630

F 142951
A

9803/7110 Issue 1
SXXXXXX
Section 3 Routine Maintenance Section 3
11 - 2 11 - 2

Fuel System
Bleeding

Air in the fuel system could cause misfiring or failure to start.

Air will enter the fuel system if any part of the system has
been drained or disconnected.

! CAUTION
Running the engine with air in the system could damage
the fuel injection pump. After maintenance, remove air
from the system as detailed below.
2-3-3-7

1 Set the starter key to the IGN position.

! WARNING
Hot oil and engine components can burn you. Make sure
X
the engine is cool before doing this job.
2-3-3-2 148070

2 Operate the fuel lift pump priming lever X slowly for

approximately two minutes.

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

lever X is operated the pump diaphragm may have rested in
a 'maximum lift' position. To move the diaphragm, use the
starter key to turn the engine over momentarily. Repeat step
1.

3 Start the engine. If the engine runs smoothly for a short

time and then begins to run roughly or stops, check
again for air in the fuel system. Check all seals and
connections, especially in the low pressure side of the
system.

4 Stop the engine.

9803/7110 Issue 1
Section 3 Routine Maintenance Section 3
12 - 1 12 - 1

Coolant System

! WARNING Coolant Mixtures

The cooling system is pressurised when the coolant is The protection provided by JCB Universal Anti-freeze is
hot. Hot coolant will burn you. Make sure the engine is shown below. If any other anti-freeze is used, refer to the
cool before checking the coolant level or draining the manufacturers' instructions and ensure that a corrosion
system. inhibitor is included.
2-3-3-3

Checking the Coolant Level - for Interval see Service DO NOT use solutions of more than 60% or less than 50%
Schedule or damage to the cooling system will occur.

1 Park the machine on level ground

Solution Maintains circulation Protects against
2 Check that the coolant level is between the COLD/MIN down to damage down
and the HOT/MAX marks on the coolant reservoir A. to

3 If necessary, remove reservoir filler cap B and top-up to

the required level. See page 1-1. Refit reservoir cap. deg C deg F deg C deg F
55% -36 -33 -41 -42
4 Run the engine to raise the coolant to working
temperature and pressure. Stop the engine and check
for leaks. The strength of the anti-freeze solution must be checked at
least once a year, preferably at the beginning of the cold
period.

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

round as it gives continued protection against corrosion.
B Always renew the anti-freeze every two years.
A A 50% anti-freeze mixture must be used even if frost
protection is not needed. This gives protection against
corrosion and raises the coolant's boiling point.

! WARNING
Antifreeze can be harmful. Obey the manufacturers
instructions when handling neat or diluted antifreeze.
7-3-4-4

181640

9803/7110 Issue 1
SXXXXXX SXXXXXX
Section 3 Routine Maintenance Section 3
12 - 2 12 - 2

Cooling System (cont'd)

Changing the Coolant - for Interval see Service Schedule
A
! WARNING
The cooling system is pressurised when the coolant is
hot. Hot coolant will burn you. Make sure the engine is
cool before checking the coolant level or draining the
system.
B
2-3-3-3

1 Park the machine on level ground. Engage the parking

brake. Stop the engine and let it cool down.

2 Open the bonnet and remove the left hand side panel.

3 Carefully loosen cap A. Let any pressure escape.

Remove the cap.
181640
! CAUTION
Keep your face away from the drain hole when removing
the drain plug.
2-3-3-4

4 Remove the drain plug C and let the coolant drain out.
Make sure the drain hole is not blocked.

5 Remove the radiator grille. Remove hose D and drain

the coolant.

6 Flush the system with clean water. Refit the drain plug
C
C and radiator hose D.

7 Use the necessary mix of clean, soft water and anti-

freeze. See Coolant Mixtures page 12-1. Fill the
reservoir to the COLD/MIN level on coolant reservoir B.

8 Start the engine and run at idle to circulate the coolant,

top up with coolant as necessary. Refit filler cap A.
181650-
9 Run the engine and raise the coolant to working
temperature and pressure. Stop the engine. Look and
listen for leaks.

10 Refit the radiator grille, engine panel and bonnet.

Note: Make sure the heater shut-off tap is in the open

position before running the engine. This will ensure the *
coolant mixture circulates through the entire cooling system.

181660

9803/7110 Issue 2
Section 3 Routine Maintenance Section 3
13 - 1 13 - 1

Fan Belt
Check Tension - for Interval see Service Schedule

Adjustment

1 Remove fan guard, if fitted.

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

C
3 Reposition the alternator until belt deflection at point W D
is approximately 10 mm (3/8 in).

! CAUTION
If any leverage is necessary, use a length of wood at the
drive end bracket only; otherwise damage to the
alternator may be caused.
ENG 1-4

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

rear of the alternator is the last to be tightened.

5 Refit fan guard, if fitted.

A
W B

145880

9803/7110 Issue 1
Section 3 Routine Maintenance Section 3
14 - 1 14 - 1

Air Filter Pre-Cleaner

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

Empty Pre-cleaner - for Interval see Service Schedule

1 Unscrew wingnut A and lift off cover B.

2 Carefully remove the dust bowl C and empty out any

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

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

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

hot water with a little detergent. Dry before refitting.

9803/7110 Issue 1
Section 3 Routine Maintenance Section 3
14 - 2 14 - 2

Air Filter

! WARNING
Do not run the engine when the outer element has been Renew Inner Element - for Interval see Service Schedule
removed.
16-3-3-1
The inner element must be renewed at latest every third time
the outer element is renewed. As a record, mark the inner
element with a felt tip pen each time the outer element is
Note: The elements must be renewed only. DO NOT
renewed.
attempt to clean them with an airline or by washing.
1 Prevent dust from entering the engine by disconnecting
Renew Outer Element - for Interval see Service Schedule
the induction hose H.
The outer element must be renewed more frequently if the
2 Unscrew nut A and remove outer element B.
warning light on the instrument panel glows.
3 Unscrew nut E and remove inner element F.
1 Unscrew nut A and remove outer element B.
4 Clean inside canister.
2 Clean inside canister.
5 Test seating of seal G by smearing with grease prior to
3 Fit new element B. Test seating of seal D by smearing
inserting new element F, then removing to check for
with grease and checking for witness mark at base of
witness mark at base.
canister.
6 If the seal is correct, re-insert new inner element and
4 If the seal is correct, re-insert new outer element and
tighten nut E.
tighten nut A.
7 Insert new outer element B and test seating of seal D
5 Check the security and condition of the induction hose
as previously described.
and its clips. Ensure that the restriction indicator sensor
is connected.
8 If the seal is correct, re-insert new outer element and
tighten nut A.

9 Reconnect the induction hose H. Ensure that the

restriction indicator sensor is reconnected.

D
H

A
G

181670
181680

9803/7110 Issue 1
Section 3 Routine Maintenance Section 3
15 - 1 15 - 1

Brakes
Parking Brake - Testing - for Interval see Service Schedule

After any parking brake adjustment or replacement of any 5 Keep the brake pedal pushed down.
parking brake component, test the parking brake as
follows:-
! WARNING
! WARNING If the machine starts to move during the following test,
Before testing the parking brake make sure the area immediately apply the foot brake and reduce engine
around the machine is clear of people. speed.
2-2-4-5 2-2-5-1

Test the brake on a level, dry surface.

6 Release the brake pedal.
Make sure your seat belt (where fitted) is securely fastened.
7 If the machine has not moved, use the accelerator
1 Raise the attachments. pedal to gradually increase engine speed to 1600
rev.min. The machine should not move.
2 Make sure the parking brake is fully engaged.
8 Reduce engine speed to idle and set the
Note: The parking brake is fully engaged when the button is forward/reverse lever to neutral.
pressed.
9 Set the gear lever to neutral.
3 Select 3rd. gear.

4 Push down hard on the brake pedal and move the

forward/reverse lever to forward.

Note: An audible alarm will sound and a warning light will

show when the parking brake is engaged with the machine
in forward drive. The alarm will stop when neutral drive is
selected.

9803/7110 Issue 1
Section 3 Routine Maintenance Section 3
16 - 1 16 - 1

Battery

! WARNING Checking the Electrolyte Level - for Interval see Service

Batteries give off an explosive gas. Do not smoke when Schedule
handling or working on the battery. Keep the battery
away from sparks and flames. 1 Unlock the battery cover A and remove the retaining
bolts B. Remove the cover.
Battery electrolyte contains sulphuric acid. It can burn
you if it touches your skin or eyes. Wear goggles. Handle 2 Remove the cell covers. Look at the level in each cell.
the battery carefully to prevent spillage. Keep metallic The electrolyte should be 6 mm (1/4 in) above the
items (watches, rings, zips etc) away from the battery plates. Top up if necessary with distilled water or de-
terminals. Such items could short the terminals and burn ionized water. Refit the cell covers and battery cover.
you.

Set all switches in the cab to OFF before disconnecting

! WARNING
and connecting the battery. When disconnecting the
battery, take off the earth (- ) lead first. Do not top the battery up with acid. The electrolyte could
boil out and burn you.
2-3-4-6
When reconnecting, fit the positive (+) lead first.

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

ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you have
installed the battery in the machine, wait five minutes
before connecting it up.
5-3-4-3

EYES

FLUSH WITH WATER FOR 15 MINUTES. GET MEDICAL

HELP FAST.

IF SWALLOWED

DO NOT INDUCE VOMITING. DRINK LARGE QUANTITIES B

OF WATER OR MILK. Then drink milk of magnesia, beaten
egg or vegetable oil.
A
SKIN

FLUSH WITH WATER. REMOVE AFFECTED CLOTHING.

181700

Cleaning the Battery

Check the battery regularly for dirt, corrosion and damage.

Dirt mixed with electrolyte or moisture on the top of the
battery can cause a discharged condition in the battery. Use
baking soda or ammonia and flush the outside of the battery
with water. Use a special cleaner to prevent corrosion on the
battery terminals.

9803/7110 Issue 1
Section 3 Routine Maintenance Section 3
16 - 2 16 - 2

Battery (cont'd)
Jump Starting - Safety Jump Starting - Procedure

1 Make sure that the parking brake has been engaged

and the transmission set to neutral.
! WARNING
If you try to charge a frozen battery, or jump-start and 2 Lower the loader shovel to the ground, if it is not
run the engine, the battery could explode. already there. If the machine is fitted with hose burst
protection valves, the shovel will not lower. In this case,
Do not use a battery if its electrolyte is frozen. To install the safety strut or block the shovel to prevent any
prevent the battery electrolyte from freezing, keep the chance of it falling.
battery at full charge.
3 Set all switches in the cab to the 'OFF' position.
Batteries give off a flammable gas that can explode.
4 Unlock battery cover A and remove screws B. Remove
Do not smoke when checking the battery electrolyte the cover.
levels. When starting from another machine, make sure
the two machines do not touch. This prevents any 5 a Connect the positive (+) jump lead from the booster
chance of sparks near the battery. Sparks could ignite supply to the positive (+) battery terminal.
the battery gas. If that happens the battery could
explode. b Connect the negative (-) jump lead from the booster
supply to a good frame earth, away from the
Even with the starter switch set to off some circuits will battery.
be energized when the external power supply is
connected. Set all the machine switches to their OFF Note: A good frame earth is part of the machine mainframe,
positions before connecting the external power supply. free from paint and dirt.

Do not connect a booster supply directly across the 6 Start the engine.
starter motor. Doing this could bypass the neutral safety
switch and the engine can start with the transmission in 7 a Disconnect the negative (-) jump lead from the
gear. The machine could then run away and kill or injure machine frame earth.
bystanders.
b Disconnect the positive (+) jump lead from the
Use only booster cables which are in good condition positive (+) battery terminal.
with securely attached connectors. Connect both ends
of one booster cable before connecting the other one. 8 Refit batter cover A and secure with screws B. Lock the
5-2-2-3
cover.

181700

9803/7110 Issue 1
Section 3 Routine Maintenance Section 3
17 - 1 17 - 1

Re-aligning the Road Wheels Fault Finding

! WARNING If the steering fails to align or goes out of alignment

frequently there is either leakage across the steer ram or the
At the start of each working period, and at least once a
alignment valve.
day, or if having difficulty in steering, check and, if
necessary, re-align the road wheels.
INT 2-1-1-10 To check the steer rams for leakage carry out the following
procedure.
Procedure
1 Carry out re-aligning the road wheels as detailed.
1 Start the engine.
2 Road the machine on right hand lock, 12 full turns.
2 Turn the steering wheel to full right lock.
3 Bring the machine to a standstill.
3 Stop the engine.
4 Position the wheels to the straight ahead position.
4 Open the bonnet. Move the setting lever A to the SET
position S as shown. If the rear wheels are still in the right turn position the
front ram seals are leaking.
5 Start the engine. If the rear wheels are still in the left turn position the
rear ram seals are leaking.
6 Continue to turn the steering wheel to full right lock until
full/maximum wheel travel is obtained.

7 Stop the engine.

8 Move setting lever A to the LOCK position L as shown.

Close the bonnet.

9 Repeat Steps 1 to 8 if necessary.

L
A
A

181710 181720

9803/7110 Issue 3*
Section 3 Routine Maintenance Section 3
18 - 1 18 - 1

Cleaning the Machine

! WARNING
Airborne particles of light combustible material such as
straw, grass, wood shavings, etc. must not be allowed to
accumulate within the engine compartment or in the
propshaft guards (when fitted). Please inspect these
areas frequently and clean at the beginning of each work
shift or more often if required. Before raising the engine
cover, ensure that the top is clear of debris.
5-3-1-12/1

Clean the machine using water and/or steam. Pay particular

attention to the underside. Do not allow mud to build up on
the engine and transmission. Make sure the radiator grille is
not clogged up. Remove debris from the kingpost mounting
rails.

It is important to note that excessive power washing can

cause damage to the seals or bearings. Take care during
routine machine washing not to direct high power water jets
directly at oil seals or universal joints.

Note: The machine must always be greased after pressure

washing or steam cleaning.

Avoid using neat detergent - always dilute detergents as per

the manufacturer's recommendations, otherwise damage to
the paint finish may occur.

With machines used in an agricultural application, pay

particular attention to the following:

1 Radiator Enclosure
Remove all combustible material from the radiator
enclosure. To gain access, loosen and remove retaining
bolts A and then remove the protection mesh B.

2 Engine Compartment
Do not allow debris to accumulate around the engine,
pay particular attention to the exhaust area, remove all
combustible material.

3 Propshaft Chaff Guard (Front Only)

Do not allow mud, stones or combustible material to
collect inside the propshaft guard.

S220260

9803/7110 Issue 1
Section A Attachments Section A

Contents Page No.

Schematic Hydraulic Circuit
* - 2CX Machines to Serial Number 658960 See Section E, page 2 - 1
* - 2DX and 2CX Machines from Serial Number 658961 See Section E, page 2 - 3

Hydraulic Tool Circuit (H.T.C.)

- 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
- Pressure Testing 2-5

9803/7110 Issue 4*
Section A Attachments Section A
2-1 * Hydraulic Tool Circuit (H.T.C.) 2-1

Schematic Hydraulic Circuit

Component Key

1 Hydraulic Tank
2 Pump
3 Loader Valve Block
4 Filter
5 Excavator Valve Block
6 B.H.T.M.A. Class 'C' Quick Release Couplings
7 Auxiliary Tool Switch
8 Priority Flow Divider
9 Hi-flow Return Line

1
5
9

2
6

A173420

A173420

9803/7110 Issue 2*
Section A Attachments Section A
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. This valve establishes a priority (and controlled) flow to the hydraulic tool circuit (HTC), if the
hydraulic tool circuit (HTC) has not been selected, the oil passes from port B of valve 8 to the backhoe valve 4. From the
backhoe valve the oil returns to the hydraulic tank 1 via an in-line filter (not shown).

When the hydraulic tool circuit (HTC) is selected, a solenoid inside the diverter valve 8 is energised, this causes the flow of oil
inside the valve to be diverted to port P and on to the hydraulic tool circuit (HTC) via quick release couplings 6. Oil returning
from the circuit returns directly to tank 1 via hose C. The flow of oil from port P is regulated regardless of changes in load
pressure or pump flow. Any excess flow (anything over 20 litres/min) is distributed to port B for use in other actuators (e.g.
backhoe valve).

The diverter valve 8 also incorporates a relief valve, when the pressure in the priority circuit (port P) exceeds the setting of the
relief valve all oil flow is returned directly back to tank via hose D.

B 4
C
2 8
P

D
1

A201040

9803/7110 Issue 1
Section A Attachments Section A
2-3 Hydraulic Tool Circuit (H.T.C.) 2-3

Flow Diverter Valve

Removal and Replacement Replacement

Replacement is a reversal of the removal sequence.

! WARNING
Make the machine safe before working underneath it.
! WARNING
Park the machine on level ground, lower the arms. Apply
the parking brake, put the transmission in neutral and Fine jets of hydraulic fluid at high pressure can penetrate
stop the engine. Chock both sides of all four wheels. the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected
Disconnect the battery, to prevent the engine being leaks. Hold a piece of cardboard close to suspected
started while you are beneath the machine. leaks and then inspect the cardboard for signs of
GEN-1-2 hydraulic fluid. If hydraulic fluid penetrates your skin, get
medical help immediately.
Removal INT-3-1-10/1

1 Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral. Make sure that the hoses are correctly installed. The hose
Lower the backhoe and loader end to the ground and connections from the flow diverter valve are as follows:
stop the engine.
Port E = to the loader valve block.
2 Operate the loader valve block control levers back and Port P = to the HTC quick release coupling
forth to vent residual hydraulic pressure. Port B = to the backhoe valve block
Port T = to the hydraulic tank
3 Disconnect all hydraulic hoses from the valve block and
plug all orifices to prevent ingress of dirt. Label each Note: The flow diverter valve ports should be stamped 'E',
hose before disconnecting, this will ensure correct re- 'P', 'B' and 'T'.
fitting.
After replacement check the flow setting and the relief valve
4 Remove the electrical solenoid connector. pressure settings (see page A/2-5).

5 Loosen and remove the two valve retaining bolts A.

S204950

A A

S204190

9803/7110 Issue 1
Section A Attachments Section A
2-4 Hydraulic Tool Circuit (H.T.C.) 2-4

Flow Diverter Valve

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 Nm kgf m lbf ft

2 5 0.5 3.7
3 45 4.6 33
7 60 6.1 44
14 200 20.4 148
25 100 10.2 74

After assembly make sure that the valve is set for the correct
flow and pressure, refer to page A/2-5 and A/2-6.

S206980

9803/7110 Issue 1
Section A Attachments Section A
2-5 Hydraulic Tool Circuit (H.T.C.) 2-5

Flow Testing & Pressure Testing

B
E
F

D
C
S198330

S205200

S205210

Z
X
S205190

Y
9803/7110 Issue 1
Section A Attachments Section A
2-6 Hydraulic Tool Circuit (H.T.C.) 2-6

Flow Testing & Pressure Testing

4 Pressure Testing
! WARNING
4.1 Use the flow restrictor valve to pressurise the
Hydraulic Fluid
circuit. As the pressure rises watch the flow
Fine jets of hydraulic fluid at high pressure can penetrate
reading, it should start to fall when the pressure
the skin. Do not use your fingers to check for hydraulic
reaches 138 bar (2000 lbf/in2)
fluid leaks. Do not put your face close to suspected
leaks. Hold a piece of cardboard close to suspected
4.2 If adjustment is required, loosen locknut E and turn
leaks and then inspect the cardboard for signs of
adjusting screw F until the correct pressure is
hydraulic fluid. If hydraulic fluid penetrates your skin, get
obtained.
medical help immediately.
INT-3-1-10/1
5 Stop the engine, vent residual pressure and remove the
pressure gauge, flow meter and flow restrictor valve.
! WARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be
started while the hoses are open.
INT-3-1-11/1

Prepare the Machine

1 Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral.
Lower the backhoe and loader end to the ground and
stop the engine.

2 Operate the loader valve block control levers back and

forth to vent residual hydraulic pressure.

3 Flow Testing

3.1 Connect a suitable pressure gauge, flow meter and

flow restrictor valve across the flow and return
couplings on the machine, as shown at A. For
reference, items are identified as:

X = Pressure Gauge
Y = Flow Meter
Z = Flow Restrictor Valve

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

OPEN (the adjusting knob screwed fully out) before starting
the engine.

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

3.3 Enable the HTC circuit, i.e. press the HTC switch B
to the 'ON' position.

3.4 Note the flow meter reading, the valve should be

set at 20 litres/min. If adjustment is required,
loosen locknut C and turn adjusting screw D until
the correct flow is obtained.

9803/7110 Issue 1
Section B Body & Framework Section B
i i

Contents Page No.

Backhoe (2CX Range of Machines)
Kingpost & Carriage - Sideshift
- Dismantling and Assembly 1-1

Air Conditioning
R-134a Refrigerant 2-1
Operation 2-1
Control 2-2
Safety Procedures 2-2
Fault Finding 3-1
Checking Refrigerant Charge Level 4-1
Leak Testing 4-1
Tightening Leaking Hoses 4-1
Blower Motor
- Removal and Replacement 5-1
Thermostat
- Removal and Replacement 5-1
Compressor Clutch Relay
- Removal and Replacement 5-1
Pressure Switches
- Testing 6-1
- Removal and Replacement 6-1
Condensor Coil 7-1
Air Conditioning Filters
- Changing/Cleaning 8-1
Adjusting the Compressor Drive Belt 9-1

Cab
Glazing - General 10 - 2
Rubber Seal Glazing 10 - 2
Direct Glazing 10 - 2
Checking the ROPS/FOPS Structure 12 - 1

Extending Dipper
- Wear Pads
- Inspecting, Reshimming and Renewing 14 - 1

* Stabiliser Leg
- Removal and Replacement 15 - 1
- Wear Pads, Removal and Replacement
(2CX, 210S, 212S from serial No. 489724) 15 - 3

Backhoe (2DX Machines)

Kingpost and Carriage
- Dismantling and Assembly 16 - 1

* 3 Point Hitch
- Removal and Replacement 17 - 1

9803/7110 Issue 4*
Section B Body & Framework Section B
1-1 Backhoe 1-1

175530

9803/7110 Issue 1
 Section B Body & Framework Section B
1-2 Backhoe 1-2

* Kingpost & Carriage - Sideshift (2CX,

210S)
When Assembling
Dismantling and Assembly
Apply anti-seize paste to all bearing surfaces.
Before removing the kingpost and carriage, slew the
kingpost to dead centre and remove the boom and dipper. Make sure that the hydraclamp units 20 are returned to the
Support the kingpost using a hoist. positions they originated from. Otherwise the pipework will
not be compatible.
The numerical sequence shown on the illustration is
intended as a guide to dismantling. Grease bushes 22 and 23 and the eye ends of rams 16 and
17 through their grease nipples.
For assembly the sequence should be reversed.
Torque Settings
When Dismantling
Item Nm kgf m lbf ft
1 Before starting, disconnect the six hoses to kingpost 8.
1/3 56 5.7 42
2 The lower pivot pin 4 should be removed via a hole in 5/6 56 5.7 42
the bottom plate of kingpost 8, the upper pivot pin 4 via 10 98 10.0 72
a hole in the top plate of the kingpost. Swing the eye 12/14 244 25 180
ends of slew rams 16 and 17 outwards and clear of the 19 98 10.0 72
assembly.

3 After removing the two thrust washers 9, disconnect

the slew ram hoses.

4 Once removed, screw bolts 10 into the vacant

diagonally opposite threaded holes in pivot pins 11.
Use the bolts to jack up and thereby withdraw the pivot
pins.

5 Note the locations of rams 16 and 17 so that they can

be returned to their original positions during re-
assembly.

6 After removing rams 16 and 17 and thrust washers 18:

a Disconnect the nine hoses from the rear of

kingpost carriage 21.
b Disconnect the hoses/pipes from hydraclamp units
20.
c Support the carriage (weight 110 kg (242 lb)) with a
hoist.

7 Identify the mounting positions of the four hydraclamp

units 20.

8 Before kingpost carriage 21 can be removed it is

necessary to remove the stop bolts from one end of
both the upper and lower carriage rails. This enables
the carriage to be slid off the ends of the rails using the
hoist.

9803/7110 Issue 2*
Section B Body & Framework Section B
2-1 Air Conditioning 2-1

R-134a Refrigerant
Due to environmental concerns, the use of ozone depleting To operate the air conditioning, the operator turns the air
chlorofluorocarbons (CFCs) in air conditioning systems is conditioning switch F clockwise to the ON position and turns
being gradually phased out. the blower switch G clockwise to select a suitable blower
running speed for the ambient conditions.
The R-12 refrigerant used in some systems contains CFCs
and is now being replaced by a hydrofluorocarbon (HFC) Note: Switch K controls the amount of coolant supplied to a
refrigerant R-134a, which does not cause ozone depletion. heater coil in the air conditioning unit. This control enables
The refrigerant used in the 2CX air conditioning system air conditioned air to be heated to supply warm, de-
is R-134a. humidified air to the cab in cool, humid climates.

Air conditioning systems using R-134a refrigerant are not Provided that the ambient temperature is above 0°C and the
compatible with systems using R-12 refrigerant. No attempt blower switch is away from the OFF position, the air
should be made to charge R-134a systems with R-12 conditioning will switch on. The compressor's
refrigerant. electromagnetic clutch operates, engaging the compressor
drive from the engine pulley system. The compressor A
Operation draws in low pressure refrigerant gas from the suction line
(evaporator to compressor) and increases refrigerant
To maintain optimum operator comfort in warm climates or pressure through compression. Increasing pressure also
during seasons of high ambient temperature, the air increases refrigerant temperature.
conditioning system delivers cool, dehumidified air into the
cab. Cooling is provided by passing the warm ambient air, High pressure refrigerant is forced from the compressor to
together with recirculated air, over an evaporator coil in the the condenser B, mounted in front of the engine radiator.
air conditioning unit. Ambient air is drawn across the condenser fins by the
engine cooling fan. In the condenser, the refrigerant changes
The air conditioning system is a closed circuit through which state to a high pressure, high temperature liquid but with a
the refrigerant is circulated, its state changing from gas to lower heat content.
liquid and back to gas again, as it is forced through the
system. The refrigerant passes through the receiver drier C. The
receiver drier serves as a reservoir for refrigerant and also
The major components of the system are the compressor A, contains a desiccant to remove moisture from the system.
condenser B, receiver drier C, expansion valve D and
evaporator coil E.

193150

9803/7110 Issue 1
SXXXXXX SXXXXXX
Section B Body & Framework Section B
2-2 Air Conditioning 2-2

Operation (cont'd) Safety Procedures

The high temperature, high pressure refrigerant is forced by The air conditioning system uses refrigerant under pressure
compressor action into the expansion valve D, which meters in a closed circuit. Any service procedure which breaks into
the amount of refrigerant entering the evaporator. In the the closed circuit and therefore requires discharging of the
expansion valve the refrigerant instantaneously expands to system, must only be carried out by an air conditioning
become a low pressure, low temperature liquid. engineer. The following guidelines should be adhered to by
all personnel servicing the air conditioning system.
The refrigerant is drawn through the evaporator coil E by the
suction of the compressor. The temperature of refrigerant is ! WARNING
now considerably below that of the air being drawn across The air conditioning system is a closed loop system and
the evaporator coil by the blower. Heat is transferred from contains pressurised refrigerant. No part of the system
the ambient and recirculated air to the refrigerant, causing must be disconnected except by a qualified refrigeration
the low pressure liquid to vaporise and become a low engineer.
pressure gas. Moisture in the air condenses on the 4-3-4-1
evaporator coil and is drained away via condensate drain
tubes through the cab floor. 1 It is critical that the correct refrigerant is used and that
charging is done only by qualified personnel. It is illegal
Cool de-humidified air is emitted through air vents into the to discharge the refrigerant into the atmosphere but as
cab. a precaution in case of accidental leakage, discharging
and charging of the vehicle refrigerant system must be
The low temperature, low pressure, high heat content conducted in a well ventilated area.
refrigerant gas, is now drawn by suction back to the
compressor, where the cycle is completed. 2 Containers of refrigerant should be stored in a cool
environment away from direct sunlight.
Control
! WARNING
Control of the system is achieved by the cyclic action of the Do not carry out welding operations close to the air
compressor's electromagnetic clutch. The thermostat switch conditioning refrigerant circuit. A poisonous gas is
senses the evaporator coil temperature by means of a produced when refrigerant comes into contact with
capillary tube and cycles the compressor clutch on and off naked flames. Do not smoke or allow naked flames close
to prevent freezing of condensate on the evaporator coil. to the refrigerant circuit.
BF 1- 9

The signal from the thermostat switch is sent to the

compressor clutch via two pressure switches. These are 3 Do Not perform welding operations close to refrigerant
designed to disengage the compressor clutch and protect hoses (maintain a distance of at least 0.5m from hoses).
the system from damage that would be caused by either
refrigerant loss or excessive pressure. 4 Do Not steam clean refrigerant system components.

The low pressure switch H is connected to the suction hose 5 When charging or discharging the refrigerant system,
adjacent to the compressor. If the pressure in the suction no smoking or naked flames should be allowed in the
hose falls below the low pressure switch setting, it opens, immediate vicinity. The refrigerant does not give off a
interrupting the supply from the thermostat to disengage the poisonous odour, however, when it comes into contact
compressor clutch. with a naked flame, a poisonous gas is produced.

The high pressure switch J is connected to the discharge 6 When handling refrigerant, rubber gloves and goggles
hose adjacent to the compressor. If the pressure in the should be worn. Operators should ensure no refrigerant
discharge hose rises above the high pressure switch setting, comes into contact with the skin. Particular care should
it opens, interrupting the supply from the thermostat to be taken when connecting or disconnecting charging
disengage the compressor clutch. hoses or pressure switches. When these components
are connected to the system, a short release of
Switch Pressures refrigerant occurs. This results in a high velocity, very
cold gas being emitted from the connection point.
Low Pressure Switch
Cut in = 2.1-2.6 bar (30-38 lbf/ in2) 7 When checking the state of the refrigerant at the
Cut out = 0.3-0.6 bar (4-8 lbf/ in2) receiver drier sight glass, it is necessary to run the
engine with the LH side panel removed and the bonnet
High Pressure Switch raised. Extreme care must be taken to avoid moving
Cut in = 15.5-19 bar (225-275 lbf/ in2) engine parts such as fans, pulleys and belts.
Cut out = 23.4-24.8 bar (340-360 lbf/ in2)

9803/7110 Issue 1
Section B Body & Framework Section B
3-1 Air Conditioning 3-1

Fault Finding
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.

It is recommended that, to locate faults on the system accurately and quickly, an electronic leak detector and a refrigerant
pressure gauge should be used. However, leaks can be detected on the system by using soapy water applied to the suspected
leak area and system pressure can be assessed by the state of refrigerant passing through the receiver drier sight glass.
Following sections of the manual deal with the major components of the air conditioning systems and give further fault finding
and maintenance information.

General Fault Indications

There are several indications that may help to determine the fault area on a system not working efficiently:

a) Poor performance Low system pressure - Evacuate and recharge system.

Condenser coil air flow restricted - Remove debris from around coil using
compressed air or low pressure water.

b) Warm or slightly cool air Expansion valve stuck open or closed - Renew expansion valve.
emitted from unit

c) Blower operates on fan Blower resistor failed - Renew resistor.

speed 3 only Blower motor failed - Renew blower motor.

d) Compressor clutch Condenser coil blockage - Remove debris from around coil/renew condenser.
continually cuts out Overcharging of refrigerant system- Evacuate and recharge system.
Blocked expansion valve/condenser - Clear blocked component .

Sight Glass Indications

An approximate indication of the condition of the refrigerant can be seen through the receiver/drier sight glass when the
compressor is running. Refer also to Checking Refrigerant Charge Level, on page B/4-1.

Clear - No fault indicated unless the system is unable to provide cool air. The indication then is that
the system is completely discharged of refrigerant.

Foam or bubbles - Refrigerant low and in need of charging.

Clouded - Dessicant breakdown in the receiver-drier.

S201520

Note: Sight glass indications cannot always give a positive identification of a problem. Further diagnosis, preferably by a
refrigeration engineer using pressure gauges, is advisable before reaching a definite conclusion.

9803/7110 Issue 1
Section B Body & Framework Section B
3-2 Air Conditioning 3-2

Fault Finding (cont'd)

Harness Wires

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 B
A Air Conditioning Power (from fuse C9)
B Controls
C
D
Pressure Switch
Pressure Switch
A
E Compressor F
F Splice

WIRE DESCRIPTION

20 Controls to Power
21 Controls to Compressor E
685 Power to Splice
686 Controls to Pressure Switch
687 Pressure Switch to Splice
688 Pressure Switch to Pressure Switch
689 Controls to Splice

D
C

A201500

S201570

9803/7110 Issue 1
 Section B Body & Framework Section B
3-3 Air Conditioning 3-3

Fault Finding (Continued)

No Air Conditioning

CHECK ACTION

1 Are the controls set correctly, i.e. air conditioning YES: Check 2
selected, thermostat switch set to coldest position NO: Reset controls and retest.
and blower switched on?

2 Is the air conditioning (evaporator) blower working? YES: Check 3.

NO: Check 4.

3 Is the compressor running (visual check of pulley/clutch)? YES: Check11.

NO: Check 7.

* 4 Is the air conditioning fuse (B8) blown? YES: Renew fuse and retest.
NO: Check 5.

5 Is there a 12V supply to the pressure switch harness? YES: Check 6.

(See Pressure Switch Testing) NO: Check 9.

6 Does the compressor clutch engage with both YES: Check 7.

pressure switches bypassed? NO: Renew the compressor clutch and retest.
(See Pressure Switch Testing)

7 Does the compressor clutch engage with YES: Renew high pressure switch and retest.
HP switch bypassed? NO: Check 8.
(See Pressure Switch Testing)

8 Does the compressor clutch engage with YES: Renew low pressure switch and retest.
LP switch bypassed? NO: Charge check required by refrigeration engineer.
(See Pressure Switch Testing)

9 Does the clutch engage with thermostat switch YES: Renew thermostat switch and retest.
bypassed? NO: Check all electrical connections.

10 Are blower switch and wiring OK? YES: Renew blower motor.
NO: Renew switch or wiring.

11 Is sight glass indication OK? YES: Check 12.

NO: Charge check required by refrigeration engineer.

12 Is condensor air flow blocked? YES: Clean condensor and radiator.

NO: Check 13.

13 Is evaporator air flow blocked? YES: Clean filter and, if necessary the evaporator.
NO: Call in refrigeration engineer.

9803/7110 Issue 2*
Section B Body & Framework Section B
4-1 Air Conditioning 4-1

Checking Refrigerant Charge Level Leak Testing

The pressure in the system, i.e. the refrigerant charge level Note: The refrigerant is heavier than air and will leak
can be determined by checking the state of refrigerant at the downwards from the defective component. Check in still
receiver drier sight glass. conditions but in a well ventilated area.

If the level of charge is correct the sight glass will be clear. If Hose or pipe connections are likely leakage points of any
the charge is low bubbles will be seen. Bubbles may also be refrigerant circuit.
an indication of inadequate cooling, due to a restriction of air
flow around the condenser coil. Recharging of the system To test for leaks in the high pressure side of the system i.e.
should be carried out by an air conditioning engineer. Check from the compressor output to the expansion valve, run the
refrigerant charge level as follows: air conditioning for a few minutes then switch off the engine
and test for leakage using an electronic leak detector.
1 Park the machine on firm, level ground. Lower the
backhoe and loader to the ground. To test for leakage in the low pressure side of the system,
switch off the air conditioning and leave for a few minutes
2 Remove the starter key. before testing.
! WARNING
3 Raise the Bonnet.
Leak testing in Air Conditioning systems should be
carried out only in a well ventilated area.
4 Remove the Left Hand Side Panel BF 1-2

! WARNING
When the engine is turning, there are parts rotating in
the engine compartment.

Before starting this job make sure that you have no

Tightening Leaking Hoses
loose clothing (cuffs, ties etc) which could get caught in
rotating parts. ! WARNING
The air conditioning system is a closed loop system and
When the engine is turning, keep clear of rotating parts. contains pressurised refrigerant. No part of the system
2-3-3-10
must be disconnected except by a qualified refrigeration
engineer.
5 Start the engine and run at idle. Switch air conditioning 4-3-4-1
ON to circulate refrigerant.
The refrigerant hoses have crimped ferrule end fittings. The
6 Check refrigerant charge level at sight glass A. hose connectors have an 'O' ring seal which compresses
when the connection is tight, creating an air tight seal.

Hoses are used to connect the inlets and outlets of the

compressor, condenser, receiver drier and expansion valve
A (the evaporator coil is connected to the expansion valve
within the air conditioning unit using rigid pipes).

If leakage is detected from a hose connector, either by

means of an electronic leak detector or soapy water, tighten
the connector up and repeat the leakage test. If leakage is
still evident, it will be necessary to de-gas the system and
renew the connector 'O' ring seal.

The 'O' rings used on an R-134a refrigerant system are of an

HNBR compound and are colour coded green. These 'O'
rings must be used as some 'O' ring materials can become
porous to R-134a systems, resulting in leakage.

S190460

9803/7110 Issue 1
SXXXXXX SXXXXXX
Section B Body & Framework Section B
5-1 Air Conditioning 5-1

Blower Motor Thermostat

Removal Removal

1 Remove the four screws and the front panel 1 of air 1 Disconnect the electrical connections from the
conditioning unit. thermostat 4.

2 Disconnect the electrical connections from the resistor 2 Remove the capillary tube 5 from the evaporator coil 6.
2. Undo the themostat mounting nut and bolt and remove
the thermostat and capillary tube from the unit.
3 Remove the four screws securing the resistor. Remove
the resistor and the blower unit 3. Note: The capillary tube is held in position between the
evaporator coil fins.
Note:The resistor unit incorporates a bridge which retains
the blower unit in position in the air conditioning unit. When Replacement
the resistor is removed the blower unit is free to be removed.
For replacement the sequence should be reversed.
Replacement
Take care when fitting not to damage the capillary tube.
For replacement the sequence should be reversed.

Compressor Clutch Relay

Removal

1 Disconnect electrical connections from relay 7.

2 Undo nut and bolt 8 and remove the relay.

Replacement

For replacement the sequence should be reversed.

S193160

9803/7110 Issue 1
SXXXXXX SXXXXXX
Section B Body & Framework Section B
6-1 Air Conditioning 6-1

Pressure Switches
The 12V supply is fed from the thermostat to the Removal and Replacement
compressor clutch via the low and high pressure switches
which are wired in series.
! WARNING
The low pressure switch requires a minimum refrigerant Goggles and rubber gloves must be worn when pressure
charge level to close its contact. The high pressure switch switches are removed or fitted. A small amount of
requires the charge level to remain below the maximum limit refrigerant is released which can be harmful to the skin
to keep its contact closed. and eyes.
BF 1-10
Both pressure switch contacts must be closed for the
compressor clutch to operate. If the compressor clutch will Removal
not operate when air conditioning is selected, the fault may
be either electrical or system pressure. 1 Disconnect the electrical connections and unscrew the
pressure switch.
Pressure Switch Testing
Replacement
1 Switch the engine off so that the air conditioning
system cannot operate. Note: The high pressure switch has a red body, the low
pressure switch has a bronze body, both have 1/4 UNF
2 Disconnect the pressure switch harness from the main female threads.
vehicle harness and connect an external 12V power
supply to the pressure switch harness connector. If 1 Screw the pressure switch into the pressure switch port
both pressure switches are working correctly, and the and torque tighten sufficiently to form a gas-tight seal.
system is at the correct charge level, the compressor
clutch will operate. 2 Run the air conditioning and check the pressure
switches for leaks. If any leaks are found, tighten the
If the compressor clutch does not operate with the pressure switch further until the leaking stops.
external power supply, one of the pressure switches is
faulty or the level of refrigerant charge is insufficient to
close the low pressure switch.

High Pressure Switch Testing

1 Disconnect the air conditioning harness male/female

connectors from the high pressure switch 1.

2 Connect an external 12V power supply to the harness

connector - wire 688. If the compressor clutch
operates, renew the high pressure switch.

If the clutch does not operate check the low pressure

switch.

Low Pressure Switch Testing

1 If the refrigerant charge level in the system is correct,

but the clutch will still not function, disconnect the air
conditioning harness male/female connectors from the
low pressure switch 2.
S193171
2 Connect an external 12V power supply to the harness
connector - wire 686. If the compressor clutch
operates, renew the low pressure switch.

Note: If both pressure switches operate correctly, check all

electrical connections and the compressor clutch relay.

9803/7110 Issue 1
SXXXXXX SXXXXXX
Section B Body & Framework Section B
7-1 Air Conditioning 7-1

Condenser Coil
It is likely that over a period of time, because of the 3 Remove the front grille.
machine's working environment, the airflow around the
condenser coil will become restricted due to a build up of 4 Remove both side panels.
airborne particles.
5 Support the condenser 1.
If the build up of particles is severe, heat dissipation from
the refrigerant to the air will be significantly reduced, 6 Undo the nuts and bolts 2 at the three mounting
resulting in poor air conditioning performance. brackets 3.

In extreme cases, over pressurisation of the system occurs, 7 Remove the screws 4 fixing the condenser to the
causing the high pressure cut out switch to operate and mounting brackets. Remove the brackets 3 to enable
switch off the system. the condenser to be moved away from the radiator.
This can be done without removing the hoses i.e. with
High pressure cut out can also be caused by an internal the system fully charged.
blockage of the condenser coil.
8 With the condenser fully supported, use compressed
Condenser Coil Cleaning air or low pressure water to backflow through the coil
fins. Take care not to damage the fins.
Take care not to damage the condenser fins or tubes.
Damaged fins must be straightened out to ensure a good 9 Refit the condenser coil by reversing the removal
airflow through the coil. procedure. Refit both side panels and bonnet.

1 Park the machine on firm level ground. Raise and block 10 Run the air conditioning and check cooling
the loader arms. Lower the backhoe to the ground and performance.
stop the engine.

2 Remove the starter key.

S193180

9803/7110 Issue 1
SXXXXXX SXXXXXX
Section B Body & Framework Section B
8-1 Air Conditioning 8-1

Air Conditioning Filters

Recirculation Filter - Change/Clean Air Intake Filter - Clean

1 Remove screws A, filter cover B and filter C. Insert a 1 Stop the engine and remove the starter key.
new filter into the cover and refit.
2 Remove Screws D, air intake cover E and filter F.
Note: The recirculation filter may be washed and re-used if
in good condition. Clean filter element using compressed air. Refit filter
into the cover and refit.

E F

B C
A S190480 D S190470

9803/7110 Issue 1
Section B Body & Framework Section B
9-1 Air Conditioning 9-1

Adjusting the Compressor Drive Belt

1 Park the machine on firm level ground. Raise and block
the loader arms. Lower the backhoe to the ground and
stop the engine.

2 Remove the starter key.

! WARNING
Make sure the engine cannot be started. Disconnect the
battery before doing this job.
2-3-3-5

A
3 Raise the Bonnet

4 Remove both Side Panels

5 Loosen pivot fastening bolt A. Loosen adjustment link

fastening bolts B and C.

6 Position the compressor so that there is approximately

10 mm (3/8 in) slack at point X midway along the belt.

7 Tighten bolts A, B and C. Make sure that bolt A is the

last to be tightened.

Note: If a new belt is fitted, check the belt tension after the
first 20 hours of operation.

X
C
S190490

9803/7110 Issue 1
Section B Body & Framework Section B
10 - 1 Cab 10 - 1

4 S136161

9803/7110 Issue 1
 Section B Body & Framework Section B
10 - 2 Cab 10 - 2

Glazing - General Direct Glazing

Two methods of glass retention are used, the rubber seal The following procedures explain how to correctly remove
method, as shown at A, and the 'direct glaze' type, as and install panes of glass that are directly bonded to the cab
shown at B. frame apertures. When carrying out the procedures, relevant
safety precautions must be taken:
* Except for 2DX machines, the two front quarter panes (items
C) are the only panes currently retained by the direct glazing 1 Always wear safety glasses during both removal and
method. On 2DX machines all panes are direct glazed. replacement.

2 Use protective gloves - heavy duty leather gauntlet type

gloves when cutting out the broken glass; 'non-slip'
type gloves when handling/moving panes of glass;
surgical type gloves when using the polyurethane
adhesives.

3 Wear protective overalls.

4 DO NOT smoke - the activators and primers used in the

A B procedures are highly flammable.

5 Do not attempt to handle or move panes of glass

unless you are using glass lifters (see Service Tools,
Section 1).
A191050
Several special tools are required to successfully complete
the removal and replacement procedures. Reference is
made to the tools in the text. The majority of these tools can
be obtained locally and the remainder from JCB Service (see
Service Tools, Section 1).

The work must only be carried out in a dry, frost free

environment. A protective canopy may be required or the

C C machine/frame must be moved to a sheltered area. In damp

or wet conditions, hinged doors and window frames can be
removed from the machine and taken to a more suitable
(dry) environment.

Glass should not be replaced at temperatures below 5°C

(41°F).
S201100

Removing the Broken Glass and Old Sealant

A toughened pane will shatter and fall apart.

Rubber Seal Glazing
Installing New Glass (refer to fig on page B/10-1). ! WARNING
Always wear safety glasses when removing or installing
Position the machine on level ground and apply parking screen glass. Never use a power operated knife when
brake. Stop the engine. removing the sealant around a toughened glass screen.
The action of the knife could cause particles of glass to
1 Fit glazing seal around edge of glass. be thrown with sufficient force to cause serious injury,
even when safety glasses are being worn. Use only hand
2 Wind string around the seal. Pull string tight to operated tools when working with toughened glass.
compress the inner seal. Apply soap to the seal. BF 2-3/1

3 Place glass into frame from outside the cab. Make sure 1 Position the machine on level ground and apply the
that the glass is in the centre of the frame. parking brake. Stop the engine. Put protective covers
over the cab seat and control pedestals.
4 Pull one end of the string slowly from inside the cab, to
lift the inner seal over the frame. 2 Remove as much of the shattered glass as possible
prior to cutting out the old sealant.
Note: The inner seal holds the glass to the frame.

9803/7110 Issue 2*
Section B Body & Framework Section B
10 - 3 Cab 10 - 3

Direct Glazing (cont'd)

Removing the Broken Glass and Old Sealant (cont'd)

3 Cut out the old sealant, leaving approximately 1 to 2

mm on the cab frame. There are several tools and
techniques for doing this:

a Pneumatic Knife A provides one of the easiest C

methods of removing the sealant around laminated
glass. The tool, powered by compressed air, should
be sourced locally.
S189880

A (ii) Insert the braided cutting wire D down the centre of

the steel tube. If necessary, from the outside, cut
out local sealant at the point of the tube to gain
access to the wire.

(iii) Using suitable pliers, pull the cutting wire through

the sealant to the outer side of the glass.

S186380
(iv) Secure each end of the braided cutting wire in the
special handles E.
Note: This tool must not be used on toughened glass (see
WARNING on previous page). (v) Move the cutting wire backwards and forwards in
a sawing motion and at the same time gently
(i) Press the handle to start the knife blade push or pull the wire to cut through the old
oscillating. sealant.

(ii) Insert the knife blade into the sealant. c Cut-out Knife F. The cut-out knife can be used as a
left handed or right handed tool. For the knife and its
(ii) Slowly move the knife along the sealant with the replaceable blades, refer to Service Tools, Section
blade positioned as close to the glass as 1.
possible. Do not allow the knife blade to overheat
or the sealant will melt. (i) Insert the knife blade into the sealant.

b Braided Cutting Wire and Handles B. This method (ii) Make sure that the blade of the knife is against
uses a 3-core wire, a wire starter tube and two the glass as shown at G.
handles (see Service Tools, Section 1).
(iii) Use the 'pull-handle' to pull the knife along and
(i) Insert the steel tube C into the old sealant on the cut out the old sealant.
inside of the glass.

S189890

9803/7110 Issue 1
Section B Body & Framework Section B
10 - 4 Cab 10 - 4

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.
1 If damp or wet, dry the aperture area using a hot air gun
(sourced locally).

H 2 Use 'Active Wipe 205' to thoroughly clean and 'prime'

the trimmed sealant. Use a lint free cloth to apply the
'Active Wipe 205', allow 5 minutes flash off (drying)
time.

Note: Do not use any other type of cleaning fluids, otherwise

they may be absorbed into the old sealant and ultimately
prevent the new glass from bonding.
S186370

Preparing the New Glass

(i) Insert the knife blade into the sealant.
1 Make sure that the new glass correctly fits the frame
(ii) Pull the knife along and cut out the old sealant. aperture K.

Note: There are other tools available to cut out the old a Put two spacer blocks L onto the bottom part of the
sealant. For example, there is a long handle type craft knife frame aperture.
to give extended reach. Refer to Service Tools, Section 1,
for details of this and any other tools. b Install the new glass on the spacer blocks - ALWAYS
USE GLASS LIFTERS M (see Service Tools, Section
4 Remove the cut off sealant and all remaining particles 1). Check that there is an equal sized gap all round
of shattered glass. the edge of the glass.

5 If necessary, trim off the remaining old sealant to leave Note: The spacer blocks are rectangular in section to give
approximately 1 to 2 mm on the upright face of the cab two common gap widths. If necessary they can be trimmed
frame aperture, as shown at J. to a smaller size to give an equal sized gap around the glass.

IMPORTANT: The glass edges MUST NOT touch the frame,

otherwise movement of the frame will chip and eventually
J break the newly installed glass.

S189900
K

6 Apply a coat of 'Black Primer 206J' to the paintwork if:

M
a Paintwork was damaged or scratched during the
glass/sealant removal procedures.

b The old sealant was inadvertently cut back to the

cab frame during the glass/sealant removal
procedures.

L
S189910

9803/7110 Issue 1
Section B Body & Framework Section B
10 - 5 Cab 10 - 5

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,
2 After checking for size, remove the new glass and place and the edge should be a neat straight line as shown
it on a purpose made glass stand N (see Service
Tools, Section 1).
R
N

S189920

at R.

5 Install the Ultra Fast Adhesive cartridge (see Sealing

S186280
and Retaining Compounds, Section 1 and Note 2
below) into a suitable applicator gun:

Small panes of glass will need locating on a 600 x 700 mm x a Remove the aluminium disc cover from the base of
15 to 19 mm thick plywood board P (sourced locally to fit the cartridge and discard the 'dessicant capsule'.
the glass stand N). It is recommended that an access hole is
cut in the board to accommodate the glass lifter, making it b Make sure that the rolled edge of the cartridge is not
easier and safer to handle small panes of glass. The board damaged - if necessary, the edges should be
should be covered with felt or carpet to give an anti-scratch pressed flat, otherwise it will be difficult to remove
surface. Resting the glass on four spacer blocks will ensure the cartridge from the applicator gun.
clearance of the cartridge nozzle tip during application of the
polyurethane sealant. c Pierce the front 'nozzle' end of the cartridge to its
maximum diameter.

d Fit the pre-cut nozzle shown at S.

P e Install the cartridge in the applicator gun.

Note 2: Cold material will be very difficult to extrude. The

cartridges must be pre-heated in a special oven (see Service
Tools) for 1 hour to a temperature of 80°C (176°F). Pre-
heating the cartridges makes the adhesive more workable
and also brings the 'curing' time down to 30 minutes.

S186291

S
3 Make sure the glass is positioned on the stand the
correct way up (i.e. with the black ceramic ink band
upwards) ready for application of primer etc.
10-15 mm
4 a Use 'Active Wipe 205' to thoroughly clean and
'prime' the black ceramic ink band printed on the T
glass (see Note 1). Use a lint free cloth to apply the
'Active Wipe 205', allow 5 minutes flash off (drying) 8-10 mm
A186410
time.
A186410

Note 1: Do not touch the glass after cleaning with the

'Active Wipe 205'.

9803/7110 Issue 1
Section B Body & Framework Section B
10 - 6 Cab 10 - 6

Direct Glazing (cont'd)

c Make sure that the glass is correctly positioned, then
Preparing the New Glass (cont'd) gently press around the edges of the glass and
ensure full adhesive contact is achieved. Do not
6 Apply the pre-heated adhesive to the glass (do not start press too hard or too much adhesive will squeeze
in a corner). Keep the nozzle guide T against the edge out.
of the glass and make sure that the adhesive forms a
continuous 'pyramid' shape. 3 Make the inside seal smooth:

a Wearing surgical gloves, dip your finger in a soapy

water solution.

b Use your finger to make the inside seal smooth.

4 All exposed edges must be sealed using Black

Polyurethane Sealant (see Sealing and Retaining
Compounds, Section 1).

5 Clean the glass after installation:

IMPORTANT: Use extreme caution when wiping the inside

of the new glass - pushing too hard on the inside of the
Note 3: Once the pre-heated adhesive has been applied to glass will affect the integrity of the bonded seal.
the glass, install the glass in the aperture as soon as
possible. After approximately 10 minutes the sealant will a Small amounts of sealant can be cleaned from the
form a 'skin', this will prevent the glass from bonding. glass using the 'Active Wipe 205'.

7 After applying the adhesive, leave a small amount of b Large amounts of excess sealant should be left to
sealant protruding from the nozzle. This will prevent any 'cure' (see Note 4) and then cut off with a sharp
adhesive left in the cartridge from 'curing'. knife.

Installing the New Glass Note 4: On completion of the glass replacement procedures,
the sealant 'curing' time is 30 minutes. This means that the
1 Make sure the two spacer blocks are in position (see machine can be driven and used after 30 minutes, but it
step 1 of Preparing the New Glass). MUST NOT be used during the curing period of 30 minutes.

2 Install the glass in the frame aperture: c Clean the glass using a purpose made glass cleaner.

a ALWAYS use the special lifting tools when moving 6 On completion of the glass installation procedures tidy
the glass. the work area:

b Sit the bottom edge of the glass on the spacer a Remove ALL broken glass from the cab area.
blocks as shown X.
b Remove the protective covers from the cab seat and
control pedestals.

c Renew all 'warning' and 'information' decals so that

the new installation conforms with the original cab
installation.

9803/7110 Issue 1
 Section B Body & Framework Section B
12 - 1 Cab 12 - 1

Checking the ROPS/FOPS Structure

! 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. If the ROPS/FOPS has been in an accident,
do not use the machine until the structure has been
renewed. Modifications and repairs that are not
approved by the manufacturer may be dangerous and
will invalidate the ROPS/FOPS certification.
INT-2-1-9/3

Failure to take these precautions could result in death or

injury to the operator.
A
Check the structure for damage. Check that the mounting
bolts are installed and undamaged. Check the bolt torques.
Tighten them to the correct torque if necessary. A
Torque-tighten bolts A to 244Nm (180lbf ft; 24.8kgf m). On
*
later machines bolt A has been changed to a screw which
must be torque loaded to 200Nm (147lbf ft; 20.5kgf m).

Note: 2DX machines are shown opposite, other machines

are shown below. S224070

A
A

S137060

9803/7110 Issue 3*
Section B Body & Framework Section B
15 - 1 Stabiliser Leg 15 - 1

230430

Y Y

9803/7110 Issue 2
Section B Body & Framework Section B
15 - 2 Stabiliser Leg 15 - 2

Stabiliser Leg
! WARNING
Removal and Replacement Make the machine safe, place blocks underneath the
sideshift rails.
The following steps (1 to 11) describe the removal BF 2-5
procedures for the stabiliser inner leg, the stabiliser foot and
the stabiliser ram. However, it is possible to remove these
11 Use the boom and dipper to raise the rear of the
items as a complete assembly, see step 12.
machine, as shown at G. Do not raise the machine too
high but allow just enough room for the stabiliser inner
Removal
leg to slide clear. Refer to the warning above.
1 Park the machine on firm level ground. Engage the
Note: Use the widest backhoe bucket available.
parking brake and set the transmission to neutral.
12 If required, the stabiliser inner leg, stabiliser foot and
2 Lower the loader shovel to the ground.
stabiliser ram can be removed as a complete assembly.
3 Make sure that the backhoe assembly is set central to
12.1 Complete steps 1 to 4.
the mainframe as shown. If necessary ‘sideshift’ the
backhoe into a central position.
12.2 Make sure the engine is switched off, vent
residual hydraulic pressure by moving the
4 Lower the stabiliser legs until the pads are
backhoe and stabiliser control levers back and
approximately 25 mm (1 in) off the ground.
forth.
5 Remove the bottom locking nut A and bolt B.
12.3 Loosen and remove the stabiliser hoses D and
E, label the hoses before removing (as an aid
6 Drive out the bottom pivot pin C to release the foot.
to assembly). Plug all open orifices to prevent
loss of fluid and ingress of dirt.
Note: Steps 7 to 10 only apply if renewing or repairing the
stabiliser ram, however, removing the ram will give more
room when refitting the stabiliser inner leg. ! WARNING
Make the machine safe, place blocks underneath the
7 Make sure the engine is switched off, vent residual sideshift rails.
BF 2-5
hydraulic pressure by moving the backhoe and
stabiliser control levers back and forth.
12.4 Loosen and remove the top pivot pin retaining
nut and bolt, as shown at F.
8 Loosen and remove the stabiliser hoses D and E, label
the hoses before removing (as an aid to assembly).
* 12.5 Slacken off leg adjusters X (2DX), or Y (2CX
Plug all open orifices to prevent loss of fluid and ingress
from serial No. 489724).
of dirt.
12.6 Use the widest backhoe bucket available (if
9 Loosen and remove the top pivot pin retaining nut and
possible, a ditching bucket), and position the
bolt, as shown at F.
backhoe as shown at G. Do not raise the
machine too high but allow just enough room
! CAUTION for the stabiliser leg assembly to slide clear.
The ram is heavy. It is recommended that the ram is Refer to the warning above.
removed with the assistance of a sling and suitable
lifting appliance. Inspection
BF 2-4

The inner leg should be free from nicks, marks or scores.

10 Remove the stabiliser ram - take the ram out from the
top. Be careful, the ram is heavy.
Replacement

Replacement is a reversal of the removal sequence.

Use suitable lifting appliances to locate the stabiliser ram.

After replacing or fitting the stabiliser leg, connect the

hydraulic pipes, making sure that the ram and leg operate
freely and do not foul. Set the leg adjusters as described on
page 15 - 3.

9803/7110 Issue 2*
Section B Body & Framework Section B
15 - 3 Stabiliser Leg 15 - 3

C
C
D
C B
B

271851

9803/7110 Issue 1
Section B Body & Framework Section B
15 - 4 Stabiliser Leg 15 - 4

Wear Pads Stabiliser Leg Removal and Replacement

2CX, 210S, 212S From Serial No. 489724
Removal
The wear pads supports and guide the inner leg section.
They ensure that during extension and retraction the inner 1 Park the machine on firm level ground. Engage the
leg is kept central and has a minimum amount of ‘float’. parking brake and set the transmission to neutral.

Upper wear pads A (4 off) are fitted to the top of the inner 2 Lower the loader shovel to the ground.
leg as shown. The upper pads are available in sizes 5, 5.5, 6,
6.5 and 7 mm. Lower wear pads comprise adjustable pads 3 Make sure that the backhoe assembly is set central to
B (2 off) and fixed pads C (2 off). the mainframe as shown. If necessary ‘sideshift’ the
backhoe into a central position.
When pads A and C have worn to a minimum thickness of
0.5 mm (0.020 in) they must be replaced with new ones. To 4 Remove the stabiliser foot D, refit pivot pin to engage
replace the pads, the stabiliser inner leg must be removed stabiliser ram.
(see procedures on this page).
5 Remove the inner leg:
It is important to note that lower pads C are designed to
take most of the ‘loading’ during stabiliser leg operation, as 5.1 Dissconnect hydralic hoses to stabilser ram.
a consequence these pads must be checked regularly for
wear. 5.2 Use suitable lifting equipment, lift the inner leg
clear.
When replacing pads, it is recommended that the complete
lower set of pads are replaced (items B and C). The top 5.3 Remove the wear pads.
pads should be inspected and replaced as required.
Replacement
Before fitting new pads, check the condition of the stabiliser
legs, make sure there are no grooves, nicks etc (caused by Replacement is a reversal of the removal sequence.
bucket teeth coming into contact with the legs). Dress off all
burrs, nicks and grooves, this will help promote a longer Select suitable size upper pads A to achieve a maximum
wear pad life. permissible float of 1 mm (0.039 in).

Wear Pad Adjustment Make sure that the bottom pads C are held in position
before guiding the inner leg into position. If the lower pads
As a guide, there should be approximately 1 mm (0.039 in) are not secured then the inner leg could dislodge the pads
float between the stabiliser inner and outer leg. during assembly.

Before adjusting the clearance make sure that the leg is When the inner leg is in position adjust the bottom pads as
raised clear of the ground but not fully retracted. described in ‘Wear Pad Adjustment’.

To adjust the clearance, screw pad B fully in until it just Apply a high pressure grease such as JCB HP Grease (part
touches the inner leg and then back the pad off by one number 4003/2000) to the threads of pad B.
quarter of a turn.

Note: Over-tightening the adjustable pad B will lock the pad

in position, it will not be possible to back the pad off. If this
should happen, operate the stabiliser leg as normal but be
aware that pads B and C will wear more rapidly.

9803/7110 Issue 1
Section B Body & Framework Section B
16 - 1 16 - 1

S230440

9803/7110 Issue 1
Section B Body & Framework Section B
16 - 2 16 - 2

Kingpost and Carriage (2DX Machines) When Assembling

Dismantling and Assembly Use new roll pins 1 when coupling the slew rams to the
kingpost. Once in position, use a suitable drift to open out
Before removing the kingpost/carriage, slew the kingpost to the end of the roll pin, to lock it in position.
dead centre and remove the boom and dipper. Support the
kingpost using a hoist. When refitting pivot pins ensure that their drill holes align
with the appropriate holes in the casing.
When Dismantling

Before starting, disconnect the six hoses to kingpost 11. Note: Pivot pins 2, 5 and 9, plus the slew ram trunnions are
sealed to the top and bottom by lip seals L. On reassembly,
ensure that the seal lips face outwards.
Kingpost
1 Drive out roll pins 1 using a suitable drift, then remove
16
the pivot pins 2.
17
2 Swing slew rams 17 outward, clear of the assembly.
18
3 Ensure the kingpost is securely supported on the hoist.
Remove top and bottom pivot pin assemblies (items 3 -
17
9). The kingpost can how be lifted clear. 16
L
Slew Rams
1 Carry out steps 1 and 2 of kingpost removal procedure.

2 Disconnect the slew ram hoses.

Note: Before removing pivot pin plate 15 mark the pivot A230510
A230510
plate and carriage 19 to ensure correct reassembly. Do not
mix slew plates and carriages from different machines.

3 Remove slew ram pivot plate assemblt (items 12 - 15).

4 Remove the rams. Retrive thrust washers 16 and 18.

Carriage
1 Remove the kingpost as described.

2 Remove the slew rams as described. Ensure that the

carriage is supported on the hoist.

3 Note the mounting points of the four hydraclamp units

X, to ensure that they are returned ti their original
positions.

4 Before the carriage can be removed it is necessary to

remove the stop bolts from one end of both upper and
lower carriage rails. This enables the carriage to be slid
off the end of the rails using the hoist.

Note: Bushes Y need only be removed if damaged. Ensure

that the same type of bush is fitted if an existing one is
removed. Where necessary, ensure that the grease holes in
the bushes align with the appropriate holes in the casing.

9803/7110 Issue 1
Section B Body & Framework Section B
17 - 1 3 Point Hitch 17 - 1

3 Point Hitch
Removal and Replacement ! WARNING
You can be injured if you use faulty lifting equipment.
Do not use the machine as a loader unless the 3 point is
Make sure that lifting equipment is in good condition.
fitted.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that
The 3 point hitch is fitted with a lift ram and either a tilt or lift
lifting equipment is strong enough for the job.
ram. An ajustable turnbuckle is fitted in place of the ram. The INT-1-3-7
illustration shows rams fitted at all positions for clarity.
Attach suitable lifting equipment and take the weight of the
For ram removal, see Section E, 3 Point Hitch. hitch (approx 312 Kg, 687 lbs).

Removal Note: If suitable lift equipment is not available securely

support the hitch, then drive the machine away from the
Remove any attachments fitted to the hitch, park the hitch when it has been disconnected.
machine on firm level ground, apply the handbrake and
lower the hitch. Remove lynch pins B, withdraw bottom pivot pins C from
each side of the machine, use a slide hammer kit.
Switch OFF the engine and remove the starter key and
disconnect the battery. Operate the control levers to vent Remove nuts D and bolts E, withdraw top pivot pins F from
residual pressure. each side of the machine, use a slide hammer kit.
! WARNING
Hydraulic fluid at system pressure can injure you. Before Remove hitch or drive machine clear.
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure Replacement
trapped in the hoses. Make sure the engine cannot be
started while the hoses are open. Replacement is the reversal of the removal procedure.
INT-3-1-11/1
Make sure that all pivot bores and pivot pins are clean and
At the bulkhead connectors A, disconnect the hydraulic greased when assembling. When fully assembled, apply
hoses, plug the hoses and connectors. Label to ensure grease at each grease nipple before operating the machine.
correct position on assembly.

A
E

B
C

S325010

9803/7110 Issue 1
Section C Electrics Section C
i i

Contents Page No.

Technical Data 1-1
Fuses & Relays 2CX from 655030 up to 656999 1-2
Fuses & Relays 2DX and 2CX from 659600 up to 761897 1-3
Fuses & Relays 2DX and 2CX from 760841 to 763230
and 481196 to 489723 1-4
Fuses & Relays 2CXU, 212SU to 489723 1-5
Fuses & Relays 2CX, 2DX, 212SU from 489724 1-6
Fuse Link Box 2CX, 2DX, 212SU from 489724 1-7

Batteries
Safety 2-1
Maintenance 2-1
Testing - Specific Gravity 2-2
Testing 2-2

Alternator
General Description 3-1
Service Precautions 3-1
Charging Circuit Check 3-1
Alternator Charging Test 3-2
Dismantling and Assembly 4-1
Removal and Replacement 4-2

Starting Circuit Test 5-1

Starter Motor
Dismantling and Assembly 6-1
Removal and Replacement 6-2

* Circuit Diagrams and Component Lists

2CX Machines up to 659598 7-1
2DX from 659249 to 760840, 2CX from 659599 to 760840 7-3
Circuit Options and Variations
Electrical Pick-up Hitch Circuit 7-7
2CX, 2DX from 760841 7-8
2CXU (212SU North America Only) 7 - 12
2CX, 2DX From Serial No. 489724 7 - 16
212SU From Serail No. 489724 7 - 19
Circuit Options 2CX, 2DX, 212SU From Serial No. 489724
Worklights, German/Italian Builds 7 - 22
Heater Circuit 7 - 23
Heater/Air Conditioning Circuit 7 - 23
Compressor Circuit 2CX, 2DX 7 - 24
Radio Circuit 7 - 24
Hammer Circuit 7 - 25
Hand Held Hydraulic Tools Circuit 7 - 25
Hydraclamp Circuit 7 - 25

9803/7110 Issue 8*
Section C Electrics Section C
ii ii

Contents Page No.

Wire Number Identification
Wire/Harness Numbers - Explanation of 8-1
Mainframe Harness 8-2
Switch Console Harness 8-4
Instrument Console Harness 8-7
Cab Roof Harness 8-8
Park Brake Switch Harness 8-9
Utility Solenoid Harness (210SU) 8-9
Trailer Socket Harness 8-9
Wire Number Identification (continued)
Diverter Valve Harness 8-9
Mainframe Harness (2DX) 8 - 10
Cab Panel Harness (2DX) 8 - 11
Cab Roof Harness (2DX) 8 - 15
Heater Harness (2DX) 8 - 16

9803/7110 Issue 1
 Section C Electrics Section C
1-1 Technical Data 1-1

System 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 180
Alternator A127, 55 Amp max. output
Starter Motor S12-85 (2M113)

The electrical circuits are protected by fuses. The fuses are located in the front console, underneath cover A. If a fuse ruptures,
find out why and rectify the fault before fitting a new one.

* The fuses are identified using column letters (A, B and C) and row numbers (1 to 9). Note that all the fuses are shown (including
optional equipment fuses). Your machine may not be equipped with all the fuses shown on these pages.

Bulbs Rating (Watts)

Headlights - main 45 W
Headlights - dip 37.5 W
Indicators 21 W (front & rear)
Instruments 1.2 W
Work lights 55 W Halogen (front & rear)
Number plate light 2x5W
Side/tail lights 5W (front & rear)
Interior lights 10 W
Stop lights 21 W (rear)
Beacon 70 W Halogen
Inspection lamp (where fitted) 55 W (floodlight pattern)
Rear fog 21 W
Warning lights 3W

9803/7110 Issue 5*
 Section C Electrics Section C
1-2 Technical Data 1-2

* 2CX from Serial No. 655030 up to 656999

Fuses Relay Identification

1 Parking brake
Fuse Circuit Fuse Rating
2 Road lights
No. (Amps)
3 Reverse
A1 Brake lights 5
4 Forward
A2 Instruments 10 5 Transmission dump
A3 LH side/tail lights; number plate lights 5 6 Flashers
A4 RH side/tail lights 5 7 Neutral start
A5 Thermostart 15 8 Stabiliser leg lock
A6 Hazard warning lights 10 9 Parking brake solenoid
A7 Interior (cab) light; beacon 20 10 Buzzer
11 Parking brake start
A8 Stabiliser leg interlock 5
12 4 Spool option
A9 Horn (front); windscreen wiper; 13 4 Spool option
headlight flash 15 14 Trailer flasher buzzer

B1 Rear wiper and wash 10

B2 Horn (rear) 10
B3 Dipped beam; rear fog light 10
B4 Main beam; warning lights 10
B5 Front work lights 10
B6 Direction indicators 10
B7 Dump relay; forward/reverse solenoid; 5
reverse alarm
B8 Heater motor 15
B9 Buzzer; hand dump 5

C1 Rear work lights 10

C2 Engine shut off system 5
C3 Parking brake solenoid 5
C4 Radio; wiper park 15
C5 Road lights relay 15
C6 Attachments socket 15
C7 Blank
C8 2/4WS steering circuit 5
C9 Air conditioning unit, High output heater 20

S181851

A201931

9803/7110 Issue 3*
Section C Electrics Section C
1-3 Technical Data 1-3

* 2DX Machines and 2CX from Serial No. 659600

up to 761897

Fuses Relays
Fuse Circuit Fuse Rating R1 Transmission Dump
No. (Amps) R2 Neutral Start
A1 Brake lights 5 R3 Parking Brake
A2 Instruments 5 R4 Buzzer
A3 LH side/tail lights/number plate light 5 R5 Parking Brake Light
A4 RH side/tail lights/number plate light 5 R6 Indicators
A5 Rear wiper and wash 10 R7 Forward
A6 Hazard warning lights 10 R8 ‘Ignition’ 1
A7 Interior (cab) light; beacon; face level fan 10 R9 Reverse
A8 Radio 5 R10 ‘Ignition’ 2
A9 Horn (front); windscreen wiper; R11 Stabiliser Leg Lock; Compressor
headlight flash 10 R12 Road Lights
R13 Hammer
B1 Attachments socket 15 R14 Neutral Lock
B2 Engine shut off system 5 R15 4 Spool Option
B3 Dipped beam 10 R16 Quick Hitch
B4 Main beam; warning lights 10 R17 4 Spool Option
B5 Front work lights 10 R18 Quick Hitch Buzzer
B6 Direction indicators 5 R19 Trailer Warning Buzzer
B7 Parking brake solenoid 5 R20 Shutdown Relay
B8 Heater motor 20
B9 Horn (rear) 10

C1 Rear work lights 10

C2 2/4WS steering circuit; compressor;
Stabiliser leg interlock 5
C3 Dump relay; forward/reverse solenoid;
reverse alarm 10
C4 Rear fog light 5
C5 Thermostart 15

R1 R2 R7 R8 S227260
Y

R3 R4 R9 R10

R5 R6 R11 R12 S1

R13 R14
9 10 10
A
15

8 5 20 R15 R16
7 10 5
R17 R18
6 10 5
10

5 10 10 15 R19 R20
4 5 10 5

3 5 10 10

2 5 5 5
A
1 5 15 10
5

A230371
A B C
S4

9803/7110 Issue 2*
 Section C Electrics Section C
1-4 Technical Data 1-4

* 2DX and 2CX Machines from Serial No. 760841

to 763230 and 481196 to 489723
Relays
Fuses
R1 Transmission Dump
Fuse Circuit Fuse Rating R2 Neutral Start
No. (Amps) R3 Parking Brake
A1 Brake lights 5 R4 Buzzer
A2 Instruments 5 R5 Brake Lights
A3 LH side/tail lights/number plate light 5 R6 Indicators
A4 RH side/tail lights/number plate light 5 R7 Forward
A5 Rear wiper and wash 7.5 R8 ‘Ignition’ 1
A6 Hazard warning lights 10 R9 Reverse
A7 Interior (cab) light; beacon; face level fan 15 R10 ‘Ignition’ 2
A8 Radio 5 R11 Stabiliser Leg Lock;Compressor
A9 Horn (front); windscreen wiper; headlight flash 20 R12 Road Lights
R13 Hammer
B1 Attachments socket 10 R14 Compressor Neutral Start
B2 Engine shut off system 5 R15 Engine Shut Off Solenoid
B3 Dipped beam 15 R16 Front Work Lights
B4 Main beam 15 R17 Front Auxiliary
B5 Front work lights 15 R18 Front Auxiliary
B6 Direction indicators 5 R19 Air Conditioning
B7 Parking brake 5 R20 Rear Quickhitch
B8 Heater motor; air conditioning 15 R21 Front Quickhitch
B9 Horn (rear) 10 R22 Trailer Indicator Buzzer

C1 Rear work lights 15

C2 Where fitted - Compressor; Stabiliser leg
interlock 5
C3 Transmission dump 7.5
C4 Rear fog light 5
C5 Thermostart 15

S227260

R1 R2 R7 R8

R3 R4 R9 R10

R5 R6 R11 R12
A
9 R13 R14
8
7 R15 R16
6
R17 R18
5
4
R19 R20
3
2
R21 R22
1
A B C
A300850

9803/7110 Issue 2*
Section C Electrics Section C
1-5 Technical Data 1-5

* 2CXU, 212SU to serial No. 489723

Fuses
Relays
Fuse Circuit Fuse Rating
No. (Amps) R1 Neutral Start
A1 Brake lights 5 R2 ‘Ignition’ 1
A2 Instruments 5 R3 Transmission Dump
A3 LH side/tail lights/number plate light 5 R4 ‘Ignition’ 2
A4 RH side/tail lights/number plate light 5 R5 Front Work Lights
A5 Rear wiper and wash 7.5 R6 Parling Brake
A6 Hazard warning lights 10 R7 Warning Buzzer
A7 Beacon 15 R8 Forward
A8 Radio 5 R9 Indicators
A9 Horn (front); windscreen wiper; headlight flash 20 R10 Reverse

B1 Attachments socket 10
B2 Engine shut off system 5
B3 Dipped beam 15
B4 Main beam 15
B5 Front work lights 15
B6 Direction indicators 5
B7 Parking brake 5
B8 Heater motor; air conditioning 15
B9 Blank

C1 Rear work lights 15

C2 Power Take Off 5
C3 Transmission dump 7.5
C4 Rear fog light 5
C5 Thermostart 15

R1 R2
9
8
R3 R4
7
6
5
R5 R6
A
4
3 R7 R8
2
1 R9 R10
A B C

A300870 S294850

9803/7110 Issue 2*
Section C Electrics Section C
1-6 Technical Data 1-6

2CX, 2DX, 212SU from 489724

Fuses Relays
Fuse Circuit Fuse Rating R1 Not used
No. (Amps) R2 Road lights
A1 Auxiliary 10 R3 Direction indicators
A2 Fuel pump solenoid (engine stop) 5 R4 Transmission forward drive
A3 Direction indicators 7.5 R5 Transmission reverse drive
A4 Parking brake solenoid 5 R6 Front working lights
A5 Transmission 10 R7 Parking brake
A6 Power take off 5 R8 Transmission dump
A7 Not used - R9 Rear working lights
A8 Brake lights 5 R10 Neutral start
A9 RH side/tail lights/number plate light 3 R11 Starter 1
A10 LH side/tail lights/number plate light 3 R12 Buzzer
B1 Instruments, buzzer 5 R13 Starter 2
B2 Horn (front), front wiper/wash 15
B3 Horn (rear) 7.5
B4 Auxiliary socket 20
B5 Rear wiper and wash 15
B6 Brake switch 10
B7 Rear work lights 25
B8 Dipped beam 20
B9 Front work lights 25
B10 Beacon 10
C1 Rear fog light 3
C2 Front fog lights 15
C3 Road lights 7.5
C4 Hazard warning lights 15
C5 Face level fan 10 A
C6 Radio 1
C7 Thermostart 20
C8 Heater 30
C9 Ignition relay coil 3
C10 Headlight flash 15

Note: Some of the light fuses may not be fitted to 212SU

North American machines.

R1 R2 R3
1 2 3 4 5 6 7 8 9 10
R4 R5 R6
A

R7 R8 R9

R10 R11

C
342600 R12 342601
R13

9803/7110 Issue 1
Section C Electrics Section C
1-7 Technical Data 1-7

2CX, 2DX, 212SU from 489724

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.

Fuse Links
1 Hazard warning lights, sidelights, face level fan.

2 Transmission, indicators, wash/wipe.

3 Worklights, road lights, fog lights.

4 Ignition, Thermostart, heater.

A335480

1 2

3 342660 4

9803/7110 Issue 1
Section C Electrics Section C
2-1 Batteries 2-1

Safety
! WARNING
Batteries give off an explosive gas. Do not smoke when Maintenance
handling or working on the battery. Keep the battery away
from sparks and flames. To ensure that the battery provides optimum performance
the following steps should be observed:
Battery electrolyte contains sulphuric acid. It can burn you if
it touches your skin or eyes. Wear goggles. Handle the 1 Make sure that the electrical connections are clean and
battery carefully to prevent spillage. Keep metallic items tight. Smear petroleum jelly on connectors to prevent
(watches, rings, zips etc) away from the battery terminals. corrosion.
Such items could short the terminals and burn you.
2 When applicable - never allow the electrolyte level to
Set all switches in the cab to OFF before disconnecting and fall below the recommended level - 6 mm (1/4 in) above
connecting the battery. When disconnecting the battery, the plates. Use only distilled water for topping up.
take off the earth (-) lead first.
3 Keep the battery at least three quarters charged,
When reconnecting, fit the positive (+) lead first. otherwise the plates may become sulphated (hardened)
- this condition makes recharging the battery very
Re-charge the battery away from the machine, in a well difficult.
ventilated area. Switch the charging circuit off before
connecting or disconnecting the battery. When you have Extra precautions must be taken when bench charging
installed the battery in the machine, wait five minutes before maintenance free batteries, they are more prone to damage
connecting it up. by overcharging than the standard type of battery:

First Aid - Electrolyte - NEVER boost-charge a maintenance free battery.

Do the following if electrolyte: - NEVER charge a maintenance free battery at a

voltage in excess of 15.8 Volts.
GETS INTO YOUR EYES
- NEVER continue to charge a maintenance free
Immediately flush with water for 15 minutes, always get battery after it begins to gas.
medical help.

IS SWALLOWED

Do not induce vomiting. Drink large quantities of water or

milk. Then drink milk of magnesia, beaten egg or vegetable
oil. Get medical help.

GETS ONTO YOUR SKIN

Flush with water, remove affected clothing. Cover burns with

a sterile dressing then get medical help.
5-3-4-3/1

9803/7110 Issue 2*
Section C Electrics Section C
2-2 Batteries 2-2

Testing - Specific Gravity

The specific gravity of the electrolyte gives an idea of the Readings should be as tabulated and should not vary
state of charge of the battery. Readings should be taken between cells by more than 0.04. A greater variation
using a hydrometer, when the electrolyte temperature is 15 indicates an internal fault on that particular cell.
°C (60 °F). If the battery has recently been on charge, wait
approximately one hour (or slightly discharge the battery) to If the electrolyte temperature is other than 15 °C (60 °F) a
dissipate the surface charge before testing. 'correction factor' must be applied to the reading obtained.
Add 0.07 per 10 °C (18 °F) if the temperature is higher than
15 °C (60 °F) and subtract the same if the temperature is
lower.

Specific Gravity at 15 °C (60 °F)

Fully Charged Half Discharged Fully Discharged

Ambient temperature up to 27 °C (80 °F) 1.270 - 1.290 1.190 - 1.210 1.110 - 1.130
Ambient temperature above 27 °C (80 °F) 1.240 - 1.260 1.170 - 1.190 1.090 - 1.110

Battery Testing
This test is to determine the electrical condition of the
battery and to give an indication of the remaining useful
‘life’. 5 Set the CHECK/LOAD switch A to LOAD and hold down
for 5 - 10 seconds until the meter reading stabilises. The
Before testing ensure that the battery is at least 75% reading should be at least 9 volts.
charged (SG of 1.23 to 1.25 for ambient temperature up to
27°C). Note: Do not hold the switch in the LOAD position for more
than 10 seconds.
Ensure that the battery is completely disconnected from the
vehicle. 6 If the foregoing tests are unsatisfactory, consult Fault
Diagnosis below.
Connect up the battery tester (part no. 993/85700) as
follows:

1 Set the CHECK/LOAD switch A to OFF.

2 Set rocker switch B to the battery voltage (12V).

3 Connect the red flying lead to the battery positive (+)

terminal and the black flying lead to the battery negative
(-) terminal.
A
4 Set the CHECK/LOAD switch A to CHECK to read the
battery no-load voltage which should be at least 12.4 B 239510
volts.
Fault Diagnosis

Battery Tester Readings Remedy

1 CHECK: 0 - 12.6 Volts Renew battery

LOAD: less than 6 Volts

2 CHECK: 6 - 12.4 Volts

LOAD: less than 9 Volts and falls steadily but remains Recharge and re-test. If tests still unsatisfactory renew
in yellow zone. battery.

3 CHECK: less than 10 Volts Indicates battery has been over-discharged and unlikely
LOAD: less than 3 Volts to recover. Renew battery.

4 CHECK: more than 11 Volts Charge battery which will probably recover.
LOAD: 6 - 10 Volts steady

9803/7110 Issue 1
Section C Electrics Section C
3-1 Engine Electrics 3-1

Alternator
General Description Charging Circuit Check

The alternator is a three phase generator having a rotating Ensure that all battery and alternator connections are in
field winding and static power windings. place, secure and making good metal - to - metal contact,
especially the 'earth' connections to chassis and engine.
When the start switch is turned on, current from the battery
flows by way of the 'No Charge' warning light to the field Adjust the alternator drive belt tension if necessary and
winding. This creates a magnetic field which supplements make sure that the battery is well charged.
the residual magnetism in the rotor poles. As the engine is
started, the fan belt drives the rotor and alternating current is Turn the start switch to the 'ON' position.
generated in the power windings as they are cut by the
rotating magnetic field. Output is controlled by a solid state 'Oil pressure' and 'No charge' warning lights should glow.
regulator which varies the field current in accordance with
electrical demand. If any light fails, proceed to Check 1.

Servicing is restricted to periodic inspection of slipring Start the engine; all warning lights should extinguish rapidly.
brushes. Bearings are 'sealed for life'.
If the 'No charge' warning light remains ON proceed to
Service Precautions Check 2.

a Ensure that the battery negative terminal is connected If the oil pressure warning light remains ON, STOP ENGINE
to the earthing cable. IMMEDIATELY and investigate the engine lubrication
system.
b Never make or break connections to the battery or
alternator, or any part of the charging circuit whilst the Check 1
engine is running. Disregarding this instruction will
result in damage to the regulator or rectifying diodes. With start switch in the 'ON' position, try the heater motor
and screen wiper.
c Main output cables are 'live' even when the engine is
not running. Take care not to earth connectors in the If they operate normally, check the warning light bulb for
moulded plug if it is removed from the alternator. blown filament.

d During arc welding on the machine, protect the Simultaneous failure of all items indicates a fault at the start
alternator by removing the moulded plug. switch. Check for cable disconnection before condemning
the switch itself.
e If slave starting is necessary refer to Section 3, page 16
- 2. See also b above. If the 'No charge' warning bulb is in good order, withdraw
the triple plug from the back of the alternator. Make a
temporary connection between the SMALL terminal in the
plug and earth as shown below. If the 'No charge' warning
bulb still fails to light check the cable for continuity. If the
bulb now lights, check the alternator for a defective regulator
(see Alternator Charging Test).

....... Continued

9803/7110 Issue 1
Section C Electrics Section C
3-2 Engine Electrics 3-2

Alternator (cont'd)
Charging Circuit Check (cont'd)

Check 2 Start the engine and run at maximum speed (see Section K,
Page 1 - 1). Meter should show maximum alternator output
Stop the engine and turn the starter switch to 'OFF'. (see Technical Data).

Withdraw the alternator plug and connect the test Note: The meter reading should be taken as soon as
meter(Service Tool 892/00281) between the large terminals possible after starting the engine, as the charging current
and 'earth'. With the selected position as shown, the meter will fall rapidly.
should show battery voltage. If the reading is zero, check the
cables for continuity, particularly at the starter terminals. A zero reading indicates failure of the alternator and may be
caused by one of the following conditions. These are listed
in the order of probability.

a Defective suppression capacitor.

b Dirty sliprings or worn brushes.

c Defective regulator.

d Defective rectifier.

e Open or short - circuited field (rotor) windings.

f Open or short - circuited power (stator) windings.

To check for fault a, disconnect the capacitor and repeat the

charging test. Renew the capacitor if necessary.
If the voltage is correct, check the alternator as follows:
To check for faults b and c, remove the regulator and brush
Alternator Charging Test box assembly. Check the condition of the brushes and, if
necessary, clean the sliprings using extra - fine glasspaper.
If the battery is in a fully charged condition, switch on the The regulator may only be checked by substitution.
working lights for 3 minutes before commencing the test.
Alternatively, operate the starter for a few moments with the Faults d, e, and f may be checked only by removing and
engine stop control pulled out. dismantling the alternator for further testing. (See Page 4 -
1).
Install a 100 amp open - type shunt between the battery
positive lead and the battery positive terminal. Connect the
test meter (Service Tool 892/00281) and select position
shown, which will produce a reading in amps.

9803/7110 Issue 1
Section C Electrics Section C
4-1 Engine Electrics 4-1

9803/7110 Issue 1
Section C Electrics Section C
4-2 Engine Electrics 4-2

Alternator (cont'd)
Removal and Replacement Torque Settings

Disconnect the battery. Item Nm kgf m lbf ft

3 2.7 0.28 2.0
Remove the fan guard, if fitted. 5 4.1 0.41 3.0
6 3.4 0.35 2.5
Disconnect cables from rear of alternator, remove bolts A, B 7 5.4 0.55 4.0
and C and withdraw unit from machine. 12 60 6.12 44.3

Replace by reversing the removal sequence. Position the

alternator until belt deflection W is approximately 10 mm
(3/8 in) before tightening bolts B and C. It may be necessary
to slacken bolt D to allow full movement of alternator.
Tighten bolt A last of all.
B
Dismantling and Assembly A
When Dismantling

Remove suppressor 2 (if fitted) by removing nut 1 and

disconnecting lead E from terminal F.

Unscrew bolts 3 and disconnect lead G from terminal H to

remove the brush box and regulator assembly 4. If the brush
length is less than 5 mm (0.2 in), new length 17 mm (0.67 in),
or if spring pressure is less than 1.3 N the brush box and
regulator assembly must be renewed.

Remove nuts and washers 5, bolts 6 and nuts 7. Remove

slip ring end bracket 8.

Carefully remove rectifier 10 and stator 11 as an assembly. 099850

Unsolder the interconnecting wires at X, Y, and Z only if
renewing either of these components.

Remove nut and washer 12 using an 8 mm Allen key in the

shaft hexagon hole to prevent rotation. If necessary, use a
press to remove rotor 19 from the drive end bracket 17.

Check the rotor poles and the inner faces of the stator for
signs of rubbing, which indicates worn bearings. The drive
end bearing is part of bracket 17 and cannot be removed
separately. If requiring renewal, needle roller bearing 20 W
should be pressed out in the direction of the arrow.

When Assembling

Reverse the dismantling procedure, but note the following:

Ensure that spacers 14,16, and 18 are correctly positioned

as shown.

Ensure that the slip rings J are clean and smooth, using
extra fine glasspaper to rectify slight imperfections.

Ensure that insulation bushes 9 and washers 5 are

positioned as shown.

Take care not to damage the brushes when fitting the brush D
box and regulator assembly. C
145880

9803/7110 Issue 1
SXXXXXX
Section C Electrics Section C
5-1 Engine Electrics 5-1

Starting Circuit Test

Before carrying out the voltmeter tests, check the battery If the reading is less than specified, connect the voltmeter
condition (see Battery Testing) and ensure that all between the neutral start relay terminal D and earth. An
connections are clean and tight. increase in reading to 8.0 V indicates a fault in the wiring
from the start relay to the solenoid. If the reading between
To prevent the engine starting during the tests ensure that terminal D and earth is below 8.0 V, connect the voltmeter
the engine stop control is in the 'Stop ' position. between terminal E and earth. An increase in the reading to
8.0 V indicates either a faulty start relay or a fault in the feed
Check the readings in the following sequence using a from the transmission selector switch to the relay solenoid.
voltmeter. Unless otherwise stated, the readings must be Check also the solenoid earth connection.
taken with the starter switch in the 'start' position and the
transmission forward/reverse selector in neutral. If the reading between E and earth is less than 8.0 V, the
fault must be in either the starter switch (terminals F and G)
1 Connect the voltmeter across the battery terminals. or in the wiring between the solenoid, starter switch, and the
Reading in 'start' position: 10.0 V approximately. start relay.

A low reading probably indicates a fault in the starter 4 Connect the voltmeter between battery negative and
motor. starter earth connection B. The reading in the 'start'
position should be practically zero.
2 Connect the voltmeter between the starter main
terminal A and the commutator end bracket B. In the If the reading is appreciably above zero, a high
'start' position, the reading should not be more than 0.5 resistance in the earth lead or connections is indicated.
V below the reading obtained in Test 1.
5 Connect the voltmeter between battery positive and the
If the reading is within this limit, carry out Test 3. If the starter main terminal A. With the starter switch 'off', the
reading is outside the limit, proceed to Tests 4 and 5. voltmeter should indicate battery voltage, but it should
fall to practically zero when the switch is turned to the
3 Connect the voltmeter between the solenoid terminal C 'on' position.
and a good earth.
Minimum reading in 'start' position: 8.0 V. If the reading is appreciably above zero, a high
resistance is present in the insulated lead or in the
solenoid. Connect the voltmeter between the battery
positive and solenoid connection H. If the voltmeter
now reads zero with the switch closed, the fault is in
the solenoid.

8302A

9803/7110 Issue 1
Section C Electrics Section C
6-1 Engine Electrics 6-1

2043C

9803/7110 Issue 1
Section C Electrics Section C
6-2 Engine Electrics 6-2

Starter Motor - Lucas M127

Removal and Replacement When Assembling

Disconnect cables and remove battery. Remove cables from Align crosspin F with the notches in the brake shoes 28
main starter terminal and solenoid terminal. Unscrew three before assembling brush carrier and back plate to motor
securing bolts and remove starter. yoke. Ensure that brushes 14a are correctly located in the
insulated brush boxes.
Replace by reversing the removal sequence.
Smear drive shaft splines and operating collar bearing
Dismantling and Assembly surface with JCB MPL Grease before assembly. Assemble
operating fork 19 with curved face towards the armature.
The numerical sequence on the illustration is intended as a
guide to dismantling. Set the movement of drive pinion 24 by connecting a 6 V
battery and switch as shown. Operate switch and check
For assembly the sequence should be reversed. dimension G. Adjust to 0.13-1.14 mm (0.005-0.045 in) by
slackening locknut 17 and rotating eccentric pin 18 as
When Dismantling necessary. Retighten locknut.

Note: Dismantle only to item 34 unless the field windings are

to be renewed. Test the windings electrically before
removing them from the motor yoke 15.

Using a slotted steel tube, displace ring 23 to permit

withdrawal of ring 22.

Allow brake shoes 28 to remain in the end plate 11 unless

requiring renewal.

Servicing and Renewal

Renew brushes 14 and 14a if their length is less than 8

mm(0.3 in).

Clean the commutator D. If individual copper bars are

burned or eroded the armature has broken windings and
must be renewed. Otherwise polish with fine grade glass
paper (not emery). Renew armature if commutator diameter
is 38 mm (1.5 in) or less.

Check the field windings for open circuits by connecting an 2303A

ohmmeter (0 to 100 ohms) between the stud terminal E and
each positive brush 14a in turn. A high or infinity reading
indicates an open circuit. Similarly, connect the meter
between brushes 14a and the motor yoke 15. Any reading
other than infinity indicates a short circuit between the coils
and the yoke. Renew the coils as necessary, removing
screws 36 with a pole shoe screwdriver C50 (obtainable
from Lucas dealers).

Check bronze bushes 32 and 34 for wear.

9803/7110 Issue 1
 7-1

95
100
C7
684 416 18

9803/7110
619 810

17

99

96
Section C

680 16

C2 C6
651

817
624 848

94
660 847

93
658 846 235 232

C1
638 215

92
98
649 819 216

91
97
202

A4
661 822

90
659 821 214

C5
637
637 820

88
637

883
201

213
818

A3
639
880
648 886

884
C4

839

82
623

81

89 87 86 84
80

228

B5
655 837
234 227

85 83
652 836 231

233
633 841
882

646/647 844/845 842

77
833
79

639 832

78
B3

76
638 831 221 229

637

222
Hydraulics

639 835

73
638 834 409 230

75 74 72
204

71

816
B4

648
A1

69
649 815 814 211
3

68
614 808 830
B2

604 800
Circuit Diagrams and Component Lists

64
65
642 863
826

669
825

61
70 67 66 63 62
A9

654 862 861 4

60

59
656 866 218 200
653 252
55

856
643 250 855 838
56
57
A7 B8

639 850 237

648 851
243
49

50

253

649 853

58 54 52
251

638 853 849 236

53 51
48
45

637 411 410

B6

10
239

223
47
255
46

633 238 217 203

627
9

644 859
A6 B1

657 857 827 8

42

44 43

412
40

415
39

414
41

400
401

637
38

640 860
102

407
10

664 406

402
23

603 405

403
37 36 35 34 33

31 30 29 28 27 26
225

101

32

618
25
A2

637 408
212 226
637 404
6

413

24

602
612
636
21
22

248

807
622

219
19
A8

249
Hydraulics

256

865

245 224
18
7

631
B7

20

620 811 806

682
B9

15

621
805

803
617 809
13
247

12
681
8

605 802 804

Circuit Diagrams and Component Lists

17 16

630 242
9

14
244

11
812

607 801 241

257

631 246 254 258

7

10
C3

249
4
668
5
6

207 11 205
2

A183040-1

1/2
4
3
A5

209
-
+
1
Section C

Issue 3
7-1
 Section C Electrics Section C
7-2 Circuit Diagrams and Component Lists 7-2

* 2CX up to Serial No. 659598

Main Components, Lights and Switches
1 Battery 61 Front Windscreen Wiper Motor
2 Starter Switch 62 Front Windscreen Wiper Switch
3 Thermostart 63 Front Windscreen Washer Pump Switch
4 Starter Motor 64 Front Windscreen Washer Pump
5 Starter Solenoid 65 Front Horn
6 Neutral Start Relay 66 Front Horn Button
7 Parking Brake Switch 67 Rear Horn Button (optional)
8 Parking Brake Interlock Relay 68 Rear Horn (optional)
9 Forward/Reverse Switch 69 Rear Brake Lights
10 Forward Relay 70 Rear Brake Light Switch
11 Forward Solenoid 71 Headlamp Flasher Switch
12 Reverse Solenoid 72 Right Hand Main Beam Lamp
13 Reverse Alarm (optional) 73 Left Hand Main Beam Lamp
14 Reverse Relay 74 Main Beam Warning Light
15 Parking Brake Warning Relay 75 Right Hand Dipped Beam Light
16 Gear Lever Dump Switch 76 Left Hand Dipped Beam Light
17 Loader Lever Dump Switch 77 Rear Fog Light (optional)
18 Dump Relay 78 Rear Fog Light Switch (optional)
19 Parking Brake Relay 79 Headlight Dip Switch
20 Parking Brake Solenoid 80 Road Lights Relay
21 Stabiliser Leg/Neutral Start Interlock Relay 81 Road Lights Switch
22 Stabiliser Leg/Neutral Start Interlock Solenoid (optional) 82 Front Working Lights Switch
23 Instrument Console 83 Front Working Lights
24 Water Temperature Sender 84 Front Working Lights Warning Light
25 Fuel Gauge 85 Left Hand Tail Light
26 Engine Coolant Temperature Switch 86 Left Hand Side Light
27 Transmission Oil Temperature Switch 87 Water Temperature Gauge Light
28 Engine Oil Low Pressure Warning Light Switch 88 Fuel Gauge Light
29 Transmission Oil Low Pressure Warning Light Switch 89 Speedo/Tachometer Light
30 Air Filter Blocked Switch 90 Number Plate Lights
31 Warning Lights Test Button (if fitted) 91 Right Hand Tail Light
32 Instrument Console Light 92 Right Hand Side Light
33 Engine Coolant Temperature Warning Light 93 Rear Working Lights
34 Transmission Oil Temperature Warning Light 94 Rear Working Lights Warning Light
35 Engine Oil Low Pressure Warning Light 95 Low Brake Pressure Warning Light
36 Transmission Oil Low Pressure Warning Light 96 Engine Shut Off System
37 Air Filter Blocked Warning Light 97 Radio Carrier
38 Speedo/Tachometer 98 Rear Work Light Switch
39 Alternator 99 Attachments Power Socket
40 Alternator No Charge Light 100 Low Brake Pressure Warning Switch
41 Buzzer 101 Diodes
42 Rear Windscreen Wash/Wipe Switch 102 Diodes
43 Rear Windscreen Wiper Motor
44 Rear Windscreen Wiper Wash Motor Fuses
45 Hazard Warning Light Switch A1 - A9
46 Flasher Unit B1 - B9 - See Technical Data pages for fuse details
47 Hazard Warning Light
C1 - C9
48 Diode
49 Direction Indicator Switch Wire Number Identification
50 Direction Indicator Light See Wire Number Identification on Page 8 - 1 for wire and
51 Right Hand Indicator Light - Front harness number details.
52 Right Hand Indicator Light - Rear
53 Left Hand Indicator Light - Front
54 Left Hand Indicator Light - Rear
55 Heater Motor
56 Heater Resistor
57 Heater Switch
58 Beacon
59 Cab Interior Light
60 Cab Interior Light Switch

9803/7110 Issue 4*
Section C Electrics Section C
7-3 Circuit Diagrams and Component Lists 7-3

15 111 114 117 26 27 81

10 82
3 64 116 118 80
6 77
5
2 63 7 71 76
8 112 75
9 17 115 119 74
20
110 113
29
4 177
11 12
78 79
174 175
171 ➁ 179 21

19 28

13
69 73 121 123 125 127 129 131 133
176 66 14
16
120 122 124 126 128 130 132
1
25
170 18 22 23 24
62

65
A1
67
178 68
173
72

70
C5 C3 B7 C2 B1 B6 A6

61
172

A230340

9803/7110 Issue 3
 Section C Electrics Section C
7-4 Circuit Diagrams and Component Lists 7-4

* Circuit Diagram

2DX from Serial No. 659249 to 760840

2CX from Serial No. 659599 to 760840

Note: Circuits shown with dashed lines indicate non-

standard equipment. For instance, compressor components
are only fitted on the JCB Airmaster machine.

Main Components
1 Battery 49 Heater Resistor
2 Thermostart 50 Heater Motor
3 Starter Motor
4 Starter Solenoid Switches
5 Forward Solenoid 61 Starter Switch
6 Reverse Solenoid 62 Forward/Reverse Switch
7 Reverse Alarm 63 Gear Lever Dump Switch
8 Parking Brake Solenoid 64 Loader Lever Dump Switch
9 PTO Solenoid ❿ 65 Parking Brake Switch
10 Compressor Temperature Sender ❿ 66 Compressor Switch ❿
11 Compressor Temperature Gauge ❿ 67 Front Proximity Switch ❿
12 Compressor Hourmeter ❿ 68 Rear Proximity Switch ❿
13 Stabiliser Leg Solenoids ❿ 69 Steer Mode Selector Switch ❿
14 Steer Mode Solenoids ❿ 70 Brake Lights Switch ❿
15 Steer Mode Unit ❿ 71 Hammer Switch
16 Junction Box 72 Hazard Warning Light Switch
17 Hammer Solenoid ❿ 73 Direction Indicator Switch
18 Flasher Unit 74 Engine Coolant Temperature Switch
19 Diode 75 Transmission Oil Temperature Switch
20 Trailer Indicator Warning Buzzer ❿ 76 Engine Oil Low Pressure Warning Light Switch
21 Side Instrument Console 77 Transmission Oil Low Pressure Warning Light Switch
22 Tachometer 78 Air Filter Blocked Switch
23 Water Temperature Gauge 79 Low Brake Pressure Warning Switch
24 Fuel Gauge 80 Compressor Air Filter Switch ❿
25 Hourmeter 81 Air Receiver Temperature Switch ❿
26 Water Temperature Sender 82 Air/Oil Delivery Temperature Switch ❿
27 Fuel Sender 83 Rear Horn Butto
28 Buzzer 84 Rear Windscreen Wash/Wipe Switc
29 Shut Down System (Compressor) ❿ 85 Front Windscreen Wash/Wipe Switc
30 Engine Shut Off System 86 Front Horn Butto
31 Front Instrument Console 87 Road Lights Switc
32 Alternator 88 Headlamp Flasher Switc
33 Rear Horn ❿ 89 Headlight Dip Switc
34 Rear Windscreen Washer Pump 90 Front Working Lights Switc
35 Rear Windscreen Wiper Motor 91 Rear Work Light Switc
36 Front Windscreen Washer Pump 92 Beacon Switc
37 Front Windscreen Wiper Motor 93 Cab Interior Light Switc
38 Front Horn 94 Heater Switch ❿
39 Dipper Socket 95 Air Conditioning Switch ❿
40 Face Level Fan ❿ 96 Freeze Valve ❿
41 Beacon Motor 97 Low Pressure Switch ❿
42 Tracker ❿ 98 High Pressure Switch ❿
43 Radio ❿ 99 Heater Switc
44 RH Speaker ❿ 100 Rear Fog Light Switch ❿
45 LH Speaker ❿
46 Heater Resistor ❿
47 Heater Motor ❿
48 Air Conditioning Motor ❿ .......... con

9803/7110 Issue 2*
 Section C Electrics Section C
7-5 Circuit Diagrams and Component Lists 7-5

* Circuit Diagram

2DX from Serial No. 659249 to 760840

2CX from Serial No. 659599 to 760840

Lights Relays
110 Left Hand Brake Light 170 Neutral Start Relay
111 Left Hand Trailer Brake Light ❿ 171 Neutral Lock Relay
112 Right Hand Trailer Brake Light ❿ 172 ‘Ignition’ Relay 1
113 Right Hand Brake Light 173 Transmission Dump Relay
114 Left Hand Trailer Indicator Light ❿ 174 Forward Relay
115 Left Hand Indicator Light - Front 175 Reverse Relay
116 Left Hand Indicator Light - Rear 176 Parking Brake Light Relay
117 Right Hand Trailer Indicator Light ❿ 177 Parking Brake Relay
118 Right Hand Indicator Light - Front 178 Compressor Neutral or Stabiliser Leg Lock Relay
119 Right Hand Indicator Light - Rear 179 Hammer Relay ❿
120 Alternator No Charge Light 180 Shutdown Relay ❿
121 Parking Brake Warning Light 181 ‘Ignition’ Relay 2
122 Engine Coolant Temperature Warning Light 182 Road Lights Relay
123 Transmission Oil Temperature Warning Light 183 Air Conditioning Relay ❿
124 Engine Oil Low Pressure Warning Light
125 Transmission Oil Low Pressure Warning Light
126 Air Filter Blocked Warning Light Fuses
127 Low Brake Pressure Warning Light A1 - A9
128 2 Wheel Steer Selected Warning Light B1 - B9 - See Technical Data pages for fuse details
129 4 Wheel Steer Selected Warning Light C1 - C9
130 Hazard Warning Light
131 Main Beam Warning Light Wire Number Identification
132 Side Instrument Console Light See Wire Number Identification on Page 8 -10 for wire and
133 Direction Indicator Light harness number details.
134 Front Instrument Console Warning Lights
135 Side Lights Warning Light Note ❿: Indicates non standard equipment
136 Rear Working Lights Warning Light
137 Front Working Lights Warning Light Note ❡: Link wire to be fitted to neutral lock relay on non
138 Rear Fog Light Warning Light ❿ Airmaster machines.
139 Left Hand Main Beam Light
140 Right Hand Main Beam Light Note ① : On standard build when no optional shutdown
141 Left Hand Dipped Beam Light system is fitted, a link wire is fitted on wire 105.
142 Right Hand Dipped Beam Light
143 Left Hand Trailer Light ❿
144 Left Hand Number Plate Light
145 Left Hand Tail Light
146 Left Hand Side Light
147 Right Hand Trailer Light ❿
148 Right Hand Number Plate Light
149 Right Hand Tail Light
150 Right Hand Side Light
151 Front Working Lights
152 Rear Working Lights
153 Rear Fog Light ❿

9803/7110 Issue 2*
Section C Electrics Section C
7-6 Circuit Diagrams and Component Lists 7-6

142 144 148 43 98

30
139 141 143 147 39 45

180 ➂ 140 93 48
153 145 149 151 152
36 38 146 41
150 40 47 50
34
97
37
33 35
32 44
B3 42 183
B4

100

88 89 A3 A4
31 96
46 49
85
128 135 130 137 83 84 86 92
134 133 131 136 138 C4
90

87 91 95

94
99

B5 C1
B2 A2 B9 A5 A9

A7 A8

B8
181
182

A230350

9803/7110 Issue 2
Section C Electrics Section C
7-7 Circuit Diagrams and Component Lists 7-7

Circuit Options and Variations

The purpose of this section (Circuit Options and Variations) is
to identify non 'basic' circuits, optional and superseded older
circuits. Where possible, the machine serial numbers will be

+
-
given to help identify the machine range(s).
1
Electrical Pick-up Hitch Circuit C6

101AL
1 Battery 2

203
10
2 Starter Switch
46 Flasher Unit
47 Hazard Warning Light B6 A6 A1

101AM

922
48 Diode
49 Direction Indicator Switch

223
217
50 Direction Indicator Light

211
51 Right Hand Indicator Light - Front 107
52 Right Hand Indicator Light - Rear 45
53 Left Hand Indicator Light - Front
54 Left Hand Indicator Light - Rear
69 Rear Brake Lights
70
70 Rear Brake Light Switch
946

237

236
103 Trailer Brake Lights

238
104 Trailer Indicator Warning Buzzer

239
105 Right Hand Trailer Indicator Light

243
106 Left Hand Trailer Indicator Light
600GC

107 Diverter Switch †

108 Diverter Solenoid Valve †
48
† The auxiliary hydraulic control lever operates either the 46
auxiliary loader service (e.g. 6-in-1 clamshovel) or the trailer 49 255
hitch ram. Diverter switch 107 must be in the ON position to
operate the hitch ram.
50

455
410

253

108
47
850

849

815
816
851

853
805K

806L
600GD

816J
853

104 69
53 51
106
600GE

105
649
648

54 52
639
649

633

103
648
638

637

9803/7110 Issue 1
Section C Electrics Section C
7-8 Circuit Diagrams and Component Lists 7-8

2CX, 2DX from Serial No. 760841

26 27 79 81
10 111 112 114 117 82
79
78 29
116 118 75 77
3 5 6 7 154 14
2 63 71 74 76
8 9 17 115 119
64 20
110 113

4
11 12
174 175 177 185

171 179

184 28
2
13 19 25
73 22
176 16 121 123 125 127 130 132
69
120 122 124 126 128129 131 133
66
1 23 24
170 18
62 21

173
65 178
72
67 68
70

61
172

A300680

9803/7110 Issue 1
Section C Electrics Section C
7-9 Circuit Diagrams and Component Lists 7-9

Circuit Diagram

2CX, 2DX from Serial No.760841

Note: Circuits shown with dashed lines indicate non-

standard equipment. For instance, compressor components
are only fitted on the JCB Airmaster machine.
Switches
Main Components 61 Starter Switch
1 Battery 62 Forward/Reverse Switch
2 Thermostart 63 Gear Lever Dump Switch
3 Starter Motor
64 Loader Lever Dump Switch
4 Starter Solenoid
65 Parking Brake Switch
5 Forward Solenoid
6 Reverse Solenoid 66 Compressor Switch ❿
7 Reverse Alarm 67 Front Proximity Switch ❿
8 Parking Brake Solenoid 68 Rear Proximity Switch ❿
9 PTO Solenoid ❿ 69 Steer Mode Selector Switch ❿
10 Compressor Temperature Sender ❿ 70 Brake Lights Switch ❿
11 Compressor Temperature Gauge ❿ 71 Hammer Switch
12 Compressor Hourmeter ❿ 72 Hazard Warning Light Switch
13 Stabiliser Leg Solenoids ❿ 73 Direction Indicator Switch
14 Steer Mode Solenoids ❿ 74 Engine Coolant Temperature Switch
15 Steer Mode Unit ❿
75 Transmission Oil Temperature Switch
16 Junction Box
76 Engine Oil Low Pressure Warning Light Switch
17 Hammer Solenoid ❿
18 Flasher Unit 77 Transmission Oil Low Pressure Warning Light Switch
19 Diode 78 Air Filter Blocked Switch
20 Trailer Indicator Warning Buzzer ❿ 79 Low Brake Pressure Warning Switch
21 Side Instrument Console 80 Compressor Air Filter Switch ❿
22 Tachometer 81 Air Receiver Temperature Switch ❿
23 Water Temperature Gauge 82 Air/Oil Delivery Temperature Switch ❿
24 Fuel Gauge 83 Rear Horn Button
25 Hourmeter 84 Rear Windscreen Wash/Wipe Switch
26 Water Temperature Sender 85 Front Windscreen Wash/Wipe Switch
27 Fuel Sender
86 Front Horn Button
28 Buzzer
87 Road Lights Switch
29 Shut Down System (Compressor) ❿
30 Engine Shut Off System 88 Headlamp Flasher Switch
31 Front Instrument Console 89 Headlight Dip Switch
32 Alternator 90 Front Working Lights Switch
33 Rear Horn ❿ 91 Rear Work Light Switch
34 Rear Windscreen Washer Pump 92 Beacon Switch
35 Rear Windscreen Wiper Motor 93 Cab Interior Light Switch
36 Front Windscreen Washer Pump 94 Heater Switch ❿
37 Front Windscreen Wiper Motor 95 Air Conditioning Switch ❿
38 Front Horn 96 Freeze Valve ❿
39 Dipper Socket
97 Low Pressure Switch ❿
40 Face Level Fan ❿
98 High Pressure Switch ❿
41 Beacon Motor
42 Tracker ❿ 99 Heater Switch
43 Radio ❿ 100 Rear Fog Light Switch ❿
44 RH Speaker ❿
45 LH Speaker ❿
46 Heater Resistor ❿
47 Heater Motor ❿
48 Air Conditioning Motor ❿
49 Heater Resistor
50 Heater Motor

.......... continued
Circuit Diagram

9803/7110 Issue 1
Section C Electrics Section C
7 - 10 Circuit Diagrams and Component Lists 7 - 10

2CX, 2DX from Serial No.760841

Lights Relays
110 Left Hand Brake Light 170 Neutral Start Relay
111 Left Hand Trailer Brake Light ❿ 171 Neutral Lock Relay ❡
112 Right Hand Trailer Brake Light ❿ 172 ‘Ignition’ Relay 1
113 Right Hand Brake Light 173 Transmission Dump Relay
114 Left Hand Trailer Indicator Light ❿ 174 Forward Relay
115 Left Hand Indicator Light - Front 175 Reverse Relay
116 Left Hand Indicator Light - Rear 176 Parking Brake Light Relay
117 Right Hand Trailer Indicator Light ❿ 177 Parking Brake Relay
118 Right Hand Indicator Light - Front 178 Compressor Neutral or Stabiliser Leg Lock Relay
119 Right Hand Indicator Light - Rear 179 Hammer Relay ❿
120 Alternator No Charge Light 180 Shutdown Relay ❿ ①
121 Parking Brake Warning Light 181 ‘Ignition’ Relay 2
122 Engine Coolant Temperature Warning Light 182 Road Lights Relay
123 Transmission Oil Temperature Warning Light 183 Air Conditioning Relay ❿
124 Engine Oil Low Pressure Warning Light 184 2 Wheel steer Relay
125 Transmission Oil Low Pressure Warning Light 185 4 Wheel Steer relay
126 Air Filter Blocked Warning Light
127 Low Brake Pressure Warning Light Fuses
128 2 Wheel Steer Selected Warning Light A1 - A9
129 4 Wheel Steer Selected Warning Light B1 - B9 - See Technical Data pages for fuse details
130 Hazard Warning Light C1 - C9
131 Main Beam Warning Light
132 Side Instrument Console Light Wire Number Identification
133 Direction Indicator Light See Wire Number Identification on Page 8 -10 for wire and
134 Front Instrument Console Warning Lights harness number details.
135 Side Lights Warning Light
136 Rear Working Lights Warning Light Note ❿: Indicates non standard equipment
137 Front Working Lights Warning Light
138 Rear Fog Light Warning Light ❿ Note ❡: Link wire to be fitted to neutral lock relay on non
139 Left Hand Main Beam Light Airmaster machines.
140 Right Hand Main Beam Light
141 Left Hand Dipped Beam Light Note ① : On standard build when no optional shutdown
142 Right Hand Dipped Beam Light system is fitted, a link wire is fitted on wire 105.
143 Left Hand Trailer Light ❿
144 Left Hand Number Plate Light
145 Left Hand Tail Light
146 Left Hand Side Light
147 Right Hand Trailer Light ❿
148 Right Hand Number Plate Light
149 Right Hand Tail Light
150 Right Hand Side Light
151 Front Working Lights
152 Rear Working Lights
153 Rear Fog Light ❿
154 Reverse light

9803/7110 Issue 1
Section C Electrics Section C
7 - 11 Circuit Diagrams and Component Lists 7 - 11

2CX, 2DX from Serial No. 760841

600

119
7 9 75
117 78
2 3 114 32
5 6 8 118 79 74 76 77
116 26 27
30 115
4 64 63

16

174 175
19

73
18 22 23 24
176
121 127 122 124 125 130
1 28
133 120 123 126 131
62
25
65
31
173 72
66

176

61
172

001
830Y
837C
200
A300690
160AH

9803/7110 Issue 1
Section C Electrics Section C
7 - 12 Circuit Diagrams and Component Lists 7 - 12

*2CXU (212SU North America Only)

600

119
7 9 75
117 78
2 3 114 32
5 6 8 118 79 74 76 77
116 26 27
30 115
4 64 63

16

174 175
19

73
18 22 23 24
176
121 127 122 124 125 130
1 28
133 120 123 126 131
62
25
65
31
173 72
66

176

61
172

001
830Y
837C
200
160AH
A300720

9803/7110 Issue 2*
Section C Electrics Section C
7 - 13 Circuit Diagrams and Component Lists 7 - 13

Circuit Diagram

* 2CXU (212SU North America only)

Main Components Switches

1 Battery 61 Starter Switch
2 Thermostart 62 Forward/Reverse Switch
3 Starter Motor 63 Gear Lever Dump Switch
4 Starter Solenoid 64 Loader Lever Dump Switch
5 Forward Solenoid 65 Parking Brake Switch
6 Reverse Solenoid 66 Power Take Off Switch
7 Reverse Alarm 70 Brake Lights Switch ❿
8 Parking Brake Solenoid 72 Hazard Warning Light Switch
9 Power Take Off Solenoid 73 Direction Indicator Switch
16 Junction Box 74 Engine Coolant Temperature Switch
18 Flasher Unit 75 Transmission Oil Temperature Switch
19 Diode 76 Engine Oil Low Pressure Warning Light Switch
22 Tachometer 77 Transmission Oil Low Pressure Warning Light Switch
23 Water Temperature Gauge 78 Air Filter Blocked Switch
24 Fuel Gauge 79 Low Brake Pressure Warning Switch
25 Hourmeter 84 Rear Windscreen Wash/Wipe Switch
26 Water Temperature Sender 85 Front Windscreen Wash/Wipe Switch
27 Fuel Sender 86 Front Horn Button
28 Buzzer 87 Road Lights Switch
30 Engine Shut Off System 88 Headlamp Flasher Switch
31 Front Instrument Console 89 Headlight Dip Switch
32 Alternator 90 Front Working Lights Switch
34 Rear Windscreen Washer Pump 91 Rear Work Light Switch
35 Rear Windscreen Wiper Motor 92 Beacon Switch
36 Front Windscreen Washer Pump 93 Cab Interior Light Switch
37 Front Windscreen Wiper Motor 99 Heater Switch
38 Front Horn 100 Rear Fog Light Switch ❿
41 Beacon Motor
43 Radio ❿
44 RH Speaker ❿
45 LH Speaker ❿
49 Heater Resistor
50 Heater Motor

continued

9803/7110 Issue 2*
Section C Electrics Section C
7 - 14 Circuit Diagrams and Component Lists 7 - 14

Circuit Diagram

* 2CXU (212SU North America only)

Lights Relays
110 Left Hand Brake Light 170 Neutral Start Relay
111 Left Hand Trailer Brake Light ❿ 172 ‘Ignition’ Relay 1
112 Right Hand Trailer Brake Light ❿ 173 Transmission Dump Relay
113 Right Hand Brake Light 174 Forward Relay
114 Left Hand Trailer Indicator Light ❿ 175 Reverse Relay
115 Left Hand Indicator Light - Front 176 Parking Brake Light Relay
116 Left Hand Indicator Light - Rear 178 Working Lights Relay
117 Right Hand Trailer Indicator Light ❿ 181 ‘Ignition’ Relay 2
118 Right Hand Indicator Light - Front
119 Right Hand Indicator Light - Rear Fuses
120 Alternator No Charge Light A1 - A9
121 Parking Brake Warning Light B1 - B9 - See Technical Data pages for fuse details
122 Engine Coolant Temperature Warning Light C1 - C9
123 Transmission Oil Temperature Warning Light
124 Engine Oil Low Pressure Warning Light Note ❿: Indicates non standard equipment
125 Transmission Oil Low Pressure Warning Light
126 Air Filter Blocked Warning Light
127 Low Brake Pressure Warning Light
128 Reverse Lights
130 Hazard Warning Light
131 Main Beam Warning Light
133 Not Fitted In This Application
134 Not Fitted In This Application
135 Not Fitted In This Application
139 Left Hand Main Beam Light
140 Right Hand Main Beam Light
141 Left Hand Dipped Beam Light
142 Right Hand Dipped Beam Light
143 Left Hand Trailer Light ❿
144 Left Hand Number Plate Light
145 Left Hand Tail Light
146 Left Hand Side Light
147 Right Hand Trailer Light ❿
148 Right Hand Number Plate Light
149 Right Hand Tail Light
150 Right Hand Side Light
151 Front Working Lights
152 Rear Working Lights
153 Rear Fog Light ❿

9803/7110 Issue 2*
Section C Electrics Section C
7 - 15 Circuit Diagrams and Component Lists 7 - 15

*2CXU (212SU North America Only)

600

143 145 147 149

45
111 151 153
34 139 141
112 35 140 142 43
110 36 38
50 152
144 146 148 150 41
113

49
93 44

100
89
88

70 90
85
178
86
84 91 92
87

99

181

001
830Y
837C
200
160AH
A300730

9803/7110 Issue 2*
 1
010 003 THERMOSTART

FUSE P4
FUSE P1
FUSE P2
FUSE P3
FUSE C7
7 - 16

2
BATTERY
IGNITION

9803/7110
SWITCH BATTERY

6
3
NEUTRAL START RELAY STARTER MOTOR

1
5
Section C

200B
004

8
2
200C 842 STARTER SOLENOID

2
6
4

9 8 7 3 4 5 6
NEUTRAL START RELAY
IGNITION RELAY 1

810
FORWARD RELAY

9
FUSE C9
FOR / REV

3
5

8
SWITCH

6
809

2
FUSE A5 F FORWARD RELAY

2
N
002 107 812
10
FORWARD SOLENOID

4
200

8
5
IGNITION R

8
REVERSE RELAY

7
10
RELAY 1
808

4
6
811

1
912
REVERSE SOLENOID

2
PARKBRAKE REVERSE RELAY
12 13

REVERSE ALARM

3
5
RELAY

11

15

14
8
TRANS DUMP

10
RELAY

001
011
7
6

200G/200L

200E/200R
200D/200M
401

9
934 DUMP SWITCH (GEAR)
16

17

DUMP SWITCH (LOADER)

1
5

934
7

18
6

967
2
Circuit Diagram - 2CX, 2DX From serial No. 489724
Electrics

PARKBRAKE
122 936
8

FUSE A4
9
10

19

953
COMPRESSOR COMPRESSOR
121
CONNECTOR CONNECTOR
FUSE A6

952 COMPRESSOR SOLIENOID

20

BRAKE LIGHTS
SWITCH LH BRAKE LIGHT
21

126 933 816 RH BRAKE LIGHT

22

FUSE B6 FUSE A8

23
105 E.S.O.S.
FUSE A2 REAR WASH/
WIPE SWITCH
5
M

863
24 25

REAR WASHER PUMP

6

27
1
M

862 REAR WIPER

26

FUSE B5
2

103 864
8
7

829

BATTERY FEED
28

829 HEATER/AIR CON HEATER/AIR CON

CONNECTOR CONNECTOR
102
FUSE C8
29

INTERIOR LIGHT

303
30

FACE LEVEL FAN

FUSE
C5
M
110 839 FRONT WASHER PUMP
31

M
FRONT WIPER
32

33
FRONT
W/W SWITCH

840

841
34

303

110 814 FRONT HORN

FUSE B2 FRONT HORN SWITCH
35

JUNCTION BOX
JUNCTION BOX
101
36

FUSE A1

HAZARD SWITCH
803

HAZARD SWITCH 805 805

37

LH FRONT INDICATOR
INDICATOR
SWITCH LH REAR INDICATOR
41

8
38

10
828

42

806
39

FLASHER
RELAY
RH FRONT INDICATOR
18
2

804 806 RH REAR INDICATOR

40

17

104 49a
1

31
FUSE A3
4

802
2
6

49
FLASHER UNIT
300 C2
3

FUSE C4
43
Circuit Diagrams and Component Lists

401

U 409 WATER TEMP SENDER

44

+ WATER TEMP GAUGE

45

U 408 FUEL SENDER

46

+ FUEL GAUGE
47

TACHOMETER
TACHOMETER
48

HOURMETER
49

9 9 9 9 9 9
A363330
852/80060

ILLUMINATION
011
007
829
830
106
828
401
412

110
804
806
805
407

50

Issue 1
7 - 16
Section C
Section C Electrics Section C
7 - 17 Circuit Diagrams and Component Lists 7 - 17

Circuit Diagram - 2CX, 2DX From Serial No. 489724

Main Components

1 Thermostart 61 Parking brake warning lamp

2 Battery 62 Engine coolant temperature warning lamp
3 Starter motor 63 Transmission oil temperature warning lamp
4 Starter relay 64 Engine oil low pressure warning lamp
5 Neutral start relay 65 Transmission oil low pressure warning lamp
6 Ignition switch 66 Air filter blocked warning lamp
7 Ignition relay 1 67 Buzzer
8 Forward/Reverse switch 68 Alternator
9 Forward relay 69 Radio socket
10 Forward solenoid 70 Rear horn switch
11 Reverse relay 71 Rear horn
12 Reverse solenoid 72 Auxiliary power connector
13 Reverse alarm 73 Ignition relay 2
14 Transmission dump relay 74 Front worklights switch
15 Parking brake relay 75 Front worklights
16 Gear lever dump switch 76 Front worklights relay
17 Loader lever dump switch 77 Rear worklights switch
18 Parking brake switch 78 Rear worklights
19 Compressor connector 79 Rear worklights relay
20 Compressor solenoid 80 Beacon
21 LH brake light 81 Beacon switch
22 RH brake light 82 Fog light
23 Brake lights switch 83 Fog light switch
24 Engine shut off solenoid (E.S.O.S.) 84 Headlight flash switch
25 Rear washer pump 85 Road lights relay
26 Rear wiper motor 86 Road lights switch
27 Rear wash/wipe switch 87 Dip/main beam switch
28 Heater/air con. connector 88 RH dipped beam
29 Interior light switch 89 LH dipped beam
30 Face level fan 90 LH main beam
31 Front washer pump 91 RH main beam
32 Front wiper motor 92 LH tail light
33 Front wash/wipe switch 93 LH side light
34 Front horn 94 RH tail light
35 Front horn switch 95 RH side light
36 Junction box
37 LH front indicator
38 LH rear indicator
39 RH front indicator
40 RH rear indicator
41 Indicator switch
42 Hazard switch
43 Flasher relay
44 Water temperature sender
45 Water temperature gauge
46 Fuel level sender
47 Fuel gauge
48 Tachometer
49 Hourmeter
50 Panel illumination
51 Front instrument console
52 Turn signals lamp
53 Side lights lamp
54 Main beam lamp
55 Hazard warning lamp
56 Rear work lights lamp
57 Front work lights lamp
58 Rear fog lights lamp
59 Side instrument console
60 Alternator ‘no charge’ lamp

9803/7110 Issue 1
 7 - 18

110
011
007
829
830
804
806
106
828
401
805
407
412

9803/7110
200G/200L

200E/200R
200D/200M
11

51
MASTER
Section C

INSTRUMENTS
WARNING

FRONT CONSOLE
LIGHTS

12
2 W STEER

TURN SIGNAL

5
4

52
SIDE LIGHRS

3
53
MAIN BEAM

2
54
HAZARD WARNING

6
55
REAR W/L

8
56
FRONT W/L

7
57
REAR FOG

9
58
3
Circuit Diagram - 2CX, 2DX From Serial

16
ALTERNATOR

7
3
HAND BRAKE
458 BRAKE PRESS SWITCH

18
WATER TEMP
406 WATER TEMP SWITCH

12
TRANS OIL TEMP

BATTERY FEED
404

9
TRANS OIL TEMP SWITCH
ENGINE OIL PRES

SIDE CONSOLE
Electrics

403 ENGINE OIL PRESS SWITCH

INSTRUMENTS
11
TRANS OIL PRES
405 TRANS OIL PRESS SWITCH

10

60 61 62 63 64 65

59
AIR FILTER
402 AIR FILTER VAC. SWITCH
17

66
No. 489724 (cont’d)

411
407

106
FUSE
Circuit Diagrams and Component Lists

B1
67

BUZZER
68
W

ALTERNATOR

RADIO SOCKET
69

304
FUSE
C6
8
7
71

70
3

871 REAR HORN

2

118
1

FUSE
B3
REAR HORN SWITCH
114

73
POWER SOCKET
72

5
FUSE

8
B4

24

6
IGNITION RELAY 2
F/W/L SWITCH
IGNITION
RELAY 2
5

76
6

LINK REQUIRED 855

FRONT WORKING LIGHTS
4

FOR UK BUILD 116

75

6
2
3

011
2

855
8
7

310
74

FUSE
B9
4

6
4
6

011 861
2
1

8
78

117
2

309 REAR WORKING LIGHTS

3

FUSE 861
B7
7

77

79
8

BEACON SWITCH

R/W/L SWITCH
8
7

BEACON
80

FUSE
81

M
B10
3

894
2

314
1

8
7

FOG LIGHT
82

83

H/LIGHT
FUSE C1
3

FLASH 835
2

862
1

84

FOG LT SWITCH

LIGHTS RELAY
ROAD LIGHTS
RELAY
834 RH DIP BEAM
88

85
5

FUSE C2
2
5

833 834 834

6

127 LH DIP BEAM

312 832
4

FUSE B8 836 837

2

837
89 90

FUSE C10 LH MAIN BEAM

3

311
87

DIP/MAIN
FUSE BEAM SWITCH 837 RH MAIN BEAM
C3
91

86

ROAD 828 829 LH TAIL LIGHT

92

LIGHTS
SWITCH FUSE A9
829 LH SIDE LIGHT
93

830
FUSE A10

DIPPER SOCKET

RH TAIL LIGHT
94

830
95

RH SIDE LIGHT
A363340

Issue 1
7 - 18
Section C
 1
010 003 THERMOSTART

FUSE P4
FUSE P1
FUSE P2
FUSE P3
FUSE C7
7 - 19

2
BATTERY

9803/7110
IGNITION
SWITCH BATTERY

5
4

6
3
NEUTRAL START RELAY STARTER MOTOR

1
Section C

5
200B
004

8
2
200C 842 STARTER SOLENOID

2
6
4

9 8 7 3 4 5 6
NEUTRAL START RELAY
IGNITION RELAY 1

892
967
FORWARD RELAY

9
FUSE C9 FOR / REV
SWITCH

3
5

6
809

8
2
FUSE A5 F FORWARD RELAY

2
N
002 107 812

10
FORWARD SOLENOID

4
200

8
5
R

7
8
IGNITION REVERSE RELAY

10
RELAY 1
808

4
6
811

1
REVERSE SOLENOID
12
912

2
11
REVERSE RELAY
13
PARKBRAKE
REVERSE ALARM

3
5
810
RELAY

14
15
TRANS DUMP

8
10
RELAY

001
011

200G
7

200E/200R
200D/200M
9
411 824
16

DUMP SWITCH (GEAR)

934 DUMP SWITCH (LOADER)
17

936
Circuit Diagram - 212SU from serial No. 489724

5
18

122
FUSE A4 936
Electrics

6
2

815 PARKBRAKE
8

10

PARKBRAKE
4 SWITCH
19

5
6
1

2
3

PTO SWITCH 891

21

20
8

JUNCTION BOX
22

101
FUSE A1 BRAKE LIGHTS
24

LH BRAKE LIGHT
SWITCH FUSE A8
126 933 816 RH BRAKE LIGHT
25

FUSE B6

23
105 E.S.O.S.
FUSE A2
27
M

863
26 28

REAR WASHER PUMP

6

REAR WASH/
1
M

WIPE SWITCH 862 REAR WIPER

29

FUSE B5
3

103 864

BATTERY FEED
8
7

829
30

829 AIR CON

CONNECTOR
31

HEATER SWITCH
1

2
33

32

102
HEATER RESISTOR HEATER FAN MOTOR
4

FUSE C8
5
M

800 HEATER
6

800B
7

8
34

INTERIOR LIGHT

303
35

FACE LEVEL FAN

FUSE
C5 FRONT W/W SWITCH
M
110 839 FRONT WASHER PUMP
36

M
FRONT WIPER
37

38

840

841
303

110 814 FRONT HORN

39
40

FUSE B2 FRONT HORN SWITCH

HAZARD SWITCH
803

HAZARD SWITCH 805 805

44

LH FRONT INDICATOR
INDICATOR
SWITCH LH REAR INDICATOR
42

10
45

828

41
Circuit Diagrams and Component Lists

806
5
46

RH FRONT INDICATOR
18
2

804 806
47

RH REAR INDICATOR
17

104 49a
1

31
FUSE A3 802
4
6

49
FLASHER UNIT
300 C2
3

FUSE C4
FLASHER
43

RELAY

411
110
011
007
829
804
806
828
411
805

A363370

Issue1
7 - 19
Section C
Section C Electrics Section C
7 - 20 Circuit Diagrams and Component Lists 7 - 20

Circuit Diagram - 212SU From Serial No. 489724 (cont’d)

Main Components
61 Engine coolant temperature warning lamp
1 Thermostart 62 Transmission oil temperature warning lamp
2 Battery 63 Engine oil low pressure warning lamp
3 Starter motor 64 Transmission oil low pressure warning lamp
4 Starter relay 65 Air filter blocked warning lamp
5 Neutral start relay 66 Buzzer
6 Ignition switch 67 Alternator
7 Ignition relay 1 68 Radio socket
8 Forward/reverse switch 69 Ignition relay 2
9 Forward relay 70 Front worklights relay
10 Forward solenoid 71 Front worklights switch
11 Reverse relay 72 Front worklights
12 Reverse solenoid 73 Rear worklights relay
13 Reverse alarm 74 Rear worklights switch
14 Transmission dump relay 75 Rear worklights
15 Parking brake relay 76 Beacon switch
16 Gear lever dump switch 77 Beacon
17 Loader lever dump switch 78 Fog light switch
18 Parking brake solenoid 79 Fog light
19 Parking brake switch 80 Headlight flash switch
20 Power take-off switch 81 Road lights relay
21 P.T.O. solenoid 82 Road lights switch
22 Junction box 83 Dip/main beam switch
23 Brake light switch 84 RH dip beam
24 LH brake light 85 LH dip beam
25 RH brake light 86 LH main beam
26 Engine shut off solenoid (E.S.O.S.) 87 RH main beam
27 Rear wash/wipe switch 88 LH tail light
28 Rear washer pump 89 LH side light
29 Rear wiper motor 90 Dipper socket
30 Air conditioning connector 91 RH tail light
31 Heater switch 92 RH side light
32 Heater resistor
33 Heater fan motor
34 Interior light
35 Face level fan
36 Front washer pump
37 Front wiper motor
38 Front wash/wipe switch
39 Front horn switch
40 Front horn
41 Hazard switch
42 Indicator switch
43 Flasher relay
44 LH front indicator
45 LH rear indicator
46 RH front indicator
47 RH rear indicator
48 Water temperature sender
49 Water temperature gauge
50 Fuel level sender
51 Fuel gauge
52 Tachometer
53 Hourmeter
54 Front instrument console
55 Turn signals lamp
56 Hazard warning lamp
57 Main beam lamp
58 Master warning lamps
59 Alternator ‘no charge’ lamp
60 Parking brake warning lamp

9803/7110 Issue 1
 7 - 21

110
011
007
829
804
806
828
411
805

9803/7110
200G

200E/200R
200D/200M
Section C

U 409 WATER TEMP SENDER

48
+ WATER TEMP GAUGE

49
-

U 408 FUEL SENDER

50
+ FUEL GAUGE

51
-

TACHOMETER
TACHOMETER

HOURMETER

9 9 9 9 9 9

52 53
ILLUMINATION

411
407
412
TURN SIGNAL

5
4
HAZARD WARNING

3
1
MAIN BEAM

2
MASTER WARNING

55 56 57 58
LIGHTS

BATTERY FEED
54
Electrics

10

ALTERNATOR

12
11

HAND BRAKE
458
Circuit Diagram - 212SU From Serial No. 489724 (cont’d)

BRAKE PRESS SWITCH

13

WATER TEMP
406 WATER TEMP SWITCH
9

TRANS OIL TEMP

404
8

TRANS OIL TEMP SWITCH

ENGINE OIL PRES

INSTRUMENTS
403 ENGINE OIL PRESS SWITCH
17

FRONT CONSOLE
Circuit Diagrams and Component Lists

TRANS OIL PRES

405 TRANS OIL PRESS SWITCH
14

AIR FILTER
402 AIR FILTER VAC. SWITCH
6

59 60 61 62 63 64 65
411
407

106
FUSE
B1
BUZZER
67

66
W

ALTERNATOR
8

RADIO SOCKET
68
7

304
FUSE
C6

8
24

6
IGNITION RELAY 2
F/W/L SWITCH
IGNITION
69
5

RELAY 2
6

011
2
72

855
8

116 FRONT WORKING LIGHTS

2

310
3

FUSE 855
B9
70
7

71
4

6
4
6

011
75

861
2
1

117
2

309 REAR WORKING LIGHTS

3

FUSE 861
73

B7
7

74
8

BEACON SWITCH

R/W/L SWITCH
8
7
76

BEACON
77

FUSE M
B10
3

894
2

314
1

8
7

FOG LIGHT
78
79

FUSE C1
3

835
H/LIGHT
2

862
1

FLASH
FOG LT SWITCH
80

LIGHTS RELAY
ROAD LIGHTS
RELAY RH DIP BEAM
84

81

FUSE C2
5

833 834
2

LH DIP BEAM
85

FUSE B8 832
6

127
312 836 837
4

LH MAIN BEAM
86

FUSE C10
2

DIP/MAIN
3

311 BEAM SWITCH RH MAIN BEAM

87

83

FUSE
C3
7

82

ROAD
LIGHTS
SWITCH 828 829 LH TAIL LIGHT
88

FUSE A9
829 LH SIDE LIGHT
89

830
FUSE A10

DIPPER SOCKET
90

RH TAIL LIGHT
91

830
92

RH SIDE LIGHT
A363380

Issue 1
7 - 21
Section C
Section C Electrics Section C
7 - 22 Circuit Diagrams and Component Lists 7 -22

Circuit Options - 2CX, 2DX, 212SU From serial No. 489724 (cont’d)
Worklights Circuit - German/Italian Builds (cont’d)

Main Components

1 Front worklights relay 11 Right hand dip beam

2 Front worklights switch 12 Left hand dip beam
3 Front worklights 13 Left hand main beam
4 Rear worklights relay 14 Right hand main beam
5 Rear worklights switch 15 Left hand rear light
6 Rear worklights 16 Left hand side light
7 Headlights flash switch 17 Dipper socket
8 Road lights relay 18 Right hand tail light
9 Road lights switch 19 Right hand side light
10 Dip/main beam switch
FRONT WORKING

DIPPER SOCKET
REAR WORKING

RH MAIN BEAM
LH MAIN BEAM
LIGHTS RELAY

RH SIDE LIGHT
LH SIDE LIGHT

RH TAIL LIGHT
LH TAIL LIGHT
RH DIP BEAM
LIGHTS

LH DIP BEAM
LIGHTS

12 14
11 13 16 19

17
834

837

829

830
3 6
834

837
15 18
834

837
FUSE C10
FUSE C2
861
855

861
855

833

836

829

830

TO INST PANEL
TO FOG LT SW
FUSE A10
FUSE A9

6 3 7 TO INST PANEL
F/W/L SWITCH

2 4 6 1 3 7
BEAM SWITCH
R/W/L SWITCH

DIP/MAIN

5 2
116

5 2 8
5 10
117

832

828

4 2 5 4 2 5

1 4 4 6 3 7
SWITCH

6 8 6 8
LIGHTS
ROAD
011

011

TO HAZARD SW 5 2 9

TO INST PANEL

SW ILUMINATION

TO INST PANEL
311
FLASH
H/LIGHT

127
309
310
ON GERMAN/ITALIAN
LINK NOT REQUIRED

ROAD LIGHTS

5 2 4
BUILDS

7
FUSE

RELAY
FUSE

B7
B9

3 1

011 IGN FEED

8
312

110 FEED
FUSE B8

FUSE C3

FUSE P4

FUSE P1

A363450

9803/7110 Issue 1
Section C Electrics Section C
7 - 23 Circuit Diagrams and Component Lists 7 - 23

Circuit Options - 2CX, 2DX, 212SU From Serial No. 489724 (cont’d)
Heater Circuit Heater/Air Conditioning Circuit

Main Components Main Components

1 Heater switch 1 Heater switch

2 Heater resistor 2 Air conditioning switch
3 Heater fan motor 3 Heater resistor
4 Heater fan motor
5 Freeze valve switch
6 Air conditioning relay
7 Low pressure switch
8 High pressure switch
9 Compressor clutch

AIR CON.
HEATER

HEATER
8

HIGH PRESS
SWITCH
HEATER FAN MOTOR

965
3 M 9
7 M

LOW PRESS
4

SWITCH
M

961
964
2 1 3

6
HEATER RESISTOR

2 4 5
800B

963
800B

FREEZE

AIR CON
VALVE

RELAY
RESISTOR

3 5
HEATER
800

962

7 3 1

1 3 4 6 7
SWITCH
AIR CON
HEATER SWITCH

1 8 2
2
800B

800A

800

2 5
8
800E

B4 B3 A4 C1

B5

B1
SWITCH
HEATER

1
102

829

600

102

829

600
FUSE C8

FUSE C8

A363460 A363470

9803/7110 Issue 1
Section C Electrics Section C
7 - 24 Circuit Diagrams and Component Lists 7 - 24

Circuit Options - 2CX, 2DX, 212SU (Later Machines) (cont’d)

Compressor Circuit - 2CX, 2DX Radio Circuit

Main Components Main Components

1 Stop/Start button 1 Radio unit

2 Start button 2 Loudspeaker
3 Compressor start relay 3 Loudspeaker
4 Compressor shut-down relay
5 Compressor interlock relay
6 Compressor hourmeter
7 Compressor temperature sender
8 Compressor temperature gauge
9 Air filter blocked switch
10 Air receiver temperature cut-out switch
11 Air delivery temperature cut-out switch
12 Compressor solenoid (already fitted)
COMPRESSOR
COMPRESSOR

COMPRESSOR

COMPRESSOR
TEMP SENDER

AIR FILTER SW

AIR RECIEVER
HOURMETER

TEMP SW

TEMP SW
AIR DELIVERY
TEMP GAUGE
SOLENOID

RADIO
12
7

2
602
511

4
3

6
2
1

8
U

-
952

860

9 10 11
952

10 7 9
COMPRESSOR

1
INTERLOCK
RELAY

5
8 6
955

459

459

459

859
951

4 2 5
COMPRESSOR
SHUTDOWN
RELAY

4
2
601

1 3
3
5 2 4
COMPRESSOR

3
RELAY
START

3 1
959
BUTTON

157
START

1
953

600

600

304
STOP/START
SWITCH
121
PARKBRAKE
LIGHTS RELAY

FUSE A6

FUSE C6

A363490
A363480

9803/7110 Issue 1
Section C Electrics Section C
7 - 25 Circuit Diagrams and Component Lists 7 - 25

Circuit Options - 2CX, 2DX, 212SU (Later Machines) (cont’d)

Hammer Circuit Hand Held Hydraulic Tools Circuit Hydraclamp Circuit

Main Components Main Components Main Components

1 Hammer relay 1 Selector switch 1 Selector switch

2 Hammer solenoid 2 Actuating solenoid 2 Actuating solenoid
3 Hammer ON/OFF switch

TOOLS SOLENOID
HAND HELD

HYDROCLAMP
SOLENOID
HAMMER
SOLENOID

2
2

801
3
801
966

1 3 7
899

1 3 7
1
1 2 8

2 8
HAMMER
RELAY

1
FEED SKT
AUXILIARY
FEED SKT

101

829

600
AUXILIARY

101

829

600
101

600

FUSE A1
FUSE A1
FUSE A1

A364130 A364140 A364150

9803/7110 Issue 1
Section C Electrics Section C
8-1 Wire Number Identification 8-1

Wire/Harness Numbers - Explanation of:

Each wire has its own unique number which is printed on the wire insulation every 50mm (2 inches). The wire numbers listed on
the following pages identify the source, route and final destination of all the wires used on the machine.

Also printed on the wire insulation is the part number of the harness from which the wire originates; the harness part number is
shortened,e.g., if the harness part number is 719/37100, the number printed on the harness wire insulation will be 9/371 (71
and 00 are common numbers and, therefore, are deleted).

The illustration shows a typical connector and wires. To summarise, the number printed on the wire insulation in the example
shown identifies the following:

819 = The wire's unique identification number.

9/371 = The part number of the harness from which the wire originates.

S164110

Finally, some more points to note regarding wire identification:

1 Wires will continue to have the same number, even after passing through a bulkhead connector into a different harness.

2 The wire number categories shown in the tables on the following pages are as follows:

2.1 Wire numbers 000 to 199. Wires in this number bracket are allocated to live feeds when the starter switch is at the
IGN position, heater start circuits and start circuits.

2.2 Wire numbers 200 to 399. Wires in this number bracket are allocated to battery feeds.

2.3 Wire numbers 400 to 599. Wires in this number bracket are allocated to instruments (alternator to tacho, fuel gauge
senders to fuel gauges etc).

2.4 Wire numbers 600 to 799. Wires in this number bracket are allocated to earth paths.

2.5 Wire numbers 800 to 999. Wires in this number bracket are allocated to switched supplies to lights, horn etc from
switches and relays.

3 When a wire terminates in a splice and a branch of wires comes from that splice, all wires will have their own unique
identification number.

9803/7110 Issue 1
Section C Electrics Section C
8-2 Wire Number Identification 8-2

Mainframe Harness
Wire No. Description Size (mm) Comments
1 Alternator to solenoid feed 4.50
2 Alternator to solenoid feed 4.50
200 Starter solenoid to fuse A7a via Mainframe plug 1, pin C 2.00
201 Starter solenoid to fuse C4 via Mainframe plug 2, pin C 2.00
202 Starter solenoid to fuse C1a via Mainframe plug 1, pin D 2.00
203 Starter solenoid to fuse A6a via Mainframe plug 2, pin D 2.00
204 Starter solenoid to fuse C5 via Mainframe plug 1, pin E 3.00
* 205 Starter solenoid to starter switch via Mainframe plug 2, pin E 2.00
207 Starter solenoid to neutral start relay via Mainframe plug 2, pin F 2.50
209 Thermostart to starter switch via Mainframe plug 1, pin H 2.00
211 Foot brake switch to fuse A1 via plug 2, pin 9 and plug 4, pin 9 1.00
212 Gauge feed to fuse A2 via plug 1, pin 11 and plug 3, pin 11 1.00
213 Side light splice CL3 to fuse A3 via plug 2, pin 2 and plug 4, pin 2 1.00
215 Right hand front side light to fuse A4 via plug 1, pin 15 and plug 3, pin 15 1.00
220 Splice CL5 to fuse A9 via plug 2, pin J and plug 4, pin J 2.00
221 Splice CL6 to fuse B3 via plug 1, pin 1 and plug 3, pin 1 1.50
222 Splice CL7 to fuse B4 via plug 2, pin 1 and plug 4, pin 1 (main) 1.50
229 Column switch to fuse B3a via plug 1, pin G and plug 3, pin G 2.00
230 Column switch to fuse B4a via plug 2, pin L and plug 4, pin L 1.50
233 Column switch to road light switch via plug 1, pin J and plug 3, pin J 2.00
237 Splice CL9 to hazard switch via Mainframe plug 2, pin 12 1.00
240 Splice CL10 to diode via plug 2, pin 8 and plug 4, pin 8 1.00
242 Column switch to reverse relay via plug 2, pin 6 and plug 4, pin 6 1.00
243 Column stalk to indicator relay via plug 1, pin 18 and plug 3, pin 18 1.00
244 Column switch to dump relay via plug 2, pin 16 and plug 4, pin 16 1.00
246 Column stalk to forward relay via plug 1, pin 19 and plug 3, pin 19 1.00
249 Column switch to brake on relay via plug 2, pin 7 and plug 4, pin 7 1.00
251 Starter solenoid to fused feed via plug 1, pin 17 1.00
254 Parking brake switch to fuse C3 via plug 2, pin 17 and plug 4, pin 17 1.00
* 270 Fuse A8a to quickhitch switch via Mainframe plug 1, pin 1 & plug 3, pin 1 1.00
400 Alternator warning light to panel via plug 4, pin 12 1.00
401 Alternator pulse to tachometer panel via Mainframe plug 3, pin B 1.50
402 Engine oil warning switch to panel via plug 4, pin 15 1.00
403 Water temperature switch to panel via plug 4, pin 18 1.00
404 Water temperature sender to panel via plug 4, pin 19 1.00
405 Transmission oil temperature switch to panel via plug 3, pin 2 1.00
406 Transmission oil pressure switch to panel via plug 3, pin 3 1.00
407 Air cleaner switch to panel via plug 3, pin 4 1.00
408 Fuel sender to panel via plug 3, pin 5 1.00
409 Instrument panel to fuse B4 via plug 1, pin 8 and plug 3, pin 8 1.00
410 Instrument panel to hazard switch via plug 1, pin 10 and plug 3, pin 10 1.00
411 Instrument panel to splice CL9 (hazard) to plug 3, pin 6 1.00
413 Instrument panel to parking brake relay via plug 1, pin 9 and plug 3, pin 9 1.00
414 Instrument panel to buzzer via plug 1, pin 16 and plug 3, pin 16 1.00
* 416 Brake pressure switch to panel via plug 4, pin 5 1.00
* 602 Water temperature sender earth to splice SA1 (was CL2) 1.00
* 603 Transmission oil temperature switch earth to splice SA1 (was CL2) 1.00
* 604 Front horn earth to splice SA1 (was CL2) 1.00
605 Reverse solenoid earth to splice CL20 1.00
* 607 Forward solenoid earth to splice CL 2 (was CL20) 1.00
608 Earth splice CL20 to starter earth ring 2.00
* 609 Splice CL20 (was starter earth ring) to cab harness earth via Mainframe plug 2, pin B 1.50
610 Earth splice CL2 to starter earth ring 1.00
* 611 Splice CL20 (was starter earth ring) to cab harness earth via Mainframe plug 1, pin B 2.00
612 Stabiliser solenoid earth to splice CL20 1.00
* 613 Splice CL20 (was starter earth ring) to cab roof earth via Mainframe plug A, pin 1 2.00
614 Rear horn earth to splice CL20 1.00
* 615 Splice CL20 (was starter earth ring) to cab harness earth via Mainframe plug 2, pin A 2.00
617 Reverse alarm earth to splice CL20 1.00

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.

9803/7110 Issue 2*
Section C Electrics Section C
8-3 Wire Number Identification 8-3

Mainframe Harness (continued)

Wire No. Description Size (mm) Comments
618 Fuel sender earth to splice CL20 1.00
619 E.S.O.S. earth to starter earth ring 1.00
* 620 Parking brake solenoid earth to splice CL 2 (was CL20) 1.00
641 Splice CL12 to splice CL2 link via Mainframe plug 3, pin A 1.50
642 Windscreen washer pump earth to splice CL2 1.00
* 643 Splice CL20 (was CL2) to fan motor earth via Mainframe plug 2, pin 11 1.00
644 Splice CL2 to rear windscreen washer pump earth 1.00
* 664 Transmission oil pressure switch earth to splice CL 2 (was CL20) 1.00
* 684 Brake pressure switch to splice CL20 1.00
* 685 Temperature switch earth to splice SA1 1.00
* 686 Air cleaner earth to splice SA1 1.00
* 687 Engine oil warning earth to splice SA1 1.00
* 703 Starter earth to splice SA1 1.50
800 Column switch to front horn feed via Mainframe plug 3, pin C 1.50
801 Forward solenoid to forward relay via Mainframe plug 1, pin 7 1.00
802 Reverse solenoid to reverse relay via Mainframe plug 2, pin 5 1.00
803 Dump switch to dump relay via Mainframe plug 1, pin 5 1.00
804 Dump switch to dump relay via Mainframe plug 2, pin 3 1.00
* 805 Dump switch to dump relay via Mainframe plug 1, pin 4 CL 2 (was CL20) 1.00
806 Dump switch to fuse B9 via Mainframe plug 2, pin H 1.50
807 Stabiliser solenoid feed from relay via Mainframe plug 1, pin 3 1.00
808 Rear horn feed to rear horn switch via Mainframe plug 2, pin 4 1.00
809 Reverse alarm feed from reverse relay via Mainframe plug 1, pin 6 1.00
810 E.S.O.S. feed from fuse C2a via Mainframe plug 1, pin 2 1.00
811 Parking brake solenoid feed from parking brake relay via Mainframe plug 2, pin 15 1.00
812 Parking brake switch to parking brake relay via plug 1, pin 14 and plug 3, pin 14 1.00
814 Foot brake switch to splice CL1 via plug 2, pin 10 and plug 4, pin 10 1.00
819 Splice CL3 to left hand rear stop light via plug 1, pin 12 and plug 3, pin 12 1.00
849 Splice CL9 (hazard) to column switch via plug 4, pin 13 1.00
850 Splice CL9 to left hand front indicator via plug 3, pin 13 1.00
851 Splice CL9 (hazard) to left hand rear indicator via Mainframe plug 1, pin 13 1.00
859 Rear windscreen wash pump to switch via Mainframe plug 2, pin 18 1.00
863 Windscreen washer pump to column switch via Mainframe plug 3, pin 17 1.00
869 Speaker plug to speaker unit via Plug 4, pin 3 and plug 1, pin K 1.50
870 Speaker plug to speaker unit via Plug 4, pin 4 and plug 1, pin L 1.50
871 Speaker plug to speaker unit via Plug 4, pin 1 and plug 2, pin K 1.50
872 Speaker plug to speaker unit via Plug 4, pin 14 and plug 2, pin 19 1.00
881 Fused feed to splice F1 via plug 2, pin 13 to plug 3, pin 7 1.00

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.

9803/7110 Issue 2*
Section C Electrics Section C
8-4 Wire Number Identification 8-4

Switch Console Harness

Wire No. Description Size (mm) Comments
3 Fuse A1a to starter switch 1.50
4 Fuse A9a to starter switch 2.00
5 Fuse A9a to fuse B8a link 2.00
6 Fuse B7a to fuse B8a link 1.00
7 Fuse B7a to fuse B9a link 1.00
8 Fuse B1a to starter switch 1.50
9 Fuse B1a to fuse B2a link 1.00
10 Fuse B6a to starter switch 1.50
11 Starter switch to neutral start relay 2.50
15 Starter switch to fuse C6 2.00
16 Fuse C6a to attachments power socket 2.00
* 17 Fuse C6 to fuse C7 link 1.00 when applicable
* 18 Fuse C7a to brake pressure warning light plug 1.00 when applicable
* 20 Fuse B2a to fuse C8 link 1.00 when applicable
* 21 Fuse C9a to air conditioning/high output heater plug 2.00 when applicable
200 Starter solenoid to fuse A7a via Mainframe plug 1, pin C 2.00
201 Starter solenoid to fuse C4 2.00
202 Starter solenoid to fuse C1a via Mainframe plug 1, pin D 2.00
203 Starter solenoid to fuse A6a via Mainframe plug 2, pin D 2.00
204 Starter solenoid to fuse C5 via Mainframe plug 1, pin E 2.00
205 Starter solenoid to starter switch via Mainframe plug 2, pin E 2.00
207 Starter solenoid to neutral start relay via Mainframe plug 2, pin F 2.00
209 Thermostart to starter switch via Mainframe plug 1, pin H 2.00
* 210 Starter switch terminal to fuse A5a 2.00
211 Foot brake switch to fuse A1 via Mainframe plug 2, pin 9 1.00
212 Gauge feed (instrument panel) to fuse A2 via Mainframe plug 1, pin 11 1.00
213 Side lights splice CL3 to fuse A3 via Mainframe plug 2, pin 2 1.00
214 Fuse A3 to number plate light splice CT1 (Cab Roof Harness) 1.00
215 Right hand front side light to fuse A4 via Mainframe plug 1, pin 15 1.00
216 Fuse A4 to right hand rear side light splice CL4 1.00
217 Fuse A6 to hazard warning light switch 1.50
218 Fuse A7 to cab light feed 1.50
219 Fuse A8 to stabiliser relay 1.00
220 Splice CL5 (column feed) to fuse A9 via Mainframe plug 2, pin J 2.00
221 Splice CL6 (dipped head light) to fuse B3 via Mainframe plug 1, pin 1 1.50
222 Splice CL7 (main beam) to fuse B4 via Mainframe plug 2, pin 1 1.50
223 Fuse B6 to hazard warning switch 1.50
224 Fuse B7 to dump relay 1.00
225 Fuse B9 to buzzer 1.00
226 Fuse A1a to fuse A2a link 2.00
227 Fuse A3a to road lights relay 2.00
228 Fuse A3a to fuse A4a link 2.00
229 Column switch to fuse B3a via Mainframe plug 1, pin G 2.00
230 Column switch to fuse B4a via Mainframe plug 2, pin L 1.50
231 Fuse B5a to front work lights switch 2.00
232 Fuse C1 to rear working lights switch 2.00
233 Column switch to road lights switch via Mainframe plug 1, pin J 2.00
234 Front working lights switch to road lights relay 2.00
235 Rear working lights switch to rear working lights splice CT2 2.00
236 Hazard warning switch to diode 1.00
237 Splice CL9 to hazard warning switch via Mainframe plug 2, pin 12 1.00
238 Hazard warning switch to flasher relay 1.50
239 Hazard warning switch to flasher relay 1.50
240 Splice CL10 to diode splice CL21 via Mainframe plug 2, pin 8 1.00
241 Forward relay to reverse relay link 1.00
242 Column switch to reverse relay via Mainframe plug 2, pin 6 1.00
243 Column switch to indicator relay via Mainframe plug 1, pin 18 1.00
244 Column switch to dump relay via Mainframe plug 2, pin 16 1.00
245 Dump relay to forward relay link 1.00

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.

9803/7110 Issue 2*
Section C Electrics Section C
8-5 Wire Number Identification 8-5

Switch Console Harness (continued)

Wire No. Description Size (mm) Comments
246 Column switch to forward relay via Mainframe plug 1, pin 19 1.00
247 Column switch neutral to parking brake relay 1.00
248 Parking brake relay to stabiliser interlock 1.00
249 Column switch neutral to interlock relay via Mainframe plug 2, pin 7 1.00
250 Heater resistor to heater motor 1.00
251 Starter to fuse C4 via plug 1, pin 17 1.00
* 252 Beacon switch to beacon sockets via sumitomo plug 2.00
254 Fuse C3 to parking brake button via Mainframe plug 2, pin 17 1.00
255 Diode to splice CL21 (right hand rear indicator) 1.00
256 Fuse A8a to fuse B6a link 2.00
257 Parking brake interlock relay to neutral start relay 1.00
258 Fuse A9 to fuse C3a link 1.00
* 270 Fuse A8a to quickhitch switch via Mainframe plug 1, pin1 1.00
* 298 Splice BF01 to interior light feed splice via sumitomo plug 1.00
* 299 Splice BF01 to beacon 2.00
* 304 Thermostart link wire 2.00
409 Instrument panel to fuse B4 via Mainframe plug 1, pin 8 1.00
410 Instrument panel to hazard warning switch via Mainframe plug 1, pin 10 1.00
413 Instrument panel to parking brake relay via Mainframe plug 1, pin 9 1.00
414 Instrument panel to buzzer relay via Mainframe plug 1, pin 16 1.00
* 415 Buzzer relay to brake pressure warning light plug 1.00 when applicable
609 Starter earth ring to cab harness earth via Mainframe plug 2, pin B 1.50
611 Starter earth ring to cab roof harness earth via Mainframe plug 1, pin B 2.00
613 Starter earth ring to cab roof earth via Mainframe plug 1, pin A 2.00
615 Earth splice (CL11) to mainframe starter earth via Mainframe plug 2, pin A 2.00
* 617 Reverse alarm earth to splice CL11 1.00
621 Parking brake relay (warning) to earth splice CL11 1.00
622 Parking brake relay to earth splice CL11 1.00
623 Front working light switch illumination earth link to hazard warning switch 1.00
624 Switch illumination earth link to front working light switch 1.00
625 Hazard warning switch illumination earth to splice C11 1.00
626 Windscreen wiper motor switch illumination earth to splice CL11 1.00
627 Windscreen wiper park to rear windscreen wiper via connecting plug, pin 2 1.00
629 Fog light switch illumination earth to splice CL11 1.00
630 Reverse relay to parking brake relay earth link 1.00
631 Forward relay to dump relay earth link 1.00
632 Flasher relay to dump relay earth link 1.00
633 Road lights relay to flasher relay earth link 1.00
636 Stabiliser relay to earth splice CL11 1.00
643 Splice CL2 to fan motor earth via Mainframe plug 2, pin 11 1.00
646 Left hand fog light earth to splice CL13 1.00
647 Right hand fog light earth to splice CL13 1.00
648 Left hand rear light earth to splice CL13 1.00
649 Right hand rear light earth to splice CL13 1.00
650 Splice CL11 to splice CL13 (earth) 1.50
662 Switch illumination earth to splice CL11 1.00
667 Forward relay earth to reverse relay earth link 1.00
668 Neutral start relay to earth splice CL11 1.00
680 Attachments power socket earth to splice CL11 2.00
681 Parking brake interlock to parking brake warning relay link 1.00
682 Parking brake warning relay link 1.00
683 Splice CL13 to left hand number plate light 1.00
* 684 Brake pressure warning light plug to earth splice CL11 1.00 when applicable
* 685 Air conditioning/high output heater earth to splice CL11 1.00 when applicable
* 698 Beacon switch illumination earth to splice CL11 1.00
* 699 Fan motor switch illumination earth to splice CL11 1.00
801 Forward solenoid to forward relay via Mainframe plug 1, pin 7 1.00
802 Reverse solenoid to reverse relay via Mainframe plug 2, pin 5 1.00
803 Dump switch to dump relay via Mainframe plug 1, pin 5 1.00

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.

9803/7110 Issue 2*
Section C Electrics Section C
8-6 Wire Number Identification 8-6

Switch Console Harness (continued)

Wire No. Description Size (mm) Comments
804 Dump switch to dump relay via Mainframe plug 2, pin 3 1.00
805 Dump switch to dump relay via Mainframe plug 1, pin 4 1.00
806 Dump switch to fuse B9 via Mainframe plug 2, pin H 1.50
807 Stabiliser solenoid feed from relay via Mainframe plug 1, pin 3 1.00
808 Rear horn feed to rear horn switch via Mainframe plug 2, pin 4 1.00
809 Reverse alarm feed from reverse relay via Mainframe plug 1, pin 6 1.00
810 E.S.O.S. feed from fuse C2a via Mainframe plug 1, pin 2 1.00
811 Park brake solenoid feed from park brake warning relay via Mainframe plug 2, pin 15 1.00
812 Parking brake switch to parking brake interlock relay via Mainframe plug 1, pin 14 1.00
813 Parking brake relay interlock to parking brake relay warning link 1.00
814 Foot brake switch to splice CL1 (brake lights ) via Mainframe plug 2, pin 10 1.00
815 Splice CL1 to right hand brake light 1.00
816 Splice CL1 to left hand brake light 1.00
817 Fuse A2 to fuse C2 link 1.00
819 Splice CL3 to left hand rear side light splice SW10 via Mainframe plug 1, pin 12 1.00
827 Fuse B1 to rear windscreen wash/wipe switch 1.50
830 Fuse B2 to rear horn switch 1.00
833 Fuse B3 to fog light switch 1.00
836 Fuse B5 to front working light splice 2.00
838 Fuse B8 to heater switch 1.50
839 Front working lights switch to switch illumination link 1.00
840 Road lights switch to switch illumination link 1.00
841 Road lights switch to road lights relay 1.00
842 Fog light switch to fog light splice CL8 1.00
843 Fog light switch to switch illumination link 1.00
844 Splice CL8 to left hand rear fog light 1.00
845 Splice CL8 to right hand rear fog light 1.00
848 Rear working lights switch to switch illumination link 1.00
851 Splice CL9 (hazard) to left hand rear indicator via Mainframe plug 1, pin 13 1.00
854 Splice CL21 to right hand rear indicator 1.00
855 Heater switch to heater resistor 1.00
856 Heater switch to heater resistor 1.00
857 Windscreen wiper switched feed to wiper motor via connecting plug, pin 1 1.00
858 Rear windscreen wash/wipe switch to illumination feed link 1.00
859 Windscreen wash/wipe switch to rear wash pump feed via Mainframe plug 2, pin 18 1.00
* 865 Parkbrake relay to parkbrake warning relay link 1.00
869 Speaker plug to left hand speaker via plug 1, pin K 1.50
870 Speaker plug to right hand speaker via plug 1, pin L 1.50
871 Speaker plug to right hand speaker via plug 2, pin K 1.50
872 Speaker plug to right hand speaker via plug 2, pin 19 1.00
880 Fuse C4a to road lights switch 1.00
881 Fuse C4a radio/wiper splice via plug 2, pin 13 1.00
884 Fuse C5a to road lights relay 1.00
885 Splice SW10 to left hand number plate light 1.00
886 Splice SW10 to left hand rear light 1.00
* 907 Fuse C8a to sumitomo plug (2/4 wheel steer solenoid feed) 1.00 when applicable
* 920 Fuse C2 to switch illumination splice IL01 1.00
* 921 Switch illumination splice IL01 to fan motor switch 1.00
* 922 Switch illumination splice IL01 to hazard switch 1.00
* 923 Switch illumination splice IL01 to beacon switch 1.00
* 941 Reverse light feed from reverse relay via Mainframe plug 1, pin 6 1.00

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.

9803/7110 Issue 2*
Section C Electrics Section C
8-7 Wire Number Identification 8-7

Instrument Console Harness

Wire No. Description Size (mm) Comments
211 Foot brake switch to fuse A1 via Mainframe plug 4, pin 9 1.00
212 Gauge feed (instrument panel) to fuse A2 via Mainframe plug 3, pin 11 1.00
213 Side lights splice CL3 to fuse A3 via Mainframe plug 4, pin 2 1.00
215 Right hand front side lights to fuse A4 via Mainframe plug 3, pin 15 1.00
220 Splice CL5 (column feed) to fuse A9 via Mainframe plug 4, pin J 2.00
221 Splice CL6 (dipped head light) to fuse B3 via Mainframe plug 3, pin 1 1.50
222 Splice CL7 (main beam) to fuse B4 via Mainframe plug 4, pin 1 1.50
229 Column switch to fuse B3a via Mainframe plug 3, pin 1 2.00
230 Column switch to fuse B4a via Mainframe plug 4, pin L 1.50
233 Column switch to road lights switch via Mainframe plug 3, pin J 1.50
240 Splice CL10 to diode via Mainframe plug 4, pin 8 1.00
242 Column switch to reverse relay via Mainframe plug 4, pin 6 1.00
243 Column switch to indicator relay via Mainframe plug 3, pin 18 1.00
244 Column switch to dump relay via Mainframe plug 4, pin 16 1.00
246 Column switch to forward relay via Mainframe plug 3, pin 19 1.00
249 Column switch to parking brake 'ON' relay via Mainframe plug 4, pin 7 1.00
254 Parking brake switch to fuse C3 via Mainframe plug 4, pin 17 1.00
* 270 Fuse A8a to Quickhitch switch via Mainframe plug 1, pin1 & plug 3, pin 1 1.00
400 Alternator warning light to panel via Mainframe plug 4, pin 12 1.00
401 Alternator pulse to tacho panel via Mainframe plug 3, pin B 1.50
402 Engine oil warning light to panel via Mainframe plug 4, pin 15 1.00
403 Water temperature switch to panel via Mainframe plug 4, pin 18 1.00
404 Water temperature sender to panel via Mainframe plug 4, pin 19 1.00
405 Transmission oil temperature switch to panel via Mainframe plug 3, pin 2 1.00
406 Transmission oil pressure switch to panel via Mainframe plug 3, pin 3 1.00
407 Air cleaner switch to panel via Mainframe plug 3, pin 4 1.00
408 Fuel sender to panel via Mainframe plug 3, pin 5 1.00
409 Instrument panel to fuse B4 via Mainframe plug 3, pin 8 1.00
410 Instrument panel to hazard switch via Mainframe plug 3, pin 10 1.00
411 Instrument panel to splice CL9 (hazard) via Mainframe plug 3, pin 6 1.00
412 Instrument panel to splice CL10 (diode) via Mainframe plug 3, pin 7 1.00
413 Instrument panel to parking brake relay via Mainframe plug 3, pin 9 1.00
414 Instrument panel to buzzer relay via Mainframe plug 3, pin 16 1.00
* 416 Brake pressure switch to panel via plug 4, pin 5 1.00
637 Instrument panel earth to splice CL12 1.00
638 Left hand head light earth to splice CL12 1.00
639 Right hand head light earth to splice CL12 1.00
* 640 Test button earth to splice CL12 1.00 when applicable
641 Splice CL12 to splice CL2 earth link via Mainframe plug 3, pin A 2.00
651 Radio earth to earth splice CL12 1.00
654 Front windscreen wiper earth to splice CL12 1.00
669 Front windscreen wiper switched return to column switch 1.00
* 689 Quickhitch solenoid earth to earth splice CL12 1.00
800 Column switch to front horn via Mainframe plug 3, pin C 1.50
812 Parking brake switch to parking brake relay via Mainframe plug 3, pin 14 1.00
814 Foot brake switch to splice CL1 (brake lights) via Mainframe plug 4, pin 10 1.00
818 Splice CL3 (side lights) to left hand front side light 1.00
819 Splice CL3 to left hand rear side light via Mainframe plug 3, pin 12 1.00
820 Splice CL3 to instrument panel illumination 1.00
825 Splice CL5 to column switch (horn feed) 1.00
826 Splice CL5 to column switch (head light flash) 1.00
831 Splice CL6 to left hand dipped head light 1.00
832 Splice CL6 to right hand dipped head light 1.00
834 Splice CL7 (main beam) to left hand main beam 1.00
835 Splice CL7 (main beam) to right hand main beam 1.00
849 Column switch to splice CL9 (hazard) via Mainframe plug 4, pin 13 1.00
850 Left hand front indicator to splice CL9 (hazard) via Mainframe plug 3, pin 13 1.00
852 Splice CL10 (right hand indicator) to column switch 1.00
853 Splice CL10 (right hand indicator) to right hand front indicator 1.00

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.

9803/7110 Issue 2*
Section C Electrics Section C
8-8 Wire Number Identification 8-8

Instrument Console Harness (continued)

Wire No. Description Size (mm) Comments
* 860 Instrument panel to test button 1.00 when applicable
861 Splice CL5 to column switch (windscreen wash/wipe feed) 1.00
862 Column switch to windscreen wiper motor feed 1.00
863 Column switch to windscreen wash pump feed via Mainframe plug 3, pin 17 1.00
869 Speaker plug to left hand speaker via Mainframe plug 4, pin 3 1.50
870 Speaker plug to left hand speaker via Mainframe plug 4, pin 4 1.50
871 Speaker plug to right hand speaker via Mainframe plug 4, pin 1 1.50
872 Speaker plug to right hand speaker via Mainframe plug 4, pin 14 1.00
881 Fused feed to splice F1 via Mainframe plug 3, pin 7 1.00
882 Windscreen wiper permanent feed from splice F1 1.00
883 Radio permanent feed from splice F1 1.00
* 895 Quickhitch switch to quickhitch solenoid 1.00

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.

Cab Roof Harness

Wire No. Description Size (mm) Comments
214 Fuse A3 to number plate light splice CT1 via connecting plug pin 7 1.00
218 Fuse A7 to interior light splice CT5 via connecting plug pin 9 1.50
235 Rear working lights switch to splice CT2 via connecting plug pin 4 1.50
252 Splice CT5 to beacon socket feed 1.00
253 Splice CT5 to rear windscreen wiper motor permanent feed link 1.00
* 298 Splice BF01 (switch console harness) via plug 11 to splice CT5 1.50
* 300 Rear beacon socket feed to splice CT6 1.00
* 301 Front beacon socket feed to splice CT6 1.00
611 Splice CT3 to starter motor earth via connecting plug pin 5 2.00
613 Splice CT4 to starter motor earth via connecting plug pin 3 2.00
627 Rear windscreen wiper switch to rear windscreen wiper via connecting plug pin 2 1.00
652 Right hand front working light earth to splice CT3 1.00
653 Beacon light socket earth to splice CT3 1.00
655 Left hand front working light earth to splice CT3 1.00
656 Interior light earth to splice CT3 1.00
657 Rear windscreen wiper permanent earth to splice CT4 1.00
658 Right hand rear working light earth to splice CT4 1.00
659 Right hand rear number plate light earth to splice CT4 1.00
660 Left hand rear working light earth to splice CT4 1.00
661 Left hand rear number plate light earth to splice CT4 1.00
* 723 Rear beacon socket earth to splice CT3 1.00
821 Splice CT1 to left hand number plate light 1.00
822 Splice CT1 to right hand number plate light 1.00
836 Fuse B5 to right hand front working light via connecting plug pin 8 1.50
837 Right hand front working light to left hand front working light link 1.00
846 Splice CT2 to left hand rear working light 1.00
847 Splice CT2 to right hand rear working light 1.00
857 Rear windscreen wiper switch to motor via connecting plug pin 1 1.00
866 Splice CT5 to interior light feed 1.00
869 Left hand loudspeaker to speaker plug via connecting plug pin 12 1.00
870 Left hand loudspeaker to speaker plug via connecting plug pin 13 1.00
871 Right hand loudspeaker to speaker plug via connecting plug pin 10 1.00
872 Right hand loudspeaker to speaker plug via connecting plug pin 14 1.00

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.

* Park Brake Switch Harness

9803/7110 Issue 2*
Section C Electrics Section C
8-9 Wire Number Identification 8-9

Wire No. Description Size (mm) Comments

254 Parkbrake switch to sumitomo plug, pin 2 1.00
812 Parkbrake switch to sumitomo plug, pin 1 1.00

*Utility Solenoid Harness (210SU)

Wire No. Description Size (mm) Comments
600A Attachment socket to earth splice 2.00
600B Earth splice to attachment power plug extension 1.00
600C Earth splice to panel switch 1.00
600D Earth splice to solenoid valve connector 1.00
800A Attachment socket to feed socket 2.00
800B Feed splice to attachment power plug 1.00
800C Feed splice to panel switch 1.00
800D Feed splice to panel switch 1.00
801A Panel switch to solenoid valve connector 1.00

*Trailer Socket Harness (m/c’s with hydraulic pick-up hitch)

Wire No. Description Size (mm) Comments
600G Earth splice to LH rear light combination unit 1.00
600H Earth splice to RH rear light combination unit 1.00
600FP Earth splice to trailer socket 1.00
600GA Console connector to earth splice 1.00
600GB Console connector to earth splice 1.00
805C Feed splice to LH rear indicator 1.00
805K Feed splice to trailer socket (LH indicator) 1.00
805M Console connector to LH indicator splice 1.00
806C Feed splice to RH indicator 1.00
806L Feed splice to trailer socket (RH indicator) 1.00
806N Console connector to RH indicator splice 1.00
816D Feed splice to LH brake light 1.00
816E Feed splice to RH brake light 1.00
816J Feed splice to trailer socket (brakes) 1.00
816K Console connector to brakes splice 1.00
829D Feed splice to LH side light 1.00
829P Feed splice to trailer socket (LH side) 1.00
829AB Console connector to RH side splice 1.00
830B Feed splice to RH side light 1.00
830S Feed splice to trailer socket (RH side) 1.00
830T Console connector to RH side splice 1.00

*Diverter Valve Harness (m/c’s with hydraulic pick-up hitch)

Wire No. Description Size (mm) Comments
101A Junction box to feed splice 2.00
101AJ Feed splice to auxiliary junction box 1.40
101AL Feed splice to diverter switch 1.00
101AM Diverter switch to switch illumination 1.00
455 Flasher relay to trailer buzzer 1.00
600CC Junction box to earth splice 2.00
600FT Earth splice to auxiliary junction box 1.40
600GC Earth splice to diverter valve switch illumination 1.00
600GD Earth splice to diverter valve 1.00
600GE Earth splice to trailer buzzer 1.00
946 Diverter switch to diverter valve 1.00

9803/7110 Issue 2*
Section C Electrics Section C
8 - 10 Wire Number Identification 8 - 10

Mainframe Harness (2DX)

Wire No. Description Size (mm) Comments

101A Fuse C3 to junction box 1.0

105 Fuse B2 to engine shut off solenoid 1.0
123 Fuse C6 to thermostart 2.0
200 Alternator to starter solenoid 4.0
200A Alternator to starter solenoid 4.0
200B Starter solenoid to ignition switch 4.0
200C Starter solenoid to ignition switch 4.0
200D Starter solenoid to ignition relay 4.0
200E Starter solenoid to road lights relay 3.0
200G Starter solenoid to fuse box 4.0
200M Starter solenoid to ignition relay 4.0
402B Air filter splice to warning lamp splice 1.0
402C Engine air filter to air filter splice 1.0
402D Compressor air filter to air filter splice 1.0
403B Engine oil pressure switch to warning lamp splice 1.0
404B Transmission oil temperature switch to warning lamp splice 1.0
405B Transmission oil pressure switch to warning lamp splice 1.0
406B Water temperature switch to warning lamp splice 1.0
407B Alternator to charge warning lamp splice 1.0
408 Fuel sender to fuel gauge 1.0
409 Water temperature sender to fuel gauge 1.0
412 Alternator ‘W’ terminal to tachometer 1.0
456 Compressor air receiver temperature switch to electrical power unit (E.P.U.) 1.0
457 Compressor air/oil delivery temperature switch to electrical power unit (E.P.U.) 1.0
458 Brake pressure switch to warning lamp 1.0
600 Starter earth to E.S.O.S. 1.0
600A Starter earth to earth splice 3.0
600B Earth splice to front horn 2.0
600C Earth splice to transmission oil temperature switch 1.0
600E Earth splice to rear lights earth splice 2.0
600J Starter earth to cab earth splice 4.0
600K Starter earth to cab earth splice 4.0
600BG Earth splice to front washer pump 1.0
600BK Earth splice to rear washer pump 1.0
600BS Earth splice to forward solenoid 1.0
600BT Earth splice to reverse solenoid 1.0
600BU Earth splice to transmission oil pressure switch 1.0
600CC Earth splice to chassis junction box 1.0
600CE Earth splice to fuel sender 1.0
600CF Earth splice to engine air filter 1.0
600CJ Earth splice to hammer solenoid 1.0
600CK E.S.O.S. earth to water temperature switch 1.0
600DK Starter earth to cab earth splice 4.0
600EL Earth splice to rear horn 2.0
600EP Starter earth to earth splice 4.0
600ER Starter earth to earth splice 4.0
600EZ Earth splice to dump switch (loader) 1.0
600FK Starter earth to cab earth splice 4.0
600FL Earth splice to dump switch (gear) 1.0
600FP Earth splice to trailer earth splice 1.4
600GX Earth splice to compressor solenoid 1.0
600GL Earth splice to brake pressure switch 1.0
600GM Earth splice to compressor earth splice 1.0
600GN Earth splice to parkbrake solenoid 1.0
600HM Earth splice to hammer switch 1.0
805L LH indicator cab splice to LH rear indicator splice 1.0

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.

Mainframe Harness (2DX) (continued)

9803/7110 Issue 1
Section C Electrics Section C
8 - 11 Wire Number Identification 8 - 11

Wire No. Description Size (mm) Comments

806J RH indicator cab splice to RH rear indicator splice 1.0

811 Reverse splice to reverse solenoid 1.0
811A Reverse splice to reverse alarm/light 1.0
811B Reverse relay to reverse splice 1.0
812 Forward relay to forward solenoid 1.0
814 Front horn switch to front horn 2.0
816 Brake light switch to brake light splice 1.0
829B Cab splice to rear LH side light splice 1.0
830R Cab splice to rear RH side light splice 1.0
835 Fog light switch to fog light splice 1.0
839 Column switch to front washer pump 1.0
842 Neutral start relay to starter solenoid 2.0
843 Stabiliser lock relay to stabiliser lock solenoid splice 1.0
863 Rear wash wipe switch to rear washer pump 1.0
871 Rear horn switch to rear horn 2.0
899 Hammer relay coil to hammer switch 1.0
934 Dump relay coil to dump splice 1.0
934A Dump splice to dump switch (loader) 1.0
934B Dump splice to dump switch (gear) 1.0
936A Parkbrake switch to parkbrake solenoid 1.0
951 Compressor start relay to compressor switch 1.0
952A Compressor switch splice to feed splice 1.0
952B Compressor splice to compressor solenoid 1.0
952C Compressor splice to neutral lock relay 1.0
966 Hammer relay to hammer solenoid 1.0

Cab Panel Harness (2DX)

Wire No. Description Size (mm) Comments

001 Ignition switch to feed splice 4.0

001A Feed splice to ignition relay 1 coil 0.6
001K Feed splice to fuse B8 (heater) 3.0
001L Feed splice to ignition relay 2 coil 0.6
001M Feed splice to road lights relay coil 0.6
002 Ignition relay 1 to feed splice 4.0
002D Feed splice to fuse B6 (indicators) 1.4
002E Feed splice to fuse C2 (steer/compressor/stabiliser lock) 1.4
002F Feed splice to fuse B1 (junction box) 3.0
002J Feed splice to fuse B2 (E.S.O.S.) 1.0
002R Feed splice to fuse C3 (start) 1.0
003 Ignition switch to fuse C5 (thermostart) 2.0
003A Ignition switch (thermostart) link wire 2.0
004 Ignition switch to neutral start relay 2.0
004A Neutral start relay to neutral start relay coil 0.6
007 Ignition relay 1 to feed splice 4.0
007A Feed splice to brake light switch 1.0
007B Feed splice to fuse A9 (column switch) 2.0
007D Feed splice to fuse A2 (instrument panel/switch illumination) 1.4
007E Feed splice to fuse B9 (rear horn) 2.0
007F Feed splice to fuse A5 (rear wash wipe) 1.0
007G Feed splice to fuse B7 (parkbrake) 1.0
009 Road lights relay to feed splice 3.0
009A Feed splice to road lights switch 1.4
009C Feed splice to fuse C1 (rear work lights) 1.4
009D Feed splice to fuse B5 (front work lights) 1.4

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.
Cab Panel Harness (2DX) (continued)

9803/7110 Issue 1
Section C Electrics Section C
8 - 12 Wire Number Identification 8 - 12

Wire No. Description Size (mm) Comments

101 Fuse B1 to feed splice 3.0

101A Feed splice to chassis junction box 1.0
101AJ Feed splice to cab junction box 2.0
101S Feed splice to hammer relay 1.0
101AN Feed splice to hammer relay coil 0.6
102D Fuse B8 to heater switch 2.0
102E Fuse B8 to air conditioning relay 1.0
103 Fuse A5 to rear wash wipe switch 1.0
U-103F Rear wash wipe switch to rear wiper self park 1.0
104 Fuse B6 to hazard switch (indicator feed) 1.4
105 Shut down connector to E.S.O.S. 1.0
105A Fuse B2 to shut down connector 1.0
G-106 Feed splice to instrument panel 0.6
R-106B Feed splice to master warning lights 1.0
106C Feed splice to buzzer 1.0
106E Fuse A2 to feed splice 1.4
106F Feed splice to hazard switch illumination 0.6
106G Feed splice to rear horn switch illumination 0.6
106H Feed splice to rear wash/wipe switch illumination 0.6
106J Feed splice to fog light switch illumination 0.6
106K Feed splice to road lights switch illumination 0.6
106L Feed splice to front work light switch illumination 0.6
106M Feed splice to rear work light switch illumination 0.6
106N Feed splice to beacon switch illumination 0.6
106S Feed splice link 1.0
R-107A Fuse C2 to LH column switch (FWD/REV) 1.0
107M Fuse C2 to dump relay 1.0
107N Dump relay to dump relay coil 0.6
109 Fuse C2 to 2/4 wheel steer splice 1.4
109G Fuse C2 to compressor/stabiliser relay 1.0
109H Compressor/stabiliser relay to compressor/stabiliser relay coil 0.6
110 Fuse A9 to feed splice 2.0
B-110A Feed splice to RH column switch (flash feed) 1.0
RW-110B Feed splice to RH column switch (wash/wipe feed) 1.0
B-110J Feed splice to LH column switch (horn feed) 2.0
116 Fuse B5 to front work light switch 1.4
117 Fuse C1 to rear work light switch 1.4
118 Fuse B9 to rear horn switch 2.0
122 Fuse B7 to parkbrake switch 1.0
123 Fuse C5 to thermostart 2.0
200B Starter solenoid to ignition switch 4.0
200C Starter solenoid to ignition switch 4.0
200D Starter solenoid to ignition relay 1 4.0
200E Starter solenoid to road lights relay 3.0
200G Starter solenoid to fuse splice 4.0
200H Fuse splice to fuse A7 2.0
200J Fuse splice to fuse A6 1.4
200K Fuse splice to fuse A8 1.0
200M Starter solenoid to ignition relay 2 4.0
200N Feed splice to road lights switch 1.4
300 Fuse A6 to hazard switch 1.4
303A Beacon switch feed to interior light 1.0
303B Fuse A7 to beacon switch 2.0
Y-303C Fuse A7 to front wiper motor self park 1.0
304 Fuse A8 to radio cassette 1.0
BW-401 Instrument panel to park brake light relay 1.0
GB-402 Instrument panel to air filter warning splice 0.6
RB-402A Electrical power unit (E.P.U.) to air filter warning splice 0.6

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.
Cab Panel Harness (2DX) (continued)

9803/7110 Issue 1
Section C Electrics Section C
8 - 13 Wire Number Identification 8 - 13

Wire No. Description Size (mm) Comments

402B Air filter warning splice to air filter chassis splice 1.0
NW-403 Instrument panel to engine oil pressure warning splice 0.6
RU-403A Electrical power unit (E.P.U.) to engine oil pressure warning splice 0.6
403B Engine oil pressure warn splice to engine oil pressure switch 1.0
W-404 Instrument panel to transmission oil temperature warning splice 0.6
RN-404A Electrical power unit (E.P.U.) to transmission oil temperature warning splice 0.6
404B Transmission oil temperature warning splice to transmission oil temperature switch 1.0
NY-405 Instrument panel to transmission oil pressure warning splice 0.6
RG-405A Electrical power unit (E.P.U.) to transmission oil pressure warning splice 0.6
405B Transmission oil pressure warning splice to transmission oil pressure switch 1.0
GU-406 Instrument panel to water temperature warning splice 0.6
YR-406A Electrical power unit (E.P.U.) to water temperature warning splice 0.6
406B Water temperature warning splice to water temperature switch 1.0
BN-407 Alternator charge warning splice to instrument panel 0.6
YG-407A Alternator charge warn splice to electrical power unit (E.P.U.) 0.6
407B Alternator charge to alternator charge warning splice 1.0
GB-408 Fuel gauge to fuel sender 1.0
L-409 Water temperature gauge to water temperature sender 1.0
0-411 Instrument panel to buzzer 1.0
G-411A Buzzer to master warning lights 1.0
R-412 Alternator ‘W’ terminal to tachometer 1.0
0B-456 Electrical power unit (E.P.U.) to compressor air receiver temperature switch 1.0
OR-457 Electrical power unit (E.P.U.) to compressor air/oil delivery temperature switch 1.0
P-458 Instrument panel to brake pressure switch 1.0
600J Starter earth to earth splice 4.0
600K Starter earth to earth splice 4.0
600N Earth splice to fog light switch illumination 0.6
600P Earth splice to front work light switch illumination 0.6
600R Earth splice to radio cassette 1.0
600T Earth splice to instrument panel 0.6
600W Earth splice to ignition relay 1 coil 0.6
600AC Earth splice to forward relay coil 0.6
600AD Earth splice to reverse relay coil 0.6
600AK Earth splice to front wiper 1.0
600AL Earth splice to roof earth splice 2.0
600AM Earth splice to roof earth splice 2.0
600AZ Earth splice to RH front light combination 1.0
600BC Earth splice to LH front light combination 1.0
600BD Earth splice to rear wiper 1.0
600BE Earth splice to rear work light switch illumination 0.6
600BF Earth splice to parkbrake relay (normally closed - N/C) 1.0
600BL Earth splice to flasher unit 0.6
600BN Earth splice to parkbrake relay coil 0.6
600CZ Earth splice link 3.0
600DK Starter earth to earth splice 4.0
600DW Earth splice to road light switch illumination 0.6
600DX Earth splice to hazard switch illumination 0.6
600DY Earth splice to beacon switch illumination 0.6
600EF Earth splice to rear wash/wipe switch illumination 0.6
GY-600EK Earth splice to master warning lights 1.0
600FF Earth splice to ignition relay 2 coil 0.6
600FJ Earth splice to road lights relay coil 0.6
600FK Starter earth to earth splice 4.0
600FR Earth splice to parkbrake light relay coil 0.6
600FT Earth splice to cab junction box 2.0
600GP Earth splice to neutral interlock relay coil 0.6
600GR Earth splice to heater earth splice 2.0
600GS Earth splice to 2/4 wheel steer earth splice 1.4

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.
Cab Panel Harness (2DX) (continued)

9803/7110 Issue 1
Section C Electrics Section C
8 - 14 Wire Number Identification 8 - 14

Wire No. Description Size (mm) Comments

600GT Earth splice to rear horn switch illumination 0.6

600GW Earth splice to electrical power unit (E.P.U.) 0.6
601 Radio cassette to LH speaker (-VE) 1.0
602 Radio cassette to RH speaker (-VE) 1.0
802 Hazard switch to indicator flasher 1.4
803 Indicator flasher to hazard switch (hazard feed) 1.4
803A Indicator flasher to column switch (indicator feed) 1.0
B-804 Hazard switch to master warning lights 0.6
804A Hazard switch to hazard diode gate 1.0
805 Hazard switch to LH indicator splice 1.0
BW-805B LH indicator splice to RH column switch 1.0
G-805E LH indicator splice to LH front light combination 1.0
Y-805G LH Indicator splice to master warning lights 0.6
805L LH indicator splice to LH rear indicator splice 1.0
806 RH indicator splice to hazard diode gate 1.0
BG-806B RH indicator splice to RH column switch 1.0
G0806E RH indicator splice to RH front light combination 1.0
W-806H RH indicator splice to master warning lights 0.6
806J RH indicator splice to RH rear indicator splice 1.0
806K RH indicator splice to LH front light combination 1.0
WG-808 Forward/reverse switch to reverse relay coil 1.0
NY-809 Forward/reverse switch to forward relay coil 1.0
W-810 Column switch to parkbrake light relay coil 1.0
811B Reverse relay to reverse splice (chassis) 1.0
812 Forward relay to forward solenoid 1.0
B-814 Horn switch to front horn 2.0
816 Fuse A1 to brake lights splice (chassis) 1.0
YR-825A 2 wheel steer splice to instrument panel 0.6
P-825C 2 wheel steer splice to master warning lights 0.6
8250 Steer mode unit to 2 wheel steer splice 1.0
G-826A Steer mode unit to instrument panel 1.0
828 Side light splice to fuse A3 (LH sidelights) 1.0
828A Side light splice to fuse A4 (RH sidelights) 1.0
N-828E Side light splice to master warning lights 0.6
828H Road light switch to side light splice 1.0
RW-828J Side light splice to instrument panel 0.6
829B Fuse A3 to LH rear side light splice 1.0
N-829E Fuse A3 to front LH side light 1.0
R-830D Fuse A4 to front RH side light 1.0
830R Fuse A4 to RH rear side light splice 1.0
WB-832 Road light switch to dip/main beam switch 1.4
832A Road lights switch to fuse C4 (fog light) 1.0
Y-833 Dip/main beam switch to fuse B3 (dip beam) 1.4
Y-834A Fuse B3 to RH dip beam 1.0
Y-834B Fuse B3 to LH dip beam 1.0
835 Fog light switch to rear fog light 1.0
K-835C Fog light switch to master warning lights 0.6
W-836 Dip/main beam switch to fuse B4 (main beam) 1.4
837 Fuse B4 to main beam splice 1.4
N-837A Main beam splice to RH main beam 1.0
N-837B Main beam splice to LH main beam 1.0
U-8370 Main beam splice to master warning lights 0.6
S-839 RH column switch to front washer pump 1.0
840 RH column switch to front wiper motor 1.0
841 Front wiper motor (self park) to RH column switch 1.0
842 Neutral lock relay to starter solenoid 2.0
842A Neutral start relay to neutral lock relay 2.0

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.
Cab Panel Harness (2DX) (continued)

9803/7110 Issue 1
Section C Electrics Section C
8 - 15 Wire Number Identification 8 - 15

Wire No. Description Size (mm) Comments

843 (951) Compressor/stabiliser relay to compressor/stabiliser connector 1.0

855 Front work light switch to front work light splice 1.4
S-8550 Front work light switch to master warning lights 0.6
859 Radio cassette to LH speaker (+VE) 1.0
860 Radio cassette to RH speaker (+VE) 1.0
861 Rear work light switch to rear work light splice 1.4
0-861D Rear work light switch to master warning lights 0.6
Y-862 Rear wiper switch to rear wiper motor 1.0
863 Rear wash switch to rear wash pump 1.0
N-864 Rear wiper motor to rear wiper switch (self park) 1.0
868 Fuse C4 to fog light switch 1.0
871 Rear horn switch to rear horn 2.0
894 Beacon switch to beacon socket 1.4
899 Hammer relay coil to hammer switch 1.0
912 Dump relay to forward relay 1.0
912A Forward relay to reverse relay 1.0
933 Brake light switch to fuse A1 1.0
934 Dump relay coil to dump switch splice 1.0
936 Parkbrake switch to parkbrake relay 1.0
936A Parkbrake relay to parkbrake solenoid 1.0
937 Parkbrake relay to parkbrake light relay 1.0
843/951 Compressor/stabiliser relay to compressor/stabiliser connector 1.0
952C Compressor splice to interlock relay 1.0
966 Hammer relay to hammer solenoid 1.0
967 Parkbrake light relay to neutral start relay coil 0.6
967A Parkbrake light relay to compressor/stabiliser relay coil 0.6

—— Relay link wire 2.0

Cab Roof Harness (2DX)

Wire No. Description Size (mm) Comments

303A Fuse A7 to Interior light 1.0

600AL Panel Earth splice to roof earth splice 2.0
600AM Panel earth splice to roof earth splice 2.0
600AP Earth splice to front beacon socket 1.0
600AR Earth splice to front RH work light 1.0
600AS Earth splice to front LH work light 1.0
600AV Earth splice to rear LH work light 1.0
600AY Earth splice to rear RH work light 1.0
600EJ Earth Splice to interior light 1.0
600HL Earth Splice to rear beacon socket 1.0
601 Radio to LH speaker (-VE) 1.0
602 Radio to RH speaker (-VE) 1.0
855 Front work light switch to work light splice 1.4
855A Splice to front RH work light 1.0
855B Splice to front LH work light 1.0
859 Radio to LH speaker (+VE) 1.0
860 Radio to RH speaker (+VE) 1.0
861 Rear work light switch to work light splice 1.4
861A Splice to rear RH work light 1.0
861B Splice to rear LH work light 1.0
894 Beacon switch to splice 1.0
894B Beacon splice to front beacon socket 1.0
894C Beacon splice to rear beacon socket 1.0

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.
Heater Harness (2DX)

9803/7110 Issue 1
Section C Electrics Section C
8 - 16 Wire Number Identification 8 - 16

Wire No. Description Size (mm) Comments

102A Heater switch illumination link 1.0

102D Console connector to heater switch 2.0
600BH Earth splice to heater earth 2.0
600EB Earth splice to switch illumination 1.0
600GR Console connector to earth splice 2.0
800 Heater switch to heater resistor (slow) 1.0
800B Heater switch to heater resistor (fast) 2.0

Note : A suffix 'a' after a fuse number, e.g., A1a, identifies the feed side of the fuse. No suffix identifies the fused (protected)
side of a circuit.

9803/7110 Issue 1
Section D Controls Section D
i i

Contents Page No.

Machine Controls
Loader Control Knob
- Dismantling and Assembly 1-1

Steering Column
- Dismantling and Assembly 5-1

9803/7110 Issue 1
Section D Controls Section D
1-1 Machine Controls 1-1

Loader Control Knob

On machines fitted with a hydraulic speed control, the
loader control knob houses two microswitches; one
microswitch energises the transmission dump solenoid and
the other microswitch energises the remote unload valve
solenoid.

For clarity, only one microswitch is shown dismantled. Make

sure that all electrical connections are clearly labelled before
removing the microswitch. Remove and replace
microswitches one at a time.

Note: Machines not fitted with a remote unload valve will

only have one microswitch fitted in the loader control knob.

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 Dismantling

To gain access to the microswitch gently prise off top cover

1. Disconnect wiring harness 2, remove locknut 3 and
shakeproof washer. Microswitch 4, adapter 5, and rubber
cover 6 may now be withdrawn through the knob.

When Assembling

Apply JCB Lock and Seal to microswitch adapter 5 prior to

assembly.

Note: Microswitch 4 is a non-service item, and must be

replaced as an assembly.

9803/7110 Issue 1
Section D Controls Section D
5-1 Machine Controls 5-1

1
2
3

8 7
9
10 16
11
15 17
12
13 14
19
A
20

21

18

A230580

9803/7110 Issue 2*
 Section D Controls Section D
5-2 Machine Controls 5-2

* Steering Column
Dismantling and Assembly When Assembling

The numerical sequence shown on the illustration is Check that bearing 13 is flush with the end of bearing
intended as a guide to dismantling. support tube A. Achieve minimum end float (maximum
permissible 2.0 mm (0.08 in)) by selecting a groove in spacer
For assembly the sequence should be reversed. 10. Fit additional shims 11 as required.

Note: Bearing support tube A is integral with the machine Note: Tension pin 9 must be fitted offset so that one end
bodywork, and is not detachable. engages with the direction indicator automatic cancel
button.
When Dismantling
Apply JCB Lock & Seal to the threads of bolts 16 before
Remove the front console and the steering column cover to fitting.
gain access to the steering column. Note that the steering
wheel must be removed to allow removal of the steering Remove all dirt etc. from the splined socket of steering valve
column. 18 before fitting the column assembly.

There should be a gap of 0.5 to 1.5 mm (0.02 to 0.06 in)

between the splined shaft of the steering column and the
bottom of the socket in the steering valve. The shaft must
not touch the bottom of the splined socket.

Position tension pin 14 in a suitable groove in washer 15 to

achieve this gap.

9803/7110 Issue 2*
Section E Hydraulics Section E
i i

Contents Page No.

Technical Data
Hydraulics
- 2CX Machines to Serial Number 658960 1-1
- 2DX and 2CX Machines from Serial Number 658961 1-2
- 2CXU (212SU North American Only) 1-3
Steering
- 2CX Machines to Serial Number 658960 1-3
- 2DX and 2CX Machines from Serial Number 658961 1-3

Schematic Hydraulic Circuit

- 2CX Machines to Serial Number 658960 2-1
- 2DX and 2CX Machines from Serial Number 658961 to
763230 and from 481196 onwards 2-3
- 2CXL, 210SL, 2CX Farm Master 2-5
- 2CXU (212SU North America Only) 2-6

Machine Neutral Circuit

- 2CX Machines to Serial Number 658960 3-1
- 2DX and 2CX Machines from Serial Number 658961 3-3

Pump Operation 4-1

Loader Valve
Neutral Circuit 5-1
Load Hold Check Valves Operation 5-3
Arms Lower 5-5
Float 5-6
A.R.V. Operation 5-7

Main Relief Valve - Operation 6-1

Excavator Valve Neutral Circuit 7-1

Excavator Valve
Operation 7-3
Bi-Restrictor Operation 7-7
Slew Operation 7-9
Slew A.R.V. and Anti-Cavitation Operation 7 - 11
A.R.V. Operation 7 - 13
Pilot-operated A.R.V. Pressure Relief Operation 7 - 15

Steering Operation
Neutral 8-1
Left Turn 8-2
Right Turn 8-3
Right Turn, Unassisted 8-4
Shock Valve 8-5
Anti-cavitation Valve (if fitted) 8-6

Priority Valve Operation

Neutral 9-1
Turning 9-2

Charge/Priority Valve (Machines from serial

number 658961 to 763230 and 481196 to 489723 10 - 1
Charge/Priority Valve (Machines from serial
number 489724 10 - 2

9803/7110 Issue 7*
Section E Hydraulics Section E
ii ii

Contents Page No.

Pump/Priority Valve (Machines up to Serial Number 658960)
Pump Flow and Pressure Testing 20 - 1
Checking the Load Sensing Priority Valve 20 - 2
Removal and Replacement 20 - 3
Dismantling and Assembly (to 657447) 20 - 4
Dismantling and Assembly (from 657448) 21 - 1
Charge/Priority Valve (Machines from Serial Number 658961)
Pressure Testing 22 - 1
Removal and Replacement 22 - 2
Dismantling and Assembly 22 - 4

Main Pump (Machines from Serial No. 658961, inc. 2DX)

Pump Flow and Pressure testing 23 - 1
Removal and Replacement 23 - 2

Auxiliary Pump (2DX Machines)

Pump Flow and Pressure Testing 24 - 1
Removal and Replacement 24 - 2
Dismantling and Assembly 24 - 3

Valves
- 3 Point Hitch Removal & Replacement
- 2CXU (212SU North America Only) 29 - 1
Loader Valve - Dismantling/Assembly
- Standard and Shovel Spools 30 - 1
- Float Spool 30 - 3
- M.R.V. & A.R.V.'s 30 - 5
- Electric Detent Spool 30 - 6

Pressure Testing - M.R.V. - In Position 31 - 1

Pressure Testing - A.R.V. - Using Hand Pump 32 - 1

Excavator Valve (2CX Machines)

- Dismantling/Assembly 33 - 1
- A.R.V. - Dismantling/Assembly 33 - 3
- Hydraclamp - Dismantling/Assembly 33 - 5

Excavator Valve (2DX Machines) 34 - 1

Dismantling and Assembly 34 - 3
ARV’s - Dismantling and Assembly 34 - 3
Hydraclamp Valve - Dismantling and Assembly 34 - 4

Hydraulic Steering Unit

- Dismantling and Assembly 35 - 1

9803/7110 Issue 6
Section E Hydraulics Section E
iii iii

Contents Page No.

Steering System - Anti-cavitation Valve
- Removal and Replacement 36 - 1
- Dismantling and Assembly 36 - 2
- System Bleeding 36 - 3

Steer Selector Valve 2CXU (212SU North America Only)

- Removal and Replacement 37 - 1
- Dismantling and Assembly 37 - 1

Steer System Bleeding

- Initial System Bleeding 40 - 1
- Anti-cavitation Valve 40 - 2
- 2CXU (212SU North America Only) 40 - 3

3 Point Hitch
Rams - Removal and Replacement 45 - 1

Rams
Typical Ram - Dismantling and Assembly 50 - 1
Slew Ram - Dismantling and Assembly 50 - 4
JCB Ram Sealing Procedure 55 - 1

9803/7110 Issue 1
 Section E Hydraulics Section E
1-1 Technical Data 1-1

* Hydraulics (2CX Machines to Serial Number 658960)

Hydraulic Pump (to machine serial number 657447)

Model/Reference Single-Priority/3939
Rotation Clockwise
Mounting Engine Timing Case (with adapter)
Flow at 2000 rev/min and system pressure litres/min UK gal/min US gal/min
58 12.76 15.32
Hydraulic Pump (from machine serial number 657448)

Model/Reference Single-Priority/4506
Rotation Clockwise
Mounting Engine Timing Case (direct - no adapter required)
Flow at 2000 rev/min and system pressure litres/min UK gal/min US gal/min
58 12.76 15.32

Relief Valve Operating Pressures bar kgf/cm2 lbf/in2

Main Relief Valve (M.R.V.) 220 225 3200

Auxiliary Relief Valves (A.R.V.)

Loader
Shovel Ram Head Side (pilot-operated) 241 246 3500
Shovel Ram Rod Side (pilot-operated) 277.7 281 4000
Auxiliary Ram Head Side (direct acting) 241 246 3500
Auxiliary Ram Rod Side (direct acting) 241 246 3500
Excavator
Slew Ram (pilot-operated) 241 246 3500
Boom Ram Head Side (pilot-operated) 241 246 3500
Boom Ram Rod Side (direct acting) 262 267 3800
Dipper Ram Head Side (pilot-operated) 241 246 3500
Dipper Ram Rod Side (direct acting) 241 246 3500
Bucket Ram Head Side (direct acting) 241 246 3500
Hammer 241 246 3500
Hydraulic Tool Circuit (HTC) 138 141 2000

Return Line Filter bar kgf/cm2 lbf/in2

By-pass pressure 1.72 1.76 25

Ram Torque Settings Nm kgf m lbf ft

Piston Head
Lift Rams 405 41.5 300
Shovel Rams 405 41.5 300
Slew Rams 405 41.5 300
Boom Ram 405 41.5 300
Stabiliser Rams 405 41.5 300
Dipper Ram 405 41.5 300
Bucket Ram 405 41.5 300
Clam Shovel Ram 405 41.5 300
End Cap
Lift Rams 678 69.2 500
Shovel Rams 678 69.2 500
Slew Rams 678 69.2 500
Boom Ram 678 69.2 500
Stabiliser Rams 678 69.2 500
Dipper Ram 678 69.2 500
Bucket Ram 678 69.2 500
Clam Shovel Ram 450 45.9 332

9803/7110 Issue 4*
Section E Hydraulics Section E
1-2 Technical Data 1-2

Hydraulics (2DX and 2CX Machines From 658961)

Main Hydraulic Pump

Model/Reference Single/5910P
Rotation Clockwise
Mounting Engine Timing Case (with adapter)
Flow at 2000 rev/min and system pressure litres/min UK gal/min US gal/min
58 12.76 15.32
Auxiliary Hydraulic Pump (2DX only)

Model/Reference Single/4240J
Rotation Anti-Clockwise
Mounting Auxiliary Take-Off
Flow at 2000 rev/min and system pressure litres/min UK gal/min US gal/min
28 6.16 7.39

Relief Valve Operating Pressures (2DX)

Note: Relief valve settings for the 2CX range of machines remain as shown on page 1 - 1.

bar kgf/cm2 lbf/in2

Main Relief Valve (M.R.V.) 240 246 3500

Auxiliary Relief Valves (A.R.V.)

Loader
Shovel Ram Head Side (pilot-operated) 241 246 3500
Shovel Ram Rod Side (pilot-operated) 277.7 281 4000
Auxiliary Ram Head Side (direct acting) 241 246 3500
Auxiliary Ram Rod Side (direct acting) 241 246 3500
Excavator
Slew Ram (Head Side) 262 267 3800
Slew Ram (Rod Side) 262 267 3800
Boom Ram Head Side 248 253 3600
Boom Ram Rod Side 316 267 4495
Dipper Ram Head Side 248 253 3600
Dipper Ram Rod Side 248 253 3600
Bucket Ram Head Side 248 253 3600
Hydraulic Tool Circuit (HTC) (When Fitted) 138 141 2000

Return Line Filter bar kgf/cm2 lbf/in2

By-pass pressure 1.72 1.76 25

Ram Torque Settings Nm kgf m lbf ft

Piston Head
Lift Rams 405 41.5 300
Shovel Rams 405 41.5 300
Slew Rams 405 41.5 300
Boom Ram 405 41.5 300
Stabiliser Rams 405 41.5 300
Dipper Ram 405 41.5 300
Bucket Ram 405 41.5 300
Clam Shovel Ram 405 41.5 300
End Cap
Lift Rams 678 69.2 500
Shovel Rams 678 69.2 500
Slew Rams 678 69.2 500
Boom Ram 678 69.2 500
Stabiliser Rams 678 69.2 500
Dipper Ram 678 69.2 500
Bucket Ram 678 69.2 500
Clam Shovel Ram 450 45.9 332

9803/7110 Issue 3
 Section E Hydraulics Section E
1-3 Technical Data 1-3

Hydraulics (2CXU & 212SU North American Only)

Relief Valve Operating Pressures

* Note: Relief valve settings for the Loader valve block are the same as 2CX shown on page 1 - 1. It is permissible to adjust the
212S and variants main relief valve (MRV) to 240 bar (3500 lbf/in2, 246 kgf/cm2.

3 Point Hitch bar kgf/cm2 lbf/in2

Lift Cylinder (Rod Side) 69 70.33 1000
Tilt Cylinder (Head Side) 69 70.33 1000

Steering (2CX Machines to Serial Number 658960)

System Type Full power hydrostatic

Pump (See 1 - 1)
Steering Unit OSPCLS
Priority Valve Integral with pump

Operation Pressures bar kgf/cm2 lbf/in2

Relief Valve Operating Pressure 139 142 2000
Shock Valve Operating Pressure 193 197 2800
Anti-cavitation Valve - 2CX Farm Master m/c’s only 20 20.4 290
(optional on 2CXL, 210SL m/c’s)

Steer Ram Torque Settings Nm kgf m lbf ft

Piston Head 300 30.6 221
End Cap 450 45.9 332

Steering (2DX and 2CX Machines From 658961)

System Type Full power hydrostatic

Pump (See 1 - 2)
Steering Unit OSPCLS
Priority Valve Integral with brakes charge valve

Operation Pressures bar kgf/cm2 lbf/in2

Relief Valve Operating Pressure 139 142 2000
Shock Valve Operating Pressure 193 197 2800
Anti-cavitation Valve 20 20.4 290

Steer Ram Torque Settings Nm kgf m lbf ft

Piston Head 300 30.6 221
End Cap 450 45.9 332

Brakes Charge/Steering/Priority Valve

Brake Circuit Operating Pressures
Cut-in 90 bar (1305 lbf/in2)
Cut-out 110 bar (1595 lbf/in2)

9803/7110 Issue 4*
Section E Hydraulics Section E
2-1 Hydraulic Schematic 2-1

2CX Machines up to 658960

Component Key Rams

1 Tank 22 Shovel Ram R.H.

2 Pump and Priority Valve 23 Shovel Ram L.H.
3 Loader Valve block (2 or 3 Spool) 24 Lift Ram R.H.
3A Loader Shovel Ram Spool 25 Lift Ram L.H.
3B Loader Lift Ram Spool with Float 26 Hydraclamps
3C Auxiliary /Quick Hitch Ram Spool 27 Stabiliser Rams
3D Main Relief Valve 28 Slew Rams
3E Shovel Ram Head Side A.R.V. 29 Boom Ram
3F Shovel Ram Rod Side A.R.V. 30 Dipper Ram
3G Auxiliary /Quick Hitch Ram Head Side A.R.V. 31 Bucket Ram
3H Auxiliary /Quick Hitch Ram Rod Side A.R.V. 32 Rockbreaker
3J Load Hold Check Valves 33 Extending Dipper
4 Excavator Valve Block (6 or 7 Spool)
4A Slew Spool Note 1: Excavator services shown here are to the JCB 'X'
4B Boom Spool control pattern. For ISO '+' control pattern, components 4B,
4C Stabiliser Spool 4L and 4K swap positions with items 4E, 4M and 4N
4D Stabiliser Spool respectively.
4E Dipper Spool
4F Bucket Spool Note 2: Blanking plug 4V is used when only the hammer
4G Hydraclamp Valve circuit is installed (the hammer return line goes straight back
4H Slew A.R.V. to the hydraulic tank).
4J Slew A.R.V.
4K Boom Ram Head Side A.R.V.
4L Boom Ram Rod Side A.R.V.
4M Dipper Ram Rod Side A.R.V.
4N Dipper Ram Head Side A.R.V.
4P Bucket Ram Head Side A.R.V.
4R Bucket Ram Rod Side A.R.V.
4S Auxiliary /Breaker Spool
4T Auxiliary/ Breaker Ram Head Side A.R.V.
4U Auxiliary Ram A.R.V. (Not used with Rockbreaker)
4V Blanking Plug (see note 2)
4W Load Hold Check Valves
5 Suction Strainer
6 Filter
6A Filter By-pass Valve
7 Cooler
8 Pressure Test Connectors
9 Steer Valve
9A Steer Relief Valve
9B Steer Shock Valves
10 Steering Alignment Valve
11 Auxiliary Attachment Quick Release Couplings
12 Rockbreaker Quick Release Couplings
13 Brakes Charge Valve
14 Accumulators
15 Brake Valve
16 Pressure Warning Switch
17 Front Brakes
18 Rear Brakes
19 Bi-restrictor
20 Hydraulic Quickhitch
21 Quickhitch Locking Tap

9803/7110 Issue 2*
Section E Hydraulics Hydraulics Section E
2-2 Hydraulic Schematic Hydraulic Schematic 2-2

2CX Machines up to 658960

20
26
11 27

21
1 4
4W
5 4A 4H
10
19 28
22
R L
19
9B 3
2 4W
4B 4J
4L
7
3A 19

24 3E 3F 4W
8
3J 4C 4K
6 LS
9

6A 9A 4W 30 31
P T 4D
3B
29

3J 4E 4W
4N

13 3C 19
15 17 25 4W
4F 4M
3G 3H 4R
3J
3D

16 18 4W
14
23 4P 27
8 4S 4T
14
8 12
12 32
4V
4U 1

4G
33
12

A210610

9803/7110 Issue 6
Section E Hydraulics Section E
2-3 Hydraulic Schematic 2-3

26
27
10

R L

1 9B 4
8
5 20 4W
2A 4A 4H
36 35
19 28
22 21
11
19
3
LS 4W
9 4B 4J
4L
7
2 9A 3A 19
P T
8
24 3E 3F 4W
G1 S 13 3J 4C 4K
6

6A 4W 30 31
4D
3B
G2 16 29

3J 4E 4W
4N
EF P T LS A1 A2

3C 19
25 4W
15 4F 4M
3G 3H
8
17 3J
3D
14

23 4P 27
14
18
4G
8 34

33A
33
33B

12 32

A228730

9803/7110 Issue 3
 Section E Hydraulics Section E
2-4 Hydraulic Schematic 2-4

* 2CX & 2DX Machines from 658961 to

763230 and from 481196 onwards
* Note: For 2CX brake circuit from machine serial number Rams
489724 see page E/10-2.
22 Shovel Ram R.H.
Component Key 23 Shovel Ram L.H.
24 Lift Ram R.H.
1 Tank 25 Lift Ram L.H.
2 Main Pump 26 Hydraclamps
2A Auxiliary Pump 27 Stabiliser Rams
3 Loader Valve block (2 or 3 Spool) 28 Slew Rams
3A Loader Shovel Ram Spool 29 Boom Ram
3B Loader Lift Ram Spool with Float 30 Dipper Ram
3C Auxiliary /Quick Hitch Ram Spool 31 Bucket Ram
3D Main Relief Valve 32 Rockbreaker
3E Shovel Ram Head Side A.R.V. 33 Breaker Valve
3F Shovel Ram Rod Side A.R.V. 33A Solenoid
3G Auxiliary /Quick Hitch Ram Head Side A.R.V. 33B Check Valve
3H Auxiliary /Quick Hitch Ram Rod Side A.R.V. 34 Check Valve
3J Load Hold Check Valves 35 Front Steer Ram
4 Excavator Valve Block (6 or 7 Spool) 36 Rear Steer Ram
4A Slew Spool
4B Boom Spool Note: Excavator services shown here are to the JCB 'X'
4C Stabiliser Spool control pattern. For ISO '+' control pattern, components 4B,
4D Stabiliser Spool 4L and 4K swap positions with items 4E, 4M and 4N
4E Dipper Spool respectively.
4F Bucket Spool
4G Hydraclamp Valve
4H Slew A.R.V.
4J Slew A.R.V.
4K Boom Ram Head Side A.R.V.
4L Boom Ram Rod Side A.R.V.
4M Dipper Ram Rod Side A.R.V.
4N Dipper Ram Head Side A.R.V.
4P Bucket Ram Head Side A.R.V.
4W Load Hold Check Valves
5 Suction Strainer
6 Filter
6A Filter By-pass Valve
7 Cooler
8 Pressure Test Connectors
9 Steer Valve
9A Steer Relief Valve
9B Steer Shock Valves
10 Steering Alignment Valve
11 Auxiliary Attachment Quick Release Couplings
12 Rockbreaker Quick Release Couplings
13 Brakes Charge/Priority Valve
14 Accumulators
15 Brake Valve
16 Pressure Warning Switch
17 Front Brakes
18 Rear Brakes
19 Bi-restrictor
20 Hydraulic Quickhitch
21 Quickhitch Locking Tap

9803/7110 Issue 3*
Section E Hydraulics Section E
2-5 Hydraulic Schematic 2-5

Schematic Hydraulic Circuit - 2CXL,

210SL, 2CX Farm Master
8 Pressure Test Connectors
Component Key 9 Steer Valve
1 Tank 9A Steer Relief Valve
2 Pump and Priority Valve 9B Steer Shock Valves
3 Loader Valve block (2 or 3 Spool) 10 Steering Alignment Valve
3A Loader Shovel Ram Spool 11 Auxiliary Attachment Quick Release Couplings
3B Loader Lift Ram Spool with Float 13 Brakes Charge Valve
3C Auxiliary /Quick Hitch Ram Spool 14 Accumulators
3D Main Relief Valve 15 Brake Valve
3E Shovel Ram Head Side A.R.V. 16 Pressure Warning Switch
3F Shovel Ram Rod Side A.R.V. 17 Front Brakes
3G Auxiliary /Quick Hitch Ram Head Side A.R.V. 18 Rear Brakes
3H Auxiliary /Quick Hitch Ram Rod Side A.R.V. 20 Hydraulic Quickhitch
3J Load Hold Check Valves 21 Quickhitch Locking Tap
5 Suction Strainer 22 Shovel Ram R.H.
6 Filter 23 Shovel Ram L.H.
6A Filter By-pass Valve 24 Lift Ram R.H.
7 Cooler 25 Lift Ram L.H.
40 Anti-cavitation Valve

40
V C
20

P 21

5
10
11
1
22
R L

9B 3
2
7
3A

24 3E 3F
8
3J
6 LS
9

6A 9A
P T
3B

3J

13 3C
15 17 25
3G 3H
3J
3D

16 18
14
23
8
14
8

A221000

9803/7110 Issue 1
 Section E Hydraulics Section E
2-6 Hydraulic Schematic 2-6

* 2CXU (212SU North America Only)

29
4A
4E

4G
28 4B

4G
27
4F 4C

40 4G
V C 26
4D
P

10 4G

31 32
5 30
1
22
L R

9B 3
2
7
3A

24 3E 3F
8
3J
6 LS
9

6A 9A
P T
3B

3J

13 3C
15 17 25
3G 3H
3J
3D

16 18
14
23
8
14
8

11

20 21

A300810

9803/7110 Issue 2*
 Section E Hydraulics Section E
2-7 2-7

* 2CXU (212SU North America Only)

Component Key
1 Tank
2 Pump and Priority Valve
3 Loader Valve block (2 or 3 Spool)
3A Loader Shovel Ram Spool
3B Loader Lift Ram Spool with Float
3C Auxiliary /Quick Hitch Ram Spool
3D Main Relief Valve
3E Shovel Ram Head Side A.R.V.
3F Shovel Ram Rod Side A.R.V.
3G Auxiliary /Quick Hitch Ram Head Side A.R.V.
3H Auxiliary /Quick Hitch Ram Rod Side A.R.V.
3J Load Hold Check Valves
4 3 Point Hitch Valve Block
4A Lift/Lower/Float Spool
4B Pitch Spool
4C Tilt Spool
4D Auxiliary Spool
4E Lift ARV
4F Tilt ARV
4G Load Hold Check Valves
5 Suction Strainer
6 Filter
6A Filter By-pass Valve
7 Cooler
8 Pressure Test Connectors
9 Steer Valve
9A Steer Relief Valve
9B Steer Shock Valves
10 Steering Alignment Valve
11 Auxiliary Attachment Quick Release Couplings
13 Brakes Charge Valve
14 Accumulators
15 Brake Valve
16 Pressure Warning Switch
17 Front Brakes
18 Rear Brakes
20 Hydraulic Quickhitch
21 Quickhitch Locking Tap
22 Shovel Ram R.H.
23 Shovel Ram L.H.
24 Lift Ram R.H.
25 Lift Ram L.H.
26 Auxiliary Cylinder
27 Tilt Cylinder
28 Pitch Cylinder
29 Lift Cylinder
30 2/4 Wheel Steer Selector Valve
31 Front Steer Cylinder
32 Rear Steer Cylinder
40 Anti-cavitation Valve

9803/7110 Issue 2*
Section E Hydraulics Section E
3-1 Descriptions 3-1
9808/9053
9803/7110 Issue 1
 * Machine Neutral Circuit - (2CX
9803/7110

3-2

Section E
Machines to Serial Number 658960)
Oil is drawn through suction strainer 5 from From the loader valve neutral gallery, oil flows via a Exhaust oil from the excavator and loader valves
hydraulic tank T by the engine-driven hydraulic high pressure carry-over line to the excavator valve flows back to the tank through an in-line filter 6 and
pump/priority valve unit P. From the pump, oil flows 4. a cooler 7. An integral pressure test connector 8 is
to the steering circuit and/or the loader valve block located between the hydraulic pump and the
3 by way of the priority valve which always gives priority valve in unit P.
priority to the steering circuit requirements.

Hydraulics
Descriptions

Section E
Issue 2*

3-2
Section E Hydraulics Section E
3-3 Descriptions 3-3
S300700
13
4

T
P
LS
T

EF
5
3
2A

2
6

7
9803/7110 Issue 2
9803/7110

Machine Neutral Circuit - (2CX and

3-4

Section E
2DX Machines from Serial Number
658961)
Oil is drawn through suction strainer 5 from From the loader valve neutral gallery, oil flows via a Exhaust oil from the excavator and loader valves
hydraulic tank T by the engine-driven hydraulic high pressure carry-over line to the excavator valve flows back to the tank through an in-line filter 6 and
pump 2. From the pump, oil flows to the steering 4. a cooler 7.
circuit and/or the loader valve block 3 by way of the
brake accumulator charge/steering priority valve 2DX Machines Only
13.
On these machines an additional pump 2A draws
oil from tank T to supply an additional flow to the
excavator valve 4. (Note that 2DX machines have a
monoblock excavator valve, while on other
machines the excavator valve is of sectional
construction.)

Hydraulics
Descriptions

Section E
Issue 1

3-4
9803/7110

Pump Operation

4-1

Section E
The pump is a gear type. The working principle of
such a pump depends on the meshing of the two
spur gears A and B. Oil is picked up on the suction
side of the pump by the gears and carried round
between the gear teeth and the pump body. As the
gears come into mesh the oil is forced through an
internal port into the integral priority valve.

Lubrication is provided by the hydraulic oil which is

directed around the unit, via special oil ways, by the
9808/9054 motion of the meshing gears.

Hydraulics
Descriptions

Section E
Issue 1

4-1
Section E Hydraulics Section E
5-1 Descriptions 5-1
9808/9055
9803/7110 Issue 1
9803/7110

Loader Valve Neutral Circuit

5-2

Section E
Oil from the pump enters the loader valve at 1A.
When all the spools are in neutral as shown, the oil
passes around the waisted central portions of the
spools and flows on to feed the excavator valve via
high pressure carry over line 1B.

Oil also fills the parallel gallery X.

The exhaust gallery is connected to the tank return

line via port T.

Component Key

3 Loader Valve Block

3A Shovel Ram Spool
3B LIft Ram Spool
3C Auxiliary Spool
3D Main Relief Valve

Hydraulics
Descriptions

Section E
Issue 1

5-2
9803/7110

Loader Valve - Load Hold Check

5-3

Section E
Valves
Operation 1

The illustration shows 'arms raise' being selected This pressure differential causes load hold check
by the lift ram spool 3B. valve 3H to close, thus preventing the load from
dropping.
The weight of the loaded shovel, as indicated by
the arrows, produces a higher pressure in service
line Y than in the parallel gallery X.

Hydraulics
Descriptions

Section E
Issue 1

5-3
9808/9013
9803/7110

Loader Valve - Load Hold Check

5-4

Section E
Valves
Operation 2

As the neutral circuit has been blocked by the At this point, load hold check valve 3H opens,
central lands of the selected spool 3B, the pressure allowing oil to flow from the parallel gallery into the
in parallel gallery X increases until it is greater than service line and operate the lift rams 24 and 25.
that in service line Y.

Hydraulics
Descriptions

Section E
9808/9014
Issue 1

5-4
9803/7110

Loader Valve

5-5

Section E
Arms Lower

When a spool is selected as shown at 3B, the spool D, opens the load hold check valves 3H and The upper land of the selected spool E blocks the
central lands of the spool C block the neutral 3G (not illustrated), and out to the rod side of lift flow from the parallel gallery to the head side port
circuit. Oil from the pump, entering at 1A, is rams 24 and 25. and oil returning from the rams is diverted into the
diverted into the parallel gallery X, flows around the exhaust gallery.
waisted section of the

Hydraulics
Descriptions

Section E
9808/9011
Issue 1

5-5
9803/7110

Loader Valve

5-6

Section E
Float

The float facility is provided to allow the arms to This is achieved by moving the lift spool 3B up Oil can then be displaced from either end of the lift
move up and down so that the shovel can follow beyond 'arms lower' into the 'float' detent, when rams 24 and 25 into the exhaust gallery, allowing
the surface contours as the machine is driven over the feed from the parallel gallery to the service the rams to open and close as required.
uneven ground. ports is blocked and the neutral circuit is re-
opened. Both service ports are connected to
exhaust via the spool waists A.

Hydraulics
Descriptions

Section E
9808/9012
Issue 1

5-6
Section E Hydraulics Section E
5-7 Descriptions 5-7
9808/9056
9803/7110 Issue 1
9803/7110

Loader Valve - A.R.V. Operation

5-8

Section E
Under normal operating conditions, with the shovel As the arms continue to rise, the back pressure
in the 'carry' position, the mechanical linkage keeps increases until it reaches the setting of A.R.V. 3E.
the shovel level as the arms are raised, to prevent This A.R.V. then opens, allowing the excess back
spillage of the load. pressure to be dumped to exhaust and prevent the
rams and linkage from being damaged.
If, as illustrated, the shovel is fully tipped when the
arms are being raised, the shovel is unable to tip The rod side A.R.V. 3F senses a higher pressure in
further, producing back pressure in the head side of the exhaust gallery than in the service port and
the shovel rams 22 and 23 and cavitation in the rod therefore opens to allow exhaust oil to overcome
side. the cavitation.

Hydraulics
Descriptions

Section E
Issue 1

5-8
Section E Hydraulics Section E
6-1 Descriptions 6-1
9808/9018
9803/7110 Issue 1
9803/7110

Main Relief Valve - Operation

6-2

Section E
The main relief valve (M.R.V.) 3D, situated in the View X. As service pressure reaches the pilot View Y. As service pressure continues to rise and
loader valve block, provides control of both loader setting of the valve, pilot poppet A lifts, allowing oil oil escapes from cavity E, the pressure differential
and excavator pressures. to escape into cavity B and pass down the sides of between the upper and lower surfaces of piston F
sleeve C into the exhaust gallery D. causes this piston to rise and seat on the point of
The illustration shows a loader service selected by pilot poppet A.
spool 3B causing pressure to rise in the service
line. In the main view the service is operating under Oil continues to escape from cavity E but the
light load and the pressure is not sufficient to cause incoming flow to the cavity has been cut off. This
any response in the M.R.V. produces a pressure drop above poppet G, causing
the poppet to lift and release service pressure into
exhaust gallery D.

Hydraulics
Descriptions

Section E
Issue 1

6-2
Section E Hydraulics Section E
7-1 Descriptions 7-1
9803/7110 Issue 1
9803/7110

* Excavator Valve Neutral Circuit - * Excavator Valve Neutral Circuit - *

7-2

Section E
2CX Machines 2DX Machines
Oil from the loader valve enters the excavator valve Note: The illustrations shown on page E/7 - 1 are
at A and flows through the neutral gallery and for the 2CX range of machines. The illustrations
around the waists of the solid spools. It also fills the below show the mono-block valve construction
parallel gallery X but is not at a high enough fitted to the 2DX machine.
pressure to open the load hold check valves B.
Oil flow details are as 2CX but component
Component Key (JCB 'X' Control Pattern) locations are as shown below. X
4A Slew Spool The following pages E/7 - 3 to E/7 - 14 show a 2CX
4B Boom Spool machine valve section, principle of operation is the
4C Stabiliser Spool same for the mono-block valve fitted to the 2DX
4D Stabiliser Spool machine.
4E Dipper Spool
4F Bucket Spool B
Note: Machines with ISO control pattern have the
boom and dipper spools interchanged.
4F 4E 4D 4C 4B 4A

Hydraulics
Descriptions
A230600

Section E
Issue 2*

A230590

7-2
Section E Hydraulics Section E
7-3 Descriptions 7-3
9803/7110 Issue 1
9803/7110

Excavator Valve - Operation 1

7-4

Section E
Flow to the service via a typical solid spool 4B is
controlled by the load hold check valve 4S which is
a spring-loaded non-return valve operating across
the pressure feed from the parallel gallery X.The
valve prevents reverse flow from the rams into the
pressure feed line, so maintaining ram pressure
until exceeded by system pressure. The illustration
shows a service selected but back pressure Y
exceeds system pressure which closes the load
hold check valve 4S.

Hydraulics
Descriptions

Section E
Issue 1

7-4
Section E Hydraulics Section E
7-5 Descriptions 7-5
9803/7110 Issue 1
9803/7110

Excavator Valve - Operation 2

7-6

Section E
When pressure in the feed line exceeds back
pressure, the load check valve 4S opens and oil
operates the ram. The remaining load hold check
valves are also opened by system pressure but the
galleries are dead-ended because the spools are in
neutral.

Hydraulics
Descriptions

Section E
Issue 1

7-6
Section E Hydraulics Section E
7-7 Descriptions 7-7
9803/7110 Issue 1
9803/7110

* Excavator Valve - Bi-Restrictor

7-8

Section E
Operation (2CX machines only)
Because of its weight, the excavator end could take
over control when boom lower was selected. The
falling boom would tend to push oil out of the ram
faster than the head side was being filled.
Consequently, when the excavator had reached the
ground, there would be a time lapse while the ram
filled with oil before the service would operate
again.

To prevent this from happening, the boom service

is fitted with bi-restrictor E.

Hydraulics
Descriptions

Section E
Issue 2*

7-8
Section E Hydraulics Section E
7-9 Descriptions 7-9
9803/7110 Issue 1
9803/7110

Excavator Valve - Slew Operation * Slew Ram End Damping

7 - 10

Section E
The illustration shows R.H. slew selected. The As ram A nears the closed position, damping rod B
lower port C has been pressurised by the spool. Oil seats in cone C, where it is held by spring D.
flows from the parallel gallery X, out past A.R.V. 4J Tapered flutes on the end of the rod produce a
to both the head side of the L.H. slew ram and the restricting orifice, thus restricting the speed of the
rod side of the R.H. slew ram. The boom therefore oil being exhausted from the ram. This provides a
slews to the right hand side of the machine. cushioning effect between the piston and the dump
Displaced oil from the rod side of the L.H. slew ram end of the ram, effectively damping out the shock
and from the head side of the R.H. slew ram flows loads which would otherwise occur when the boom
back through the upper service port D and back to reaches the end of its slewing arc.
tank.

* Note: The above description applies to 2CX and

2DX machines. For pictorial details of 2DX spool
arrangement, see page 7 - 2.

Hydraulics
Descriptions
D
A

s
w

C A230420

Section E
7 - 10
Issue 2*
Section E Hydraulics Section E
7 - 11 Descriptions 7 - 11
9803/7110 Issue 1
9803/7110

Excavator Valve - Slew A.R.V. and

7 - 12

Section E
Anti-Cavitation Operation
The spool 4A is in neutral but the momentum of the
slewing excavator end creates back pressure in the
head side of the R.H. slew cylinder and in the rod
side of the L.H. slew cylinder. This opens A.R.V.
4H and dumps oil to exhaust. At this point the
cylinders cavitate and exhaust oil pressure causes
A.R.V. 4J to open, allowing oil from the exhaust
gallery to fill the L.H. cylinder.

Hydraulics
Descriptions

Section E
7 - 12
Issue 1
Section E Hydraulics Section E
7 - 13 Descriptions 7 - 13
9803/7110 Issue 1
9803/7110

Excavator Valve - A.R.V. Operation

7 - 14

Section E
The illustration shows the bucket spool 4F selected When this pressure reaches the setting of A.R.V. See page 7-15 for detailed description of the pilot-
to operate the service against an immovable object. 4N, this valve opens, relieving the pressure into the operated A.R.V. pressure relief operations.
This forces the dipper away from the obstruction exhaust gallery. Cavitation occurs in the rod side of
and pressurises the head side of the dipper ram. the dipper service.

Hydraulics
Descriptions

Section E
7 - 14
Issue 1
Section E Hydraulics Section E
7 - 15 Descriptions 7 - 15
9803/7110 Issue 1
9803/7110

Excavator Valve - Pilot-Operated

7 - 16

Section E
A.R.V. Pressure Relief Operation
1 Valve at Rest 2 Pilot Valve Opens 3 Main Poppet Opens

A.R.V's are positioned in the excavator valve block As service pressure reaches the pilot setting of the As service pressure continues to rise and oil
in order to relieve excessive pressure in the valve, pilot poppet E lifts, allowing oil to escape into escapes from cavity L, the pressure differential
services as shown on page E-7-13. cavity H and pass down the sides of sleeve J into between the upper and lower surfaces of piston C
the exhaust gallery K. causes this piston to rise and seat on the point of
When the service is in neutral and there are no pilot poppet E.
excessive forces acting on the equipment, service
pressure at A will be acting on the lower face of Oil continues to escape from cavity L but the
poppet B and will also be felt inside the valve via incoming flow to the cavity has been cut off. This
hollow piston C. produces a pressure drop above poppet B, causing
the poppet to lift and release service pressure into
The force of springs D and F, combined with the exhaust gallery K.
service pressure acting on the upper faces of
poppet B and piston C, keeps poppets B and E
tightly seated.

Hydraulics
The force of spring F is adjustable to suit the

Descriptions
relevant service by means of adjuster screw and
locknut G.

Section E
7 - 16
Issue 1
9803/7110

Steering Operation 1 - Neutral

8-1

Section E
Flow from the priority valve enters the steering unit
through the bottom right hand port past the non-
return valve 43C. When the steering wheel is
stationary the inner spool A and sleeve B are held
in the neutral position by the centring springs K. As
the unit is 'closed centre' the flow from the pump is
dead ended by the steering unit.

Hydraulics
Descriptions

Section E
Issue 1

8-1
9803/7110

Steering Operation 2 - Left Turn

8-2

Section E
The illustration shows the flow through the steering The relative movement between A and B directs The rotor lobes pump the oil out to the head side of
unit in a left hand turn condition. Turning the pressure oil through 6 of the 12 holes in the bottom rear steering ram 41 turning the rear wheels to the
steering wheel rotates the inner spool A a few of sleeve B. The metering unit is linked to the right. At the same time pressurised oil from the rod
degrees relative to the outer spool B, and sends a spools by a cross pin. As the steering is operated side of steering ram 41 is fed to the rod side of
pressure signal to the relief valve 43B and through the oil is diverted by inner spool A into the stator D. front steering ram 40, hence turning the front
the LS port back to the priority valve. wheels the required degree of left turn.

Hydraulics
Descriptions

Section E
Issue 2

8-2
9803/7110

Steering Operation 3 - Right Turn

8-3

Section E
The illustration shows the flow through the steering
unit in a right hand turn condition. The operation is
identical to that described on the previous page,
except that the oil is diverted by spool A to the
other side of stator D and rams 40 and 41.

Hydraulics
Descriptions

Section E
Issue 1

8-3
9803/7110

Steering Operation 4 -

8-4

Section E
Right Turn, Unassisted
The illustration shows the circuit operation with the As there is no supply from the pump, oil from one
engine stopped. Turning the steering wheel rotates side of the rams, supplemented by exhaust oil if
the inner spool A until the cross pin engages with necessary, is used to feed the other side via non-
and rotates outer sleeve B, metering oil to the return valve F.
stator D, and pumping it out to rams 40 and 41
under manual pressure only.

Hydraulics
Descriptions

Section E
Issue 2

8-4
9803/7110

Steering Operation 5 - Shock Valve

8-5

Section E
In normal operation oil flow from the pump enters In the event of a pressure shock wave being Non-return valve J2 is held on its seat by the
the steering unit via the right hand port, opening a generated in the system by an outside force, shock generated pressure and non-return valve 43C
spring-loaded non-return valve 43C. The flow is valve 43A vents this pressure to exhaust preventing closes to prevent the shock wave being fed back to
directed by the steering unit to achieve the desired damage to the steering unit. the pump. Some of the excess flows via non-return
turn (right hand shown). valve J1 to the opposite side of the ram to prevent
cavitation occuring.

Hydraulics
Descriptions

Section E
Issue 1

8-5
9803/7110

Steering Operation 6 -

8-6

Section E
Anti-cavitation Valve (if fitted)
* Machines that have large tyres and/or use a trailer
(such as the Farm Master and the 2DX), may have
an increased load applied to the steer system. C

When the machine turns a corner, the frictional P

turning action of the wheels on the road and the V
additional weight of the trailer create this induced
load.

The induced load could in turn cause steer ram

cavitation. To prevent cavitation, a valve 40 is fitted
in the steer circuit as shown. S220850

High pilot pressure at port P moves the anti-

cavitation valve off its seat against the force of a V C
spring. The open valve now allows oil from the 40
steering unit 9 to return to tank via port V. P
1

Hydraulics
When the pressure at port P drops below the

Descriptions
setting of the spring, the valve closes, oil can not 5
return to tank and is locked in preventing cavitation
of the rams. 10

R L

9B
2

8
LS
9

9A
P T

Section E
Issue 2*

8-6
A220590
9803/7110

Priority Valve Operation 1 - Neutral

9-1

Section E
When the steering is not being operated, flow to the The high pressure differential created across the
steering circuit is dead ended by the closed spool causes it to move to the left against the force
centre steering unit 43 and no load is sensed of spring 2A. This allows full pump flow to the
in line LS. Pressure from the main pump to the loader control valve 3.
integral priority valve 2 is fed via drilling 2C to
the rear of spool 2B.

Hydraulics
Descriptions

Section E
Issue 3*

9-1
9803/7110

Priority Valve Operation 2 - Turning

9-2

Section E
As the steering of unit 43 is operated, pressure is which directs the flow to rams 40 and 41 until the Because the pump output is always greater than
applied to the spring end of priority valve spool 2B required steering lock is reached. When the the flow required to operate the steering system,
via sensing line LS from the steering unit. steering lock is held the pressure signal across the flow to the loader control valve is never completely
side port LS of the steering unit ceases, restoring cut off.
This reduces the pressure differential across the the pressure differential across spool 2B. The
spool, causing it to move to the right under spring spool moves back to the left, allowing full pump Maximum steering system pressure is controlled by
pressure. This allows priority flow to the steering flow to the loader control valve 3. relief valve 43B, located in the steering unit 43.
unit

Hydraulics
Descriptions

Section E
Issue 1

9-2
Section E Hydraulics Section E
10 - 1 Descriptions 10 - 1

* Charge/Priority Valve (machines from

658961 to 763230 and 481196 to 489723)
The charge/priority valve has two functions: it charges the The flow rate to the accumulators is controlled by orifice O1
brake accumulators and provides priority flow to the steering and the spring force on the main spool 2. When the
circuit when required. Any excess flow is made available to accumulators become fully charged the pilot valve 1 opens,
the main hydraulic circuit. and remains open until the accumulator pressure falls due to
brake usage.
The operation of the valve is as follows:
If the steering wheel is turned while the accumulators are
At start-up of the pump, if the brake accumulators are charging, some flow will be bled off to the steering circuit via
discharged, pilot valve 1 is closed, due to the action of its port P, which would theoretically reduce the flow through
spring, and main spool 2 is held to the left by its spring. orifice O1 to the accumulators; however at the same time
Pump flow is directed to the steering unit via port P and to the main spool 2 would move to re-establish the specified
the brake accumulators via orifice O1, check valve C1 and flow through O1 while maintaining the required flow to the
distributor valve 4. (The distributor valve caters for slight steering unit.
differences in accumulator characteristics by switching
charging pressure between either or both acccumulators as While the pilot valve is open, the steering load sensing line
required.) LS is connected to the spring end of the main spool 2. The
maximum pressure in this line, the steering supply line and
As pilot valve 1 is closed, no flow passes through the pilot the accumulator charge line is controlled by relief valve 3,
lines (shown dotted) and pressure downstream of orifice O1 which is set at a higher pressure than pilot valve 1. The
is applied via orifice O2 to the spring end of main spool 2. accumulators therefore operate at a minimum pressure
Pressure upstream of orifice O1 is applied to the other end which is set by the cut-in pressure of the main spool 2, a
of the main spool. The pressure drop created by the flow ‘normal’ maximum which is controlled by the pilot valve 1
though O1 means that the pressure applied to the spring and an upper maximum which is controlled by relief valve 3.
end of main spool 2 is lower than that applied to the other
end. If the pump output flow is high enough, this pressure Note: The remainder of the brakes circuit is as described on
difference will be sufficient to overcome spring pressure and page G/4 - 2. The remainder of the steering circuit is as
move the spool to its central position. In this position, some described in section E/8.
flow is made available to the main hydraulic circuit, via port
EF, as well as to the accumulators.

G1 S LS A1
T
G2
S

02
2 3 A2
EF P
C1

01 4
G2
230470
1

EF P T LS A1 A2

A230550

9803/7110 Issue 2*
Section E Hydraulics Section E
10 - 2 Descriptions 10 - 2

Charge/Priority Valve (machines from

489724)

S 13 15
2 8
3 G1
EF
T F
P 02
LS
G2 C1 01 1 17
16
4 T1
B1
A1 A2
G

14 14

P2 B2

18

346480

9803/7110 Issue 1
Section E Hydraulics Section E
10 - 3 Descriptions 10 - 3

Charge/Priority Valve machines from

489724 (continued)
The charge/priority valve has two functions: it charges the When the pressure in accumulators attains set pressure,
brake accumulators and provides priority flow to the steering spool 2 is moved fully across by pilot pressure to allow oil
circuit when required. Any excess flow is made available to flow to the main machine hydraulic circuit via port EF, note
the main hydraulic circuit. that not ALL the oil flow is available to the accumulators.

The operation of the valve is as follows: When the brake pedal is pressed, the spool F in brake valve
15 is moved against spring force. This allows oil from the
At start-up of the pump, if the brake accumulators are charged accumulators to the brake packs 17 and 18 in the
discharged, pilot valve 1 is closed, due to the action of its front and rear axle hubs respectively. Because of the drop in
spring, and main spool 2 is held to the left by its spring. pressure, spool 2 is pushed back by spring force, ensuring
Pump flow is directed to the steering unit via port P and to the accumulators are re-charged.
the brake accumulators via orifice O1, check valve C1 and
distributor valve 4. (The distributor valve caters for slight If there is a difference in the volume of oil required by the
differences in accumulator characteristics by switching front and rear brake packs (e.g if one brake pack is worn
charging pressure between either or both acccumulators as more than the other), then compensating spool 4 operates.
required.) The higher pressure in the pilot line combined with spring
force moves the spool to allow sufficient oil into either brake
As pilot valve 1 is closed, no flow passes through the pilot pack to make up the difference. Once the pressure
lines (shown dotted) and pressure downstream of orifice O1 equalises, the spool 4 returns to its central position.
is applied via orifice O2 to the spring end of main spool 2.
Pressure upstream of orifice O1 is applied to the other end Proportional braking effort between the front and rear brake
of the main spool. The pressure drop created by the flow packs (17 and 18 respectively) is achieved with the
though O1 means that the pressure applied to the spring assistance of internal pilot line G.
end of main spool 2 is lower than that applied to the other
end. If the pump output flow is high enough, this pressure
difference will be sufficient to overcome spring pressure and
move the spool to its central position. In this position, some
flow is made available to the main hydraulic circuit, via port
EF, as well as to the accumulators.

The flow rate to the accumulators is controlled by orifice O1

and the spring force on the main spool 2. When the
accumulators become fully charged the pilot valve 1 opens,
and remains open until the accumulator pressure falls due to
brake usage.

If the steering wheel is turned while the accumulators are

charging, some flow will be bled off to the steering circuit via
port P, which would theoretically reduce the flow through
orifice O1 to the accumulators; however at the same time
the main spool 2 would move to re-establish the specified
flow through O1 while maintaining the required flow to the
steering unit.

While the pilot valve is open, the steering load sensing line
LS is connected to the spring end of the main spool 2. The
maximum pressure in this line, the steering supply line and
the accumulator charge line is controlled by relief valve 3,
which is set at a higher pressure than pilot valve 1. The
accumulators therefore operate at a minimum pressure
which is set by the cut-in pressure of the main spool 2, a
‘normal’ maximum which is controlled by the pilot valve 1
and an upper maximum which is controlled by relief valve 3.

9803/7110 Issue 1
 Section E Hydraulics Section E
20 - 1 20 - 1

Pump/Priority Valve
The hydraulic pump, with integral load sensing priority valve,
is mounted on the left side of the engine and driven from the
power take off point below the injector pump. The unit
supplies hydraulic fluid to the machine's main services
circuit and to the steering circuit which is given priority on
demand.

If a hydraulic fault is suspected, check flow and pressure of

the pump and the operation of the load sensing priority valve
before removing and dismantling the unit. S204950

Pump Flow and Pressure Testing

1 Switch off the engine and remove the starter key.

2 Relieve system pressure by operating the services

controls a few times.

3 Disconnect the hose from valve port EF. Connect a

flow meter to the port and connect the hose to the T
output of the flow meter.

4 Connect a pressure gauge to the test point T on the

end face of the valve body

5 Start the engine and adjust the speed to 2000 rpm.

*
6 With a maximum pressure of 220 bar and the steering
circuit in neutral, a flow of 57.42 litres/min (12.6 (U.K.)
gallons/minute) or greater should be acheived.

7 If the flow is less than that specified replace the pump

section complete. DO NOT individually renew the gears
or the housing as this will not effect a permanent cure. EF
8 When testing is complete repeat steps 1 and 2.
Remove the flow meter and the pressure gauge.
Reconnect the hose to port EF and refit the blanking
plug to test point T.

.
S204670

9803/7110 Issue 3*
Section E Hydraulics Section E
20 - 2 20 - 2

Pump/Priority Valve
Checking the Load Sensing Priority Valve

1 Switch off the engine and remove the starter key.

2 Relieve system pressure by operating the service

controls a few times.

3 Disconnect the hose from the load sense (LS) adapter

A, plug the hose to prevent loss of fluid. Connect in its
place a hose to enable any leakage to be collected in a S204950
container. Make sure the end of the hose is in the
container before starting the engine.

4 Disconnect the hose from valve port P. Install a T-

connector into the port and connect the hose to it.
Connect a pressure gauge to the other T-connector
outlet.

5 Start the engine and adjust the speed to 1000 rpm.

6 With the steering circuit in neutral a pressure reading of

10.1 - 10.7 bar should be obtained and a small amount
of leakage should occur at valve port A.

7 If the pressure is above or below that specified, repeat

steps 1 and 2 and then dismantle the Load Sensing LS
Priority Valve (see Dismantling and Assembly on page
E/20-5 or E/21-2). Make sure the spool moves freely in
the bore and that the metering orifices in the load sense A
adapter and the spring recess of the spool are clear of
any obstruction or dirt.

8 Re-assemble the Load Sensing Priority Valve (see P

Dismantling and Assembly on page E/20-5 or E/21-2)
and re-test.

9 If the pressure measured is still not as specified, check

the other components of the steer circuit.

10 When checking is complete, repeat steps 1 and 2.

Remove the T-connector and re-connect the original
S204670
hoses to ports LS and P.

9803/7110 Issue 2
Section E Hydraulics Section E
20 - 3 20 - 3

Pump/Priority Valve
Note: The illustration shows the later type hydraulic pump,
on machines prior to serial number 657448 the hydraulic
pump has only two mounting bolts E.

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 appropriate pump section must be
renewed completely. Renewal of components such as
gears, bearings and housing will not effect a permanent
S204950
cure. If the pump output is satisfactory but there is external
leakage, the pump should be removed and dismantled for
re-sealing only.

Removal

Operate the controls to vent residual pressure.

Disconnect and plug feed hose A and B.

E
Disconnect and plug sensing hose C.

Disconnect and plug suction hose D.

Undo bolts E , remove pump from machine.

Replacement

Replacement is a reversal of the removal procedure.

C
After fitting a new or serviced pump and before starting the
engine screw the MRV out 4 full turns. Adjust the MRV.

D
B
A
S204670

9803/7110 Issue 2
Section E Hydraulics Section E
20 - 4 20 - 4

S175680

9803/7110 Issue 2
Section E Hydraulics Section E
20 - 5 20 - 5

Pump/Priority Valve (to machine serial no. When Assembling

657447) Wash all components and apply hydraulic oil immediately to
prevent corrosion.
Dismantling & Assembly
Before dismantling/assembling make sure that the exterior Renew all seals and 'O' rings. Lubricate using JCB Special
surfaces of the unit and the working area are spotlessly Hydraulic Fluid.
clean.
For ease of assembly proceed as follows:
When Dismantling
1 Before commencing: 1 Fit bushes 13 and 14 into the undowelled end of pump
a Remove any burrs or sharp edges from the drive body 15, making sure the grooves for seals 7 and 8
shaft of gear 9 to avoid causing damage to shaft face outwards.
seals 16 and 18.
b Make relative location marks on valve body 3, 2 Locate valve body 3 against pump body 15. Stand the
pump body 15 and mounting flange 5 to ensure assembled components on the valve body, i.e. with the
their correct positioning during assembly. pump body dowels uppermost.

2 Dismantle in the numerical order shown on the 3 Fit drive shaft 9 and gear 12 in their original positions in
illustration opposite, bearing in mind the following the pump body, followed by bushes 10 and 11 with
points: their seal grooves outwards. Fit new seals 7 and 8.
a DO NOT prise apart any machined faces. Always
use a soft faced hammer to avoid damaging the 4 Fit a new 'O' ring 6 into the groove in pump body 15. Fit
surfaces. a new inner shaft seal 18, garter spring facing into the
b Mark bushes 10, 11, 13 and 14 on a plain area pump, followed by circlip 17 and then a new outer shaft
away from the seals so that they are returned to seal 16, garter spring facing upwards. Coat the lips of
their original location during assembly. both seals with high melting point grease.
c Remove drive shaft 9 with bushes 10 and 11 as an
assembly, and gear 12 with bushes 13 and 14 as 5 Carefully refit mounting flange 5, ensuring a square fit
an assembly. on the pump body dowels.
d Retain any shims fitted to the Load Sensing Priority
Valve. 6 Turn over the assembly and support it on the mounting
e Discard all seals. flange, making sure there is no weight placed on the
drive shaft.
Inspection
1 Generally check all pump parts for damage and/or 7 Lift off valve body 3. Fit new seal 7 and 8 and a new 'O'
wear. Renew the pump if: ring 4 to pump body 15.
a There is more than minor damage to the grooves in
pump body 15 where 'O' rings 4 and 6 locate. 8 Replace the valve body and install the bolts 1 with their
b The recess for seals 16 and 18 in mounting flange 5 spring washers 2. Progressively and evenly torque
is scored. tighten the bolts.
c There is a noticeable wear groove on shaft 9 where
the lips of seals 16 and 18 run. 9 Pour a small amount of clean hydraulic fluid into port B
d The track cut by the gear in the inlet side of pump and check that the drive shaft rotates without undue
body 15 is deeper than 0.08 mm (0.003 in) or has a force.
scored matt finish.
e The side faces of gears 9 and 12 and/or the inner 10 Fit a new 'O' ring 20 to spool plug 19 and torque
faces of bushes 10,11, 13, 14 are scored. tighten.
f The bores A of bushes 10,11, 13, 14 are worn to
the extent that the bronze backing is visible 11 Install spool 24 in the valve body bore with its spring
through the grey P.T.F.E. coating. recess facing the load sensing adapter port.

2 When checking the Load Sensing Priority Valve pay 12 Fit spring 23 and any shims retrieved during
particular attention to the following: dismantling.
a The bore of valve body 3 must be free of score
marks and damage to the metering edges. 13 Fit a new 'O' ring 22 to load sensing adapter 21 and
b The spool 24 must be free of score marks and torque tighten.
other damage and should move freely in the bore.
c The 0.7 mm orifices in the spring recess of the Torque Setting
spool and in load sensing adapter 21 must be clear Item Nm kgf m lbf ft
of any obstruction or dirt. 1 88-102 9-14 65-75
19 73-83 7.4-8.4 54-61
Renew the Load Sensing Priority Valve complete if any 21 103 10.5 76
of the above checks are unsatisfactory.

9803/7110 Issue 1
Section E Hydraulics Section E
21 - 1 21 - 1

S183930

9803/7110 Issue 1
 Section E Hydraulics Section E
21 - 2 21 - 2

Pump/Priority Valve (from machine serial

no. 657448)
* Note: On machines from 658961 the pump does not
incorporate a priority valve. The dismantling/assembly
procedure remains the same except that all references to
item 11 and items 30 - 35 should be ignored.

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
and housing will not effect a permanent cure. If the pump
output is satisfactory but there is external leakage, the pump
should be removed and dismantled for re-sealing only.

Before removing and dismantling the pump, make sure the

exterior of the pump and working area is thoroughly cleaned
and free of possible sources of contamination.

Dismantling Inspecting

Remove drive gear 1 and key 4 using a suitable puller, do Remove and discard all seals. Remove sealant from flange 6
not lever or hammer as this will result in internal damage to and body 5.
the pump.
Inspect 'O' ring groove and shaft seal recess in mounting
Remove sharp edges and burrs from the shaft to avoid seal flange 6, make sure there is no damage and is free of burrs.
damage.
Check that the mating faces on the mounting flange 6 and
Mark body 5 and flange 6 to ensure correct assembly. priority valve housing 12 are not scored.

Undo bolts 7 to remove the priority valve housing 12. Inspect priority valve spool 33 for scoring and damage, pay
particular attention to the metering edges.
Note: Bolt 9 is used to secure the pump to the engine.
Insect priority valve housing 12, examine the valve bore for
Undo nuts 13 and separate body 5 from flange 6, slide the scoring and damage, pay particular attention to the metering
flange off square to the shaft. Take care not to damage edges.
machined faces by prising them apart - use a soft faced
hammer. The priority valve spool 33 should slide freely in the housing
12.
Use a drift to remove the outer shaft seal 15, then remove
circlip 16 and inner shaft seal 17. Take care not to damage Check that the metering orifices in the priority valve spool 33
the shaft seal recess. and load sensing connector 30 are not blocked, shown at A.

Remove drive shaft 20 and balance plate 21 then remove The pump must be renewed if:-
driven gear 24 and balance plate 25. Note the positions of
balance plates 21 and 25 to ensure correct assembly. The PTFE coated bearings in the body or flange are worn
through so that the bronze base is visible.
Unscrew load sense connector 30 and plug 34, remove
spring 32 and priority valve spool 33. The gear side faces or balance plates are scored.

The drive shaft has a wear groove where the shaft seal lips
run.

For Assembling see next page.

9803/7110 Issue 2*
 Section E Hydraulics Section E
21 - 3 21 - 3

Pump/Priority Valve (from machine serial

no. 657448)

* Note: On machines from 658961 the pump does not Pour a small amount of clean hydraulic oil into the inlet port
incorporate a priority valve. The dismantling/assembly and check that the drive shaft can be turned by hand
procedure remains the same except that all references to without undue force.
item 11 and items 30 - 35 should be ignored.
Use new seal 35 and fit priority valve spool end cap 34,
Assembling torque load.

Wash all components and apply hydraulic oil immediately Refit priority valve spool 33, spring 32, new 'O' ring seal 31
afterwards to prevent moisture collecting. and connector 30, torque load.

Renew all seals and 'O' rings using JCB Special Hydraulic Fit new 'O' rings 28 and locate priority valve assembly in its
fluid as a lubricant. original position. Secure with bolts 7 and bolt 9, make sure
spacer 11 is fitted in the correct position. Torque load bolts
Fit inner shaft seal 17 into mounting flange 6 with the garter evenly.
spring B facing toward the pump.
Note: Bolt 9 will have to be removed when fitting the pump
Fit circlip 16 and outer shaft seal 15 with garter spring C to the machine.
facing away from the pump. Coat seal lips with JCB HP
grease. Fit key 4, drive gear 1, tab washer 2 secure with nut 3.
Torque load nut 3 and lock with tab.
Fit seal 26 and back up seal 27 to balance plate 25, locate
assembly into main body 5. Torque Settings

Note: Make sure that the two small holes D in the balance Item Nm Kgf. m Ibf. ft
plate are on the low pressure side of the pump, i.e. the side 3 100 10 74
adjacent to the threaded inlet port. 7&9 48 48.9 35.5
13 95 9.7 70
Fit drive shaft 20 and driven gear 24 into their original bores. 30 103 10 76
34 78 8 58
Fit seal 22 and back up seal 23 to balance plate 21, locate
assembly over drive shaft 20 and driven gear 24.

Note: Make sure that the two small holes D in the balance
plate are on the low pressure side of the pump, i.e. the side
adjacent to the threaded inlet port.

Fit 'O' ring 19 to mounting flange 6. Apply a small amount of

JCB Multi-gasket to main body mating face, shown at E.

Fit protective sleeve over driveshaft, locate mounting flange

to main body in its original position, drain hole to low
pressure side i.e. the side with the threaded inlet port.

Secure with washers 14 and nuts 13, torque load.

9803/7110 Issue 2*
Section E Hydraulics Section E
22 - 1 Charge/Priority Valve 22 - 1

Pressure Testing
1 Thoroughly clean and dry the outside of the valve and
its fittings. Run the engine until the brake accumulators
are charged, then operate the steering hard against full
lock. Check the valve and fittings for leaks.

2 Stop the engine. Fully discharge the accumulators as

described on page G/5 - 1.

! WARNING
A minimum of 30 applications of the service brake is
possible from the stored accumulator pressure. Before
removing an accumulator or disconnecting any part of
S204950
the brake hydraulic system, make sure that engine is
switched off and hydraulic pressure is fully discharged
as described in this manual.
BRAK 2-4

3 Connect pressure gauges to test points X.

4 Start the engine and, without operating the brakes or LS A1

steering, observe the gauges. Pressure should rise T
equally in the accumulators and the steering until the
S
charge valve cuts out, when steering pressure should
drop back to standby level. At this point note the
accumulator cut-out pressures and the steering
pressure, which should be as stated in Technical Data. A2

5 Operate the brakes repeatedly while watching the EF P

accumulator gauges. The pressures should gradually
fall to a minimum, then rise again when the charge
valve ‘cuts in’. Note this minimum pressure, which X
should be as stated in Technical Data.

6 Turn the steering to full lock and maintain a firm pull on

the steering wheel. Note the steering and accumulator
pressures. These should both be equal to the relief
valve setting specified in Technical Data.
X
X
7 Stop the engine and check that brake pressure is
maintained by the accumulators. (A slow decline in
pressure when parked for a long time is to be expected,
but there should be no significant pressure drop within
30 seconds.)
A230470

Note: If there are not enough pressure gauges available,

perform the tests twice, with a gauge connected into each
test point X in turn.

9803/7110 Issue 2
Section E Hydraulics Section E
22 - 2 Charge/Priority Valve 22 - 2

LS A1
T
G2
S

S204950

A2
EF P

A230470

9803/7110 Issue 1
Section E Hydraulics Section E
22 - 3 Charge/Priority Valve 22 - 3

Removal & Replacement

Removal Replacement

! WARNING Replacement is a reversal of the removal sequence.

Make the machine safe before working underneath it.
Park the machine on level ground, lower the arms. Apply ! WARNING
the parking brake, put the transmission in neutral and Fine jets of hydraulic fluid at high pressure can penetrate
stop the engine. Chock both sides of all four wheels. the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected
Disconnect the battery, to prevent the engine being leaks. Hold a piece of cardboard close to suspected
started while you are beneath the machine. leaks and then inspect the cardboard for signs of
GEN-1-2 hydraulic fluid. If hydraulic fluid penetrates your skin, get
medical help immediately.
Removal INT-3-1-10/1

1 Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral. Make sure that the hoses are correctly installed. The hose
Lower the backhoe and loader end to the ground and connections are as follows:
stop the engine.
Port S = from the hydraulic pump
! WARNING Port T = to the hydraulic tank
Port P = to the steering unit
A minimum of 30 applications of the service brake is
Port LS = to the steering unit
possible from the stored accumulator pressure. Before
Port EF = to the loader valve block
removing an accumulator or disconnecting any part of
Port G2 = no hose - pressure switch port
the brake hydraulic system, make sure that engine is
Port A1 = to the accumulator block
switched off and hydraulic pressure is fully discharged
Port A2 = to the accumulator block
as described in this manual.
BRAK 2-4
Torque tighten the valve retaining bolts B to 28 Nm (21 lbf ft).
2 Operate the foot brake pedal several times to vent
residual hydraulic pressure. Fully discharge the After replacement check the pressure settings (see page
accumulators as described on page G/5 - 1. E/22 - 1).

3 Disconnect all hydraulic hoses from the valve block and

plug all orifices to prevent ingress of dirt. Label each
hose before disconnecting, this will ensure correct re-
fitting.

4 Remove the electrical connector.

5 Loosen and remove the three valve retaining bolts B.

9803/7110 Issue 1
Section E Hydraulics Section E
22 - 4 Charge/Priority Valve 22 - 4

1
3 10A 4
26 10
24 23 25 8 9
21 22 5 6 7
2

18 20
19
17

12 11
13

S230460

16
15
14

9803/7110 Issue 1
Section E Hydraulics Section E
22 - 5 Charge/Priority Valve 22 - 5

Dismantling and Assembly

The numerical sequence shown on the illustration is Pressure Setting

intended as a guide to dismantling.
Refit the valve to the machine and test the pressures as
For assembly the sequence should be reversed. described on page 22 - 1. If, during step 4, the pressures do
not cut out as described, reset the relief valve as follows:
When Dismantling
Turn steering to full lock, screw in relief valve seat 22 until
A peg spanner will be required to remove item 4. the specified steer pressure is achieved, then screw in a
further quarter turn.
Remove and discard all seals and back-up rings, after noting
their relative positions. If the above pressures cannot be achieved, the valve should
be renewed.
Inspection

Thoroughly wash all components. Apply hydraulic oil

immediately, to prevent rusting. Inspect all bores and ‘O’
ring grooves for damage and wear.

Note: The valve components and the valve body are not
repairable. If there is damage or wear to the body the valve
should be renewed. Components may be replaced by new
ones, provided the body itself is serviceable. Do not
dismantle the capsule 4, check valve assembly 17 or
relief valve seat 14.

During Assembly

Fit new seals and back-up rings, ensuring correct

positioning as noted during dismantling.

Check valve 6 should be secured in the body with locking

fluid.

Torque Settings

Item Nm kgf m lbf ft

1 38 - 42 3.9 - 4.3 28 - 31
4 58 - 62 5.9 - 6.4 43 - 46
11 75 - 81 7.6 - 8.3 55 - 60
14 100 - 105 10.2 - 14.5 74 - 77
17 38 - 42 3.9 - 4.3 28 - 31

9803/7110 Issue 2
Section E Hydraulics Section E
23 - 1 23 - 1

Main Pump (machines from 658961, S204950

including 2DX)
The hydraulic pump is mounted on the left side of the engine
and driven from the power take off point below the injector
pump. The unit supplies hydraulic fluid to the machine's
main services circuit and also to the steering circuit via the
charge/priority valve.

If a hydraulic fault is suspected, check flow and pressure of

the pump and the operation of the charge/priority valve
before removing and dismantling the unit. (See page 22 - 1
for testing the charge/priority valve.)

Pump Flow and Pressure Testing

S
1 Switch off the engine and remove the starter key.

2 Relieve system pressure by operating the services

controls a few times.

3 Disconnect the pump hose from port S. Connect a flow

meter between the port and the hose.
G1
4 Connect a pressure gauge to the test point G1 on the
end face of the valve body

5 Start the engine and adjust the speed to 2000 rpm.

6 With a maximum pressure of 243 bar and the steering

circuit in neutral, a flow of 57.42 litres/min (12.6 UK
gals/min; 15.2 US gals/min.) or greater should be
achieved.

7 If the flow is less than that specified replace the pump

section complete. DO NOT individually renew the gears
or the housing as this will not effect a permanent cure.
A231670
8 When testing is complete repeat steps 1 and 2.
Remove the flow meter and the pressure gauge.
Reconnect the hose to the port S and refit the blanking
plug to test point.

9803/7110 Issue 1
 Section E Hydraulics Section E
23 - 2 23 - 2

Main Pump (machines from 658961,

including 2DX)
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. If the pump output
is satisfactory but there is external leakage, the pump should
be removed and dismantled for re-sealing only.
S204950
Removal

Operate the controls to vent residual pressure.

Disconnect and plug feed hose A.

E
Disconnect and plug suction hose B.
A
Undo bolts E, remove pump from machine.

Replacement

Replacement is a reversal of the removal procedure.

* Use a new gasket between pump and engine.

After fitting a new or serviced pump and before starting the

engine screw the MRV out 4 full turns. Adjust the MRV.

Dismantling and Assembly

The dismantling and assembly procedures for this pump are

covered on pages 21 - 1 and 21 - 2.

A230520

9803/7110 Issue 2*
Section E Hydraulics Section E
24 - 1 24 - 1

Auxiliary Pump (2DX machines)

On these 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.

If a hydraulic fault is suspected, check flow and pressure of

the pump before removing and dismantling the unit.

Pump Flow and Pressure Testing

1 Switch off the engine and remove the starter key. S204950

2 Relieve system pressure by operating the excavator

controls a few times.

3 Disconnect the hose from port A. Connect a flow meter

to the port and connect the hose to the output of the
flow meter.

4 Connect a pressure gauge to the test point X.

5 Start the engine and adjust the speed to 2000 rpm. X

6 With a maximum pressure of 243 bar (3525 lbf/in2) a
flow of 28 litres/min (6.16 UK gal/min; 7.4 US gal/min.) A
or greater should be achieved.

7 If the flow is less than that specified replace the pump

complete. DO NOT individually renew the gears or the
housing as this will not effect a permanent cure.
A230530
8 When testing is complete repeat steps 1 and 2.
Remove the flow meter and the pressure gauge.
Reconnect the hose to port A and refit the blanking
plug to test point X.

9803/7110 Issue 1
Section E Hydraulics Section E
24 - 2 24 - 2

Auxiliary Pump (2DX machines)

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. If the pump output
is satisfactory but there is external leakage, the pump should
be removed and dismantled for re-sealing only.

Removal
S204950

Operate the controls to vent residual pressure.

Disconnect and plug feed hose A.

Disconnect and plug suction hose B.

Undo bolts E, remove pump from machine.

Replacement
E
Replacement is a reversal of the removal procedure.
A

A230530

9803/7110 Issue 1
Section E Hydraulics Section E
24 - 3 24 - 3

9
10
11
22
23
A

6 7
8 A
B
21
20
17
18
15
14 13
12
A

A
4
19

16
5
3
2
1

S230540

9803/7110 Issue 1
Section E Hydraulics Section E
24 - 4 24 - 4

Auxiliary Pump (2DX machines) When Assembling

Wash all components and apply hydraulic oil immediately to

Dismantling & Assembly prevent corrosion.
Before dismantling/assembling make sure that the exterior
surfaces of the unit and the working area are spotlessly Renew all seals and 'O' rings. Lubricate using JCB Special
clean. Hydraulic Fluid.
When Dismantling For ease of assembly proceed as follows:
1 Make relative location marks on pump body 23, 1 Fit bushes 21 and 22 into the undowelled end of pump
mounting flange 12 and cover 8 to ensure their correct body 23, making sure the grooves for seals 10 and 11
positioning during assembly. face outwards.
2 Dismantle in the numerical order shown on the 2 Locate cover 8 against pump body 23. Stand the
illustration opposite, bearing in mind the following assembled components on the cover, i.e. with the
points: pump body dowels uppermost.
a DO NOT prise apart any machined faces. Always
use a soft faced hammer to avoid damaging the 3 Fit drive shaft 17 and gear 20 in their original positions
surfaces. in the pump body, followed by bushes 18 and 19 with
b Mark bushes 18, 19, 21 and 22 on a plain area their seal grooves outwards. Fit new seals 14 and 15.
away from the seals so that they are returned to
their original location during assembly. 4 Fit a new 'O' ring 13 into the groove in pump body 23.
c Remove drive shaft 17 with bushes 18 and 19 as Fit a new shaft seal 16, garter spring facing into the
an assembly, and gear 20 with bushes 21 and 22 flange, followed by circlip 5. Coat the lips of the seal
as an assembly. with high melting point grease.
d Discard all seals.
5 Carefully refit mounting flange 12, ensuring a square fit
Inspection on the pump body dowels.
1 Generally check all pump parts for damage and/or 6 Turn over the assembly and support it on the mounting
wear. Renew the pump if: flange, making sure there is no weight placed on the
a There is more than minor damage to the grooves in drive shaft.
pump body 23 where 'O' rings 9 and 13 locate.
b The recess for seal 16 in mounting flange 12 is 7 Lift off cover 8. Fit new seals 10 and 11 and a new 'O'
scored. ring 9 to pump body 23.
c There is a noticeable wear groove on shaft 17
where the lips of seal 16 runs. 8 Replace the valve cover and install the bolts 6 with their
d The track cut by the gear in the inlet side of pump spring washers 7. Progressively and evenly torque
body 23 is deeper than 0.08 mm (0.003 in) or has a tighten the bolts.
scored matt finish.
e The side faces of gears 17 and 20 and/or the inner 9 Pour a small amount of clean hydraulic fluid into port B
faces of bushes 18,19, 21, 22 are scored. and check that the drive shaft rotates without undue
f The bores A of bushes 18,19, 21, 22 are worn to force.
the extent that the bronze backing is visible
through the grey P.T.F.E. coating. 10 If the check at step 9 is satisfactory, fit items 4, 3, 2 and
1. Use a new key 4.
2 Remove any burrs and sharp edges from the shaft of
gear 17 to avoid causing damage to seal 16 on Torque Setting
assembly.
Item Nm kgf m lbf ft
1 88-102 9-14 65-75

9803/7110 Issue 1
Section E Hydraulics Section E
29 - 1 Valves 29 - 1

*3
Point Hitch Valve Block
2CXU (212SU North America Only) ! CAUTION
This component is heavy. Do not attempt to remove it
Removal and Replacement unless its weight is held by a sling. Make sure that the
sling is attached to a suitable lifting appliance.
! DANGER HYD 2-3/1

Hydraulic fluid at system pressure can injure you. Before 6 Wrap a suitable sling around the valve, make sure that
disconnecting or connecting hydraulic hoses, stop the the weight of the valve is supported by the sling.
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be 7 Remove nuts F and remove the valve block.
started while the hoses are open.
INT-3-1-11/1
Replacement
Removal
Replacement is a reversal of the removal sequence.
1 Switch OFF the engine and remove the starter key.
Hoses and pipes must be re-connected and phased in same
Operate the valve block levers back and forth to vent
position as removal.
residual pressure.

2 Remove valve block control lever knobs A. Undo ! WARNING

screws B and lift the rear instrument panel to one side. Fine jets of hydraulic fluid at high pressure can penetrate
It should be possible to remove the valve block without the skin. Do not use your fingers to check for hydraulic
disconnecting the panel, if the panel has to be removed fluid leaks. Do not put your face close to suspected
for any reason disconnect the throttle lever C, heater leaks. Hold a piece of cardboard close to suspected
switch D and electrical connections. leaks and then inspect the cardboard for signs of
hydraulic fluid. If hydraulic fluid penetrates your skin, get
4 Disconnect all hydraulic hoses E from the valve block medical help immediately.
and plug all orifices to prevent ingress of dirt. Label INT-3-1-10/1

each hose before disconnecting, this will ensure correct

position when refitting. After replacement check the auxiliary relief valve (A.R.V.)
pressure settings.
5 Loosen nuts F - do not completely remove the retaining
nuts. Note: All hydraulic adapters that are installed together with a
bonded sealing washer must also have Threadlocker and
Sealer applied to the threads of the adapter.

E
A

S303240

9803/7110 Issue 3*
Section E Hydraulics Section E
30 - 1 Valves 30 - 1

175580

9803/7110 Issue 1
 Section E Hydraulics Section E
30 - 2 Valves 30 - 2

Loader Valve
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 wipers 5 and 14 and 'O' rings 6, 15 and 18.

Torque Settings

Item Nm kgf m lbf ft

7 6.1 - 7.5 0.62 - 0.76 4.5 - 5.5
9 9.5 - 10.9 0.97 - 1.11 7-8

* Note: All valve block adapters, items A and B are torqued to

81 Nm (60 lbf ft; 8.3 kgf m).

B
B
A
S204750

9803/7110 Issue 2*
Section E Hydraulics Section E
30 - 3 Valves 30 - 3

9803/7110 Issue 1
Section E Hydraulics Section E
30 - 4 Valves 30 - 4

Loader Valve - Float Spool

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 Dismantling

Remove retainer 7 and spacer 8. Using a suitable tool on

ball 12, compress spring 13 and allow detent balls 11 to roll
into their holes in the detent pin 14. Carefully remove the
spool cap 10 and collect detent balls 11.

When Assembling

Renew wiper 5 and 'O' rings 6, 20, 21 and 24.

Apply grease liberally to detent pin 14 to hold detent balls 11

in position during assembly and to provide lubrication.

Torque Settings

Item Nm kgf m lbf ft

9 6.1 - 7.5 0.62 - 0.76 4.5 - 5.5
14 9.5 - 10.9 0.97 - 1.11 7-8

9803/7110 Issue 1
Section E Hydraulics Section E
30 - 5 Valves 30 - 5

Loader Valve - M.R.V. & A.R.V's. Torque Settings

Dismantling and Assembly Item Nm kgf m lbf ft

1 5.4 - 8.2 0.55 - 0.83 4-6
Note: The M.R.V. and loader valve A.R.V.'s are identical in 3 41 - 68 4.15 - 6.9 30 - 50
design. 5 5.4 - 8.2 0.55 - 0.83 4-6
10 41 - 68 4.15 - 6.9 30 - 50
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 'O' rings.

Lubricate parts with JCB 'Special' Hydraulic Fluid before

assembling.

Adjust pressure setting (see page 31 - 1 for the M.R.V and

page 32 - 1 for the A.R.V's).

139190

9803/7110 Issue 1
Section E Hydraulics Section E
30 - 6 Valves 30 - 6

6
1
7

2
8

16
17

14

13
3

22

26
5
12

25

21
4 24 11
20

23
19

10
18

15

9803/7110 Issue 1
Section E Hydraulics Section E
30 - 7 Valves 30 - 7

Loader Valve - Electric Detent Spool

Dismantling and Assembly When Assembling

The numerical sequence shown on the illustration is Renew seals and 'O' rings.
intended as a guide to dismantling.
Make sure the 'O' rings and wiper seals are not trapped or
For assembly the sequence should be reversed. damaged.

The following points MUST be avoided when dismantling When fitting screw 23, clean the threads thoroughly using
and assembling the valve: Super Clean Safety Solvent, leave it for 10 minutes then
apply a small quantity of JCB Lock and Seal to the threads
• CONTAMINATION of the spool.
• DAMAGE TO SPOOL
• DAMAGE TO SEAL GROOVES Check the operation of the solenoid 17 after assembly by
connecting a 12V supply. The spool should be held when it
All or any of the above points may result in possible is pushed into the detent position and returned when the
problems with the valve. supply is disconnected.
When Dismantling After re-fitting the valve block to the machine, run the engine
and inspect the valve for external leaks.
When removing 'O' rings and seals, use an appropriately
rounded tool that WILL NOT cause any damage to the spool Torque Settings
or seal grooves.
Item Nm lbf ft kgf m
Care must be taken to ensure that the spool 22 is not 10 9.5 7 0.95
damaged when removing it from the valve block. 23 9.5 7 0.95
Carefully hold the spool when removing screw 23, spring 25
with cups 24 and 26.

Check for surface contamination on the under side of the

seal plate 7. Clean if necessary. Check for flatness of the
seal plate. If found to be bent - replace with new (any work
previously carried out on this valve may have resulted in the
bending of the seal plate).

9803/7110 Issue 1
 Section E Hydraulics Section E
31 - 1 Valves 31 - 1

Pressure Testing - Main Relief Valve

(M.R.V.) - In Position

* 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; stop the engine; operate the control levers to vent
residual hydraulic pressure.

*1 Connect a 0 - 400 bar (0 - 6000 lbf/in2) pressure gauge S204950

to test connector A.

2 With the engine running at 1500 revs/min, check M.R.V.

pressure by raising or lowering the loader arms until the
rams are fully open or closed and noting the maximum
gauge reading. CAUTION: Do not select 'float'. The
maximum pressure should be as stated in Technical
Data.

Note: The rams must be 'held' open or closed when reading

gauge.

3 If the pressure is incorrect, remove dome nut B,

slacken locknut C and adjust screw D. Turn it
clockwise to increase pressure and anti-clockwise to
decrease the pressure. When the pressure is correct, B
tighten the locknut.

D C

A
A

S204670 A230861

Machines to Serial Number 658960 Machines from Serial Number 658961

9803/7110 Issue 3*
 Section E Hydraulics Section E
32 - 1 Valves 32 - 1

* Pressure Testing - Auxiliary Relief Valves * Pressure Testing - Auxiliary Relief Valves
(A.R.V's) - Using Hand Pump (2CX Range (A.R.V's) - Using Hand Pump (2DX Machines)
of Machines)
Auxiliary relief valves (A.R.V.’s) are set 15 bar (220 lbf/in2)
Insert the A.R.V. into the test block, part no 892/00252. below the nominal figure stated on the Technical Data page
Connect hand pump 892/00223 and a 0-400 bar (0-6000 when using a hand pump.
lbf/in2) pressure gauge.
Insert the A.R.V. into test block part no. 892/00153. Connect
Plug the two large diameter (3/4 inch B.S.P.) ports of the test hand pump 892/00223 and a 0-400 bar (0-6000 lbf/in2)
block using blanking plugs (892/00059) and bonded washers pressure gauge.
(1406/0021).
Pressurise until oil begins to escape from the drain hole
Pressurise until oil begins to escape from the drain hole D. when the gauge will indicate the A.R.V. setting. Remember
At this point the gauge will indicate the crack pressure of the to set the A.R.V. 15 bar (220 lbf/in2) below the nominal figure
A.R.V. shown on the Technical Data page.

The pressure should be as given below. If required, adjust the pressure by removing the A.R.V. from
the test block and turning screw A.
If required, adjust the pressure by removing dome nut A,
slackening locknut B and turning screw C.

Relief Valve Test Pressures

Pilot-operated relief valves - 7 bar (102 lbf/in2) below the

operating pressure given in Technical data.

Direct acting relief valves - 10 bar (145 lbf/in2) below the

operating pressure given in Technical data.

Note: See Technical Data (page E/1 - 1) for type of relief

valve fitted to service.

D B

C
A A
D

A230560
S221130

9803/7110 Issue 4*
Section E Hydraulics Section E
33 - 1 Valves 33 - 1

9803/7110 Issue 1
 Section E Hydraulics Section E
33 - 2 Valves 33 - 2

Excavator Valve
Dismantling and Assembly

The numerical sequence shown on the illustration is

intended as a guide to dismantling.

For assembly the sequence should be reversed.

Check Valves
S204950
Each of the identical load hold check valves 4R to 4W can
be removed as shown at 4W. Note only 4W shown on
illustration.

Ensure good condition of seating face on poppet 10 and on

the mating face in the valve block.

* Note: Valve block adapters, types A, B, C and D are torqued

to 81 Nm (60 lbf ft; 8.3 kgf m).

Spools

Spools 4B, 4C, 4D, 4E and 4F are identical but must not be D
interchanged as they are matched to their bores. Slew spool
4A is different in design from the above spools.

All spools have the same centring and sealing components

items 11 to 19 and 24 to 27.

To completely dismantle a spool, follow the sequence 11 to

19 and 24 to 27. To prevent spool rotation when turning
screw 13, hold a rod through the eye end of the spool.
C
Lubricate new seals with JCB Hydraulic Fluid and take care S205350 B
to prevent them from being damaged by the sharp edges of A
the spool.

Apply JCB Lock and Seal to threads of screw 13.

Torque Settings

Item Nm kgf m lbf ft

1A 17.6 - 20.4 1.76- 2.04 13 - 15
1B 41 - 49 4.2 - 5 30 - 36
11 6.1 - 7.5 0.62 - 0.76 4.5 - 5.5
13 9.5 - 10.9 0.97 - 1.11 7-8
22 41 - 68 4.15 - 6.9 30 - 50

Relief Valves

Ensure that A.R.V's 4H to 4P are correctly adjusted and

fitted in their specified positions.

Torque tighten A.R.V's 4H, 4J, 4K and 4N to 41 - 68 Nm (30

- 50 lbf ft, 4.15 - 6.9 kgf m).

Torque tighten A.R.V's 4L, 4M and 4P to 41 - 68 Nm (30 - 50

lbf ft, 4.15 - 6.9 kgf m).

For relief valve dismantling and assembly procedure see

page 33 - 3.

9803/7110 Issue 2*
Section E Hydraulics Section E
33 - 3 Valves 33 - 3

9803/7110 Issue 1
Section E Hydraulics Section E
33 - 4 Valves 33 - 4

Excavator Valve
Dismantling and Assembly - A.R.V. When Assembling

Seven A.R.V's are fitted to the excavator valve block. The Renew all seals, using JCB Hydraulic Fluid as a lubricant.
following procedure covers the dismantling and assembly of
A.R.V's 4L, 4M and 4P. A.R.V's 4H, 4J, 4K and 4N are Fit shims 7 to the same total thickness as those removed.
identical in design to those covered in page 30 - 5 for the
loader valve. The A.R.V's have various pressure settings(see Note: The shims are only intended to limit the maximum
Technical Data - page 1 - 1). pressure setting to which it is possible to adjust the valve.
The specified pressure setting of each valve is achieved by
The numerical sequence shown on the illustration is adjusting screw 5 (see page 32 - 1). If the specified pressure
intended as a guide to dismantling. cannot be achieved under test, it is permissible to add
further shims as required.
For assembly the sequence should be reversed.
Torque Settings
When Dismantling
Item Nm kgf m lbf ft
Retain shims 7 for re-assembly. 1 21.3 - 26.7 2.22 - 2.78 16 - 20
3 21.3 - 26.7 2.22 - 2.78 16 - 20
Note: The arrangement of A.R.V.'s shown opposite is that 6 41 - 68 4.15 - 6.9 30 - 50
used with the JCB 'X' control pattern.

For ISO '+' control pattern 4K and 4M swap positions, 4L

and 4N swap positions.

9803/7110 Issue 1
Section E Hydraulics Section E
33 - 5 Valves 33 - 5

9803/7110 Issue 1
Section E Hydraulics Section E
33 - 6 Valves 33 - 6

Hydraclamp
Dismantling and Assembly When Assembling

The numerical sequence shown on the illustration is Note: View 'A' shows the clamp in the OFF position.
intended as a guide to dismantling.
Ensure that orifice X is clear.
For assembly the sequence should be reversed.
Lubricate new seals with JCB Hydraulic Fluid.
When Dismantling
Ensure that plug 7 locates in groove Y of rotary spool 9.
Plug hose 1 to prevent loss of oil and entry of dirt.
Torque nut 5 finger-tight before locking lever 4.

Ensure that spool 9 rotates freely after tightening nuts 5 and

3.

Torque Settings

Item Nm kgf m lbf ft

3 55 - 67 5.6 - 6.84 40.5 - 49.5
7 3.3 - 4.7 0.35 - 0.49 2.5 - 3.5
14 21.3 - 26.7 2.22 - 2.78 16 - 20

9803/7110 Issue 1
Section E Hydraulics Section E
34 - 1 Valves 34 - 1

11

12 5
10A
6
10
7
8 X
9

1
3

2
4

21
20 X
19

18

17
16
15
14

13
S230481

9803/7110 Issue 1
Section E Hydraulics Section E
34 - 2 Valves 34 - 2

Excavator Valve (2DX machines)

Dismantling and Assembly

The numerical sequence shown on the illustration is

intended as a guide to dismantling.

For assembly the sequence should be reversed.

Check Valves

The 6 load hold check valves (each comprised of items 1 - 4)

are identical.

Ensure good condition of seating face on poppet 4 and on

the mating face in the valve block.

Spools

Excavator spools 10 are identical but must not be

interchanged as they are matched to their bores. Stabiliser
spools 10A are identical to each other but different from the
excavator spools. They must be returned to their original
bores.

To completely dismantle a spool, follow the sequence 5 to

21. To prevent spool rotation when turning screw 15, hold a
rod through the eye end of the spool.

If only renewing the seals, dismantle as far as cap 14 then

remove items 14 to 21 as an assembly. Note that seal 16 is
not included on the stabiliser spools (i.e. the two centre
spools).

Lubricate new seals with JCB Hydraulic Fluid and take care
to prevent them from being damaged by the sharp edges of
the spool.

Apply JCB Lock and Seal to threads of screw 15.

Torque Settings

Item Nm kgf m lbf ft

1 122 12.4 90
13 7 0.7 5
15 11 1.1 8

Auxiliary Relief Valves (A.R.V.s)

A.R.V.s X should be dismantled as described on page 34 -

3. Ensure that they are returned to their original positions.

Hydraclamp Valve

See page 34 - 4 for dismantling/assembling Hydraclamp

valve Y.

9803/7110 Issue 1
Section E Hydraulics Section E
34 - 3 Valves 34 - 3

Excavator Valve (2DX machines)

4M 4K 4H
A.R.V.s - Dismantling and Assembly

The following procedure covers the dismantling and

assembly of A.R.V's 4H to 4P. The A.R.V's have various
pressure settings (see Technical Data).

The numerical sequence shown on the illustration is

intended as a guide to dismantling.

For assembly the sequence should be reversed.

Note: A.R.V. 4L is different to the others and should only be

used in the position shown. Do not mix components
between A.R.V.s. 4P 4N 4L 4J
S231590
When Assembling

Note: Before assembling the A.R.V.s into the valve block

they should be tested and set as described on page 32 - 2.

Renew all seals, using JCB Hydraulic Fluid as a lubricant.

Note the relative positions of seal 4 and back-up ring 3.

Renew spring 9. 3
Renew screw 6. 4
1
Note: The arrangement of A.R.V.’s shown below is that used
7
with the JCB ‘X’ control pattern. For ISO ‘+’ control pattern
4L and 4N exchange positions.
8

2
5
6

S230491

9803/7110 Issue 1
Section E Hydraulics Section E
34 - 4 Valves 34 - 4

Excavator Valve (2DX machines)

Hydraclamp Valve - Dismantling and Assembly When Assembling

The numerical sequence shown on the illustration is Note: View A shows the valve in the OFF position.
intended as a guide to dismantling.
Renew all seals, using JCB Hydraulic Fluid as a lubricant.
For assembly the sequence should be reversed. Note the relative positions of seal 3 and back-up ring 4.

When Dismantling Ensure that all bleed holes in items 2, 8 and 16 are clear.

Plug the valve connecting hoses to prevent loss of oil and Ensure that filter 6 is installed with its coarse mesh seated
ingress of dirt. Do not remove plug 17 unless there are signs on the filter support 7.
of damage or leakage.
Ensure that the valve operates smoothly after assembly.

Torque Settings

Item Nm kgf m lbf ft

11 13.6 1.3 10
17 7 0.7 5

6
4 8

5
7
3

2
1
17

13
11 9
10

14 15 16
12 S230500

9803/7110 Issue 1
Section E Hydraulics Section E
35 - 1 Valves 35 - 1

S10221A

9803/7110 Issue 1
Section E Hydraulics Section E
35 - 2 Valves 35 - 2

Hydraulic Steering Unit

Dismantling and Assembly
Use the numerical sequence on page 35 - 1 as a guide to dismantling.

During manufacture, a small mark X will have been made on sleeve 12 and spool 15, close to one of the slots for the centring
springs 13. Before removing the centring springs, check that this mark is visible; if not, make a new mark to ensure correct
assembly.

Shock valves (items 29 to 35) are pressure set during manufacture and the adjusting screw 31 secured with Loctite. Due to the
difficulty of resetting the pressure it is recommended that the valves are not disturbed. If dismantling is unavoidable, however,
measure and record the depth of adjusting screw 31 below the top face of the steering unit before removing the screw.

Assembly
Note: The unit illustrated in the following sequence represents a typical Danfoss valve. The relief valve (items 25 to 28) and
shock valves (items 29 to 35) are not therefore shown in the photographs.

1 Fit spool 15 into sleeve 12, aligning slots for centring

springs 13 and checking that the small marks X are
aligned. Ensure that three slots in spool partially
uncover three holes in sleeve, as at A.

2 Fit two flat centring springs 13 with four curved springs

between them, as shown at B.

3 Fit seal 24 into steer unit body and insert sleeve of tool
892/00180. Fit back up ring 20 and seal 21 onto
plastic boss, and position on tool spindle, as shown.

9803/7110 Issue 1
Section E Hydraulics Section E
35 - 3 Valves 35 - 3

Hydraulic Steering Unit (cont'd)

4 Lower steering unit body and tool sleeve over tool
spindle until plastic bush is flush with end of bore.
Assemble sleeves 12 and 15 with cross pin 14 and
centring springs 13. Fit bearing components 16 to 19
with chamfered face of 17 facing away from bearing 18.

5 Remove body from tool leaving plastic bush in position,

and lower body over assembled spool.

6 Apply downward pressure on body until plastic boss is

forced out of bore, leaving seals correctly located.

7 Invert unit and place on a suitable hollow support so

that body does not rest on protruding sleeve, thus
preventing displacement of the new seals (support
example is a pump drive housing). Place ball 23 into
check valve hole and fit bush 22.

9803/7110 Issue 1
Section E Hydraulics Section E
35 - 4 Valves 35 - 4

Hydraulic Steering Unit (cont'd)

8 Fit new 'O' ring 10.

9 Fit distributor plate 9 ensuring that holes align. Locate

shaft 11 onto cross-pin 14, noting position of slot. When
rotor 7 is fitted, slot must align with hollows of rotor as
shown at C.

10 Use a suitable piece of rigid flat material, 0.25mm

(0.010 in.) thick, to support the shaft and ensure positive
engagement with the splines of rotor 7.

11 Locate rotor onto shaft, ensuring alignment as at C. Fit

spacing bush 6 into rotor.

9803/7110 Issue 1
Section E Hydraulics Section E
35 - 5 Valves 35 - 5

Hydraulic Steering Unit (cont'd)

12 Fit 'O' rings 4 and 8 each side of body 5, then position
body over rotor.

13 Refit the end plate and fit at least one bolt 2 before
removing support material.

14 Fit remaining bolts, ensuring that special bolt 1 is

correctly located. Tighten all bolts to 29Nm (22 lbf ft).

Pressure Relief Valve Cartridge

After renewing the 'O' ring, torque tighten the cartridge to 50Nm (37lbf ft). The valve is preset to the figures quoted in Technical
Data (see page E/1-2) but the setting should be rechecked after fitting the steering unit to the machine.

Shock Valves

If the shock valves have been dismantled, clean the threads of adjusting screw 31 and the threads in the bore of the steering
unit body using Super Clean Safety Solvent and allow to dry. Assemble seat 35, ball 34, cap 33 and spring 32 then coat
threads of screw 31 with JCB Lock and Seal. Assemble screw to depth measured during dismantling (see page 35 - 2) then fit
plug 29 and washer 30.

9803/7110 Issue 1
Section E Hydraulics Section E
36 - 1 Valves 36 - 1

Steering System - Anti-cavitation Valve

Removal and Replacement

! WARNING
Make the machine safe before working underneath it.
Park the machine on level ground, lower the arms. Apply
the parking brake, put the transmission in neutral and
stop the engine. Chock both sides of all four wheels.

Disconnect the battery, to prevent the engine being

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

When Removing
When Replacing
Park the machine on level ground, engage the parking brake
Replacement is a reversal of the removal sequence.
and set the transmission to neutral. Lower the attachments
to the ground. Stop the engine and remove the starter key.
Make sure the hoses are correctly installed. The hose
connections are as follows:
Turn the steering wheel to the left and to the right several
times to vent system pressure.
Port P - to tee piece (steer ram rod side)
Port C - to steer orbitrol unit (port T)
Note that the hoses A and B connected to ports ‘P’ and ‘C’
Port V - to tank (steel stub pipe connection)
respectively may still have some residual hydraulic pressure,
follow the instructions described in the warning below.

! WARNING
It is not possible to vent all residual pressure. Loosen the
connection one full turn and allow the pressure to
dissipate. Keep face and hands well clear of pressurised
hydraulic oil and wear protective gloves.
HYD 4 - 3

To remove the valve from the machine, disconnect and cap

all hydraulic hoses from the anti-cavitation valve. Label the
hoses to ensure correct refitting. Loosen and remove the
adapter C attached to the steel pipe and the valve.

B
C

P A
V

S220850

9803/7110 Issue 1
Section E Hydraulics Section E
36 - 2 Valves 36 - 2

Steering System - Anti-cavitation Valve

Dismantling and Assembly

Following removal of the valve from the machine, plug all

ports and thoroughly clean the outside of the casing.

Make sure the working area is clear.

Repair maintenance is limited to the replacement of external

‘O’ ring seals A and back-up rings B located on the cartridge
assembly .

Check the valve cartridge and valve seats for signs of

damage, such as burrs, nicks, cuts or scratches.

After replacing the cartridge ‘O’ rings and back up rings,

check that there is no leakage:

Attach a hand pump to port P on the anti-cavitation valve

and pressurise with hydraulic oil to 138 bar (2000 lbf/in2).

Check for leakage through the pilot valve, if the pilot valve is
faulty oil will leak from port V. In the event of oil leaking
through port V, check the ‘O’ rings and back-up rings are
correctly installed. If the valve still leaks at port V when
pressurised, replace the complete cartridge assembly.

After the anti-cavitation valve has been refitted bleed the

steer system as described on page E/36-3.

B
A
B
B

V
P

C
S221160

9803/7110 Issue 1
 Section E Hydraulics Section E
37 - 1 Valves 37 - 1

Steer Selector Valve

* 2CXU (212SU North America Only)

Removal Dismantling and Assembly

1 Park the machine on level ground, engage the parking The only serviceing permitted is the removal of the centre
brake and set the transmission to neutral. Lower the spindle to replace the seals.
attachments to the ground. Stop the engine and remove
the starter key. Replacing

2 Turn the steering wheel to the left and to the right Replacement is a reversal of the removal sequence.
several times to vent system pressure.
Make sure the hoses are correctly installed.
3 Remove valve block control lever knobs A. Undo
screws B and lift the control panel clear for access. Make sure the selector lever D aligns with correct decal.

4 To remove the selector valve C from the machine, Bleed the system as detailed on page E/40-3 and check for
disconnect and cap all hydraulic hoses from the valve. correct operation.
Label the hoses to ensure correct refitting.

5 Remove steer selector lever D.

6 Undo bolts E and remove valve from the machine.

A
B

C
D

E
S303920

9803/7110 Issue 2*
Section E Hydraulics Section E
40 - 1 Steer System Bleeding 40 - 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:
S
1 Start the engine.

2 Carefully raise the front wheels just clear of the ground

using the shovel.

3 Stop the engine.

A

4 Open the bonnet. Move the setting lever A to the SET

position S as shown.

5 Start the engine.

6 Turn the steering wheel to full left lock (only the rear
wheels will move).

7 Stop the engine.

181710
8 Disconnect the hydraulic hose from the rod side of the
rear steer ram, draining the hydraulic fluid into a suitable
container.

9 Start the engine.

10 Turn the steering wheel to full right lock.

11 Stop the engine.

12 Reconnect the rear steer ram rod side hose.

L
13 Start the engine.

14 Turn the steering wheel to full right lock.

A
15 Move setting lever A to the LOCK position L as shown.

16 Repeat steps 1 to 16 if necessary.

17 Lower the front wheels to the ground and stop the

engine.

18 Top up the hydraulic fluid level as required.

181720

9803/7110 Issue 1
Section E Hydraulics Section E
40 - 2 Steer System Bleeding 40 - 2

Anti-cavitation Valve
S
The following procedure is specifically for steer systems
fitted with the anti-cavitation valve.
A
1 Start the engine.

2 Carefully raise the front wheels just clear of the ground

using the shovel.

3 Stop the engine.

4 Open the bonnet. Move the setting lever A to the SET

position S as shown.

5 Start the engine.

6 Turn the steering wheel to full left lock (only the rear S181710
wheels will move).

7 Stop the engine.

8 Loosen the pilot feed hose (port P) on the anti-

cavitation valve. Refer to the warning below.

! WARNING
Do not loosen the connection more than one full turn.
Keep face and hands well clear of pressurised oil. Wear
protective glasses. C
Hyd 4 - 1

9 Disconnect the hydraulic hose from the rod side of the P

rear steer ram, draining the hydraulic fluid into a
suitable container.
V

10 Start the engine.

11 Turn the steering wheel to full right lock.

12 Stop the engine.

13 Reconnect the rear steer ram rod side hose, and

S220850
tighten the pilot feed hose (loosened in step 8).

14 Start the engine.

15 Turn the steering wheel to full right lock.

16 Move setting lever A to the LOCK position L as shown. L

17 Repeat steps 1 to 16 if necessary.

18 Lower the front wheels to the ground and stop the A

engine.

19 Top up the hydraulic fluid level as required.

S181720

9803/7110 Issue 1
 Section E Hydraulics Section E
40 - 3 Steer System Bleeding 40 - 3

* 2CXU (212SU North America Only)

Whenever any hydraulic steering component is
disconnected or removed the system must be bled as
follows.

With the engine running, this procedure must be carried out

in the correct order that is laid down. You must not alter the
order of selections and operations.

1 Select 4 Wheel Steer

2 Carry out the initial bleed procedure.

3 Select 2 Wheel Steer

(a) Turn steering wheel to left, until front wheels are

fully locked to the left.
(b) Turn steering wheel to right, until front wheels are
fully locked to the right.

2 Select 4 Wheel Steer

(a) Turn steering wheel to left, until front wheels are

fully locked to the left.
1
3 Select 2 Wheel Steer

(a) Turn steering wheel to full right lock.

(b) Turn steering wheel to full left lock.
(c) Turn steering wheel to full right lock.

4 Select 4 Wheel Steer

(a) Turn steering wheel to left, until the front wheels

are fully locked to the left.
3
5 Select 2 Wheel Steer
S297480
(a) Turn steering wheel to full right lock.
(b) Turn steering wheel to full left lock.
(c) Turn steering wheel to full right lock.

6 Select 4 Wheel Steer

(a) Turn steering wheel to left, until front wheels are

fully locked to the left.

7 Select 2 Wheel Steer

(a) Turn steering wheel to full right lock.

(b) Turn steering wheel to full left lock.
(c) Turn steering wheel to full right lock.

8 Select 4 Wheel Steer

(a) Turn steering wheel to left, until the front and rear
wheels are fully locked.

9803/7110 Issue 2*
Section E Hydraulics Section E
45 - 1 3 Point Hitch 45 - 1

Rams
Removal and Replacement

Removal Replacement

Remove any attachments fitted to the hitch, park the Replacement is the reversal of the removal procedure.
machine on firm level ground, apply the handbrake and
lower the hitch. Make sure that all pivot bores and pivot pins are clean and
greased when assembling. When fully assembled, apply
Switch OFF the engine and remove the starter key and grease at each grease nipple before operating the machine.
disconnect the battery. Operate the control levers to vent
residual pressure.
! WARNING
Hydraulic fluid at system pressure can injure you. Before
disconnecting or connecting hydraulic hoses, stop the
engine and operate the controls to release pressure
trapped in the hoses. Make sure the engine cannot be
started while the hoses are open.
INT-3-1-11/1

Disconnect the hoses to the ram being removed, plug hoses

and ram.

If the lift ram A is being removed, undo nuts B, remove bolts

C and pivot pins D.

If the pitch ram E is being removed, undo nut F, remove bolt

G and pivot pin H.

If the tilt ram J is being removed, undo nuts K, remove bolts

L and pivot pins M. Washers P are fitted to the bottom pivot
pin of the tilt ram.

Use suitable lifting equipment to remove the ram/s from the

machine.

G
L H
C
D
M F
K
B

M J C
D
L E
A
P
B
K
S325010

9803/7110 Issue 1
Section E Hydraulics Section E
50 - 1 Rams 50 - 1

9803/7110 Issue 1
 Section E Hydraulics Section E
50 - 2 Rams 50 - 2

TYPICAL RAM (with dowelled piston

head)
Note: Neither Loctite nor Activator must be allowed to
Dismantling and Assembly contact seals, bearing rings or 'O' rings.

When Dismantling Fit the locking dowel 5 to the piston head/rod as follows:

Place the ram assembly on a locally manufactured 1 New rod and piston head.
strip/rebuild bench.
If both are required, the following procedure should
Slacken the end cap 1 using a special spanner (see Service be followed:
Tools, Section 1) and remove the piston rod assembly from
the cylinder. i Drill through the piston head into the piston rod,
shown at Z. Use an undersized diameter drill first
as a guide and then drill using the correct size
! WARNING diameter drill to suit: refer to the table overleaf for
If air or hydraulic pressure is used to force out the piston drill diameters and depths.
assembly ensure that the end cap is fitted securely.
Severe injury can be caused by a rod being released ii Remove all swarf and contamination. Insert dowel
suddenly. C into the drilled hole, making sure that the
HYD 1-3
tapped extractor hole is to the outside.
Position the piston rod assembly on the bench in place of
2 New piston head fitted to a pre-drilled piston rod.
the ram cylinder. Remove the piston head seals 2, 3 and 4.
i Redrill and dowel BOTH the piston head and piston
Extract dowel 5 from the piston head using a metric
rod at 90° from the existing drilled dowel hole in the
screw(M3) threaded into the extractor hole.
piston rod. Follow the procedure described in step
1.
Note: Any attempt to remove the piston head without
removing the dowel will cause damage to both the piston
3 New piston rod fitted to a pre-drilled piston head.
head and rod.
Use the pre-drilled hole in the piston head. Care must
Remove piston head 6 from rod 7 using a special
be taken not to elongate the existing hole in the piston
spanner (see Service Tools, Section 1). Remove the piston
head.
head internal 'O' ring 8.
i Use a drill of the same diameter as the pre-drilled
Remove the end cap 1 from the piston rod and remove the
hole in the piston head to make a 'centre mark' in
inner and outer seals 9, 10 and 11.
the piston rod. DO NOT drill the piston rod at this
stage.
Ensure that all metal components are free from scoring,
nicks and burrs. A damaged rod will impair the life of the
ii Use an undersize diameter drill as a guide and drill
inner rod and wiper seals.
into the piston rod to the required depth (see the
table overleaf), making sure that the drill has
centred correctly on the 'centre mark' made in step
When Assembling
3i.
Renew all seals and 'O' rings.
iii Use the correct size diameter drill to suit the dowel
and drill to the required depth (see the table
Thoroughly clean the threads of the piston rod, piston head,
overleaf).
end cap and cylinder using a wire brush. Use JCB Cleaner &
Degreaser to ensure that all threads are free from grease,
iv Remove all swarf and contamination. Insert the
hydraulic oil and Loctite. Allow 15 minutes for the solvent to
dowel C into the drilled hole, making sure that the
dry before applying Loctite.
tapped extractor hole is to the outside.
Ensure that lubricants used during assembly do not come
Fit piston head seals 2, 3 and 4.
into contact with Loctite.
Position the cylinder on the bench and install the rod
* Refer
to the JCB Ram Sealing Procedure for the correct
assembly into the cylinder.
method of fitting seals to the end cap and piston head.

9803/7110 Issue 2*
Section E Hydraulics Section E
50 - 3 Rams 50 - 3

Typical Ram (with dowelled piston head)

Dismantling and Assembly (cont'd) DRILLING DETAILS FOR PISTON HEAD RETENTION
(all dimensions in mm)
When Assembling (cont'd)
Ram Dowel Guide Guide Dowel Dowel
Apply Loctite 932 to the first three threads of the cylinder. Fit Size Size Drill Ø Drill Drill Drill
the end cap and torque tighten. Depth Dia. X Depth Y

Note: If hydraulic oil contacts uncured Loctite, a weakening 50 x 25 20 x 6Ø 4 19 6.1/6.02 23/22

of the bond will result. Cure times vary according to the
ambient temperature and type of Activator used. The 60 x 30 20 x 6Ø 4 19 6.1/6.02 23/22
following approximate cure times apply at 20 deg C and are
the minimum periods between assembly and filling the ram 70 x 40 20 x 6Ø 4 19 6.1/6.02 23/22
with oil.
80 X 50 20 X 6Ø 4 19 6.1/6.02 23/22
Loctite 262 or 932 with Activator N - 1 hour
Loctite 262 or 932 with Activator T - 2 hours * 100 x 60 35 x 12Ø 8 33 12.02/12.10 37/38

Torque Settings

Refer to the Technical Data page - E/1-1 for torque setting

figures.

Note: When fitting cylinder and piston eye bushes 12,

ensure that the split in the bush is set at 90° to the
longitudinal centreline of the cylinder.

Note: Cold weather operation. When operating in conditions

which are consistently below freezing, it is recommended
that the rams are operated slowly to their full extent before
commencing normal working.

9803/7110 Issue 3*
Section E Hydraulics Section E
50 - 4 Rams 50 - 4

ilLUST 175620

9803/7110 Issue 1
 Section E Hydraulics Section E
50 - 5 Rams 50 - 5

Slew Ram
Dismantling and Assembly

When Dismantling
Place the ram assembly on a locally manufactured Position the cylinder on the bench and install the rod
strip/rebuild bench. assembly into the cylinder.
Slacken the end cap 1 using a special spanner (see Service Apply Loctite 932 to the first three threads of the cylinder. Fit
Tools, Section 1) and remove the piston rod assembly from the end cap and torque tighten.
the cylinder.
Note: If hydraulic oil contacts uncured Loctite, a weakening
! WARNING of the bond will result. Cure times vary according to the
If air or hydraulic pressure is used to force out the piston ambient temperature and type of Activator used. The
assembly ensure that the end cap is fitted securely. following approximate cure times apply at 20 deg C and are
Severe injury can be caused by a rod being released the minimum periods between assembly and filling the ram
suddenly. with oil.
HYD 1-3
Loctite 262 or 932 with Activator N - 1 hour
Position the piston rod assembly on the bench in place of Loctite 262 or 932 with Activator T - 2 hours
the ram cylinder. Remove the piston head seals 2, 3 and 4.
Torque Settings
Extract dowel 5 from the piston head using a metric
screw(M3) threaded into the extractor hole. Refer to the Technical Data page - E/1-1 for torque setting
figures.
Note: Any attempt to remove the piston head without
removing the dowel will cause damage to both the piston Note: When fitting cylinder and piston eye bushes 16 and
head and rod. spacer 17, ensure that the split in the bushes/spacer is set
at 90° to the longitudinal centreline of the cylinder.
Remove piston head 6 from rod 7 using a special
spanner (see Service Tools, Section 1). Remove the piston Note: Cold weather operation. When operating in conditions
head internal 'O' ring 8. which are consistently below freezing, it is recommended
that the rams are operated slowly to their full extent before
Remove the end cap 1 from the piston rod and remove the commencing normal working.
inner and outer seals 9, 10 and 11.
Remove circlip 12, collar 15, restrictor 13 and spring 14. 2DX Machines only
Note: If the ram is to be dismantled for seal renewal only, do Items 16 and 17 on the main illustration are replaced by
not remove the restrictor. items 16 - 18 on the view below. Ensure that lips L of seals
16 face outwards on reassembly.
Ensure that all metal components are free from scoring,
nicks and burrs. A damaged rod will impair the life of the
inner rod and wiper seals.

When Assembling
Renew all seals and 'O' rings. 16
Thoroughly clean the threads of the piston rod, piston head,
end cap and cylinder using a wire brush. Use JCB Cleaner & 17
Degreaser to ensure that all threads are free from grease,
hydraulic oil and Loctite. Allow 15 minutes for the solvent to 18
dry before applying Loctite.
Ensure that lubricants used during assembly do not come 17
into contact with Loctite. 16
Fit spring 14, restrictor 13, collar 15 and circlip 12. L
* Refer to the JCB Ram Sealing Procedure for the correct
method of fitting seals to the end cap and piston head.

Note: Neither Loctite nor Activator must be allowed to

contact seals, bearing rings or 'O' rings.

Fit locking dowel 5 to the piston head/rod as detailed on A230510

page 50 - 2.
Fit piston head seals 2, 3 and 4.

9803/7110 Issue 4*
Section E Hydraulics Section E
55 - 1 Rams 55 - 1

JCB Ram Sealing Procedure

To fit new rod seal:

Use seal fitting tool (892/00334) to fit rod seals, the size B A
(diameter) and position of pins A is determined by the
diameter and radial width of the rod seal being fitted.

The pins are screwed into threaded holes in the tool body,
the spacing of the holes is designed to suit small or large
diameter rod seals.

1 Open the tool as shown at B and insert the new rod C D

seal, the seal must be fitted behind the two front pins
but in front of the rear pin as shown.

Note: Later ram end caps and piston heads have metric
threads. The seals are also different, make sure the correct 161750
seals are fitted. On metric threaded rams make sure the
seals are fitted the correct way round, as shown at P and Q.

2 Close the tool as shown at C. The seal must form a

reniform (kidney shape).
P
3 Before fitting the rod seals check the seal grooves are
free of contamination and sharp edges,

4 Locate the seal in the end cap groove, shown at D,

when the seal is in position, open the tool to release the
seal. Make sure the seal is correctly installed in its
groove and remove the tool. Q
5 Fit rod wiper seal P into seal groove. Make sure the seal 153212
is correctly installed as shown.

Note: Some rod wipers, ie power track rod, may use a metal
encased seal which is pressed into the housing. Care must
be taken to ensure the seal is square before it is pressed in.

Sleeve E must be used to protect the rod seals from damage

when fitting end cap onto the piston rod. There are various
sizes of sleeve, see Service Tools, Section 1. Make sure the
hexagon on the end cap is towards the eye end of the rod.

E
A187361

9803/7110 Issue 1
Section E Hydraulics Section E
55 - 2 Rams 55 - 2

JCB Ram Sealing Procedure (continued)

Fit new piston head seals:

6 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. There are identification marks on the
outer diameter of the seal, make sure the marks are F
visible and the seal is free to rotate, if not remove the
seal and refit

7 Fit outer seal H using the same procedure as step 6. G

Check the external grooves are visible.

8 Ensure O ring is fitted into the internal seal groove on 338470

the piston head. Screw the piston head onto the thread
of the piston rod, refer to the relevant section for torque
figure and completion of ram assembly.

9 Fit the piston head retaining dowel, see ram dismantling

and assembling relevant section

10 Fit wear rings J and K. Rotate the wear rings so that the
piston retention dowel is covered by the wear ring, NOT
as shown at L.
H
Fit the piston rod and head assembly into the cylinder:

11 Insert the piston/rod assembly into the cylinder. Align

338480
the rod and head assembly until parallel with the
cylinder then push the assembly into the cylinder.

12 Fit the end cap, refer to the relevant section for torque
figure and completion of ram assembly. K
J

338490

9803/7110 Issue 1
Section F Transmission Section F
i i

Technical Data
Front Axle & Rear Axle (SD40) 1-1
Front Axle & Rear Axle (SD55) 1-1
Syncro Shuttle 1-1
Tyres 1-4
Product Changes 1-5

Towing Procedure 2-1

Synchromesh - Description 3-1

Fault Finding
Syncro Shuttle - Hydraulic 4-1
Syncro Shuttle - Mechanical 4-3
Parking Brake 4-6

Front Axle
Removal and Replacement 6-1

Rear Axle
Removal and Replacement 8-1

Front and Rear Axles

Drive Head
- Dismantling and Assembly 11 - 1
Drive Head with Limited Slip Differential (SD40 Axles)
- Dismantling and Assembly 11 - 6
Drive Head with Limited Slip Differential (SD55 Axles)
- Dismantling and Assembly 11 - 11
Crown Wheel and Pinion
- Adjustment 12 - 1
Renewing the Pinion Oil Seal 12 - 2
Axle Hub and Driveshaft
- Dismantling and Assembly (SD40 & SD55 Axles) 13 - 1
Axle Hub (Splined) and Driveshaft (SD55 Axles)
- Dismantling and Assembly 14 - 1

Propshafts
Removing and Replacing 31 - 1

Syncro Shuttle Transmission

Gearbox Dismantling and Assembly 41 - 1
Reverser Unit Dismantling and Assembly 42 - 1
Torque Converter Replacing 44 - 1
Pressure & Flow Testing 45 - 1
Torque Converter Stall Test 45 - 4

Power Take Off Clutch

- Description of Operation 50 - 1
- Removal & Replacement 51 - 1
- Dismantling & Assembly 51 - 1

Transfer Gearbox
- Removal & Replacement 55 - 1
- Dismantling & Assembly 55 - 2

9803/7110 Issue 5
Section F Transmission Section F
ii ii

* Salvage/repair
- Drive Shaft Oil Seal (all JCB axles) 60 - 1
- Wear Sleeve Fitting 61 - 1
- Axle & Gearbox Driveshaft Flange Seals (all JCB axles) 62 - 1
- Hub & Driveshaft - Fitting Bearing Carrier Combination Seal63 - 1

9803/7110 Issue 1
 Section F Transmission Section F
1-1 Technical Data 1-1

Front Axle & Rear Axle (SD40) - used on 2CX, 210S

* Note: From machine serial No. 489724 machines are fitted with SD55 axles, see below.

Type JCB spiral bevel input with epicyclic hub reduction

Designation SD40 (with brakes)
Type of Brakes Oil immersed multi-plate disc located in hubs
Installation
Front Centre pivot
Rear Rigid pad mount
Weight (dry, less wheels; approx.) 245 kg (540 lb)
Overall Gear Ratio 16.154:1
Crownwheel & Pinion Ratio 2.692:1
Number of Teeth
Crownwheel 35
Pinion 13
Hub reduction 6:1
Toe-in 0°
Castor angle 0°
Camber angle 1°
Kingpin inclination 0°
Number of steer rams 1
Input type Yoke coupling

Front Axle & Rear Axle (SD55) - used on 2CXAM, 2CXL, 2CXU, 210FM, 210SL, 2DX, 212SU
Type JCB spiral bevel input with epicyclic hub reduction
Designation SD55 (with brakes)
Type of Brakes Oil immersed multi-plate disc located in hubs
Installation
Front Centre pivot
Rear Rigid pad mount
Weight (dry, with no steer rams and
without wheels) 330 kg (728 lb) approx
Overall Gear Ratio 2CX, 2DX, 212SU from machine serial No. 489724
18 inch wheel 16.1:1
20 inch wheel 18.6:1
Overall Gear Ratio 16.2:1
Crownwheel & Pinion Ratio 3:1
Number of Teeth
Crownwheel 33
Pinion 11
Hub reduction 5.4:1
Toe-in 0°
Castor angle 0°
Camber angle 1°
Kingpin inclination 0°
Number of steer rams 1

Note: When appropriate, the service information (e.g. dismantling and assembly procedures etc.) will identify differences
between the SD40 and SD55 axles.

Syncro Shuttle
Syncro Shuttle Combined torque converter, reverser, and gearbox unit with
integral parking brake.
Type SS400
Drive Output 4 wheel-drive, double yoke
Weight (dry) 150 kg (330 lb)
Gear Ratios 30 kph (18 mph) 20 kph (12 mph)
1st 4.27:1 6.31:1
2nd 2.50:1 3.70:1
3rd 1.18:1 1.75:1
4th 0.70:1 1.03:1

9803/7110 Issue 6*
 Section F Transmission Section F
1-2 Technical Data 1-2

Syncro Shuttle (cont’d)

Torque Converters

Ratio 2.8:1 2.78:1 2.4:1

Colour Coded Dots 3 Brown 1 Pink & 1 Yellow 2 Orange & 1 Green
Designation SSL11 SSS11 WH11

Stall Figures

2CX Airmaster Farm 2CX - 20 kph 2CXU 2DX

2CXL Master 210SU

Engine Stall Speed

1 Converter only
max r.p.m. 2127 2127 1790 2170 2127 N/A
min. r.p.m. 2027 2027 1700 2070 2027 N/A

2 Converter + MRV
max. r.p.m. 1825 1825 1490 1848 1825 N/A
min. r.p.m. 1725 1725 1400 1748 1725 N/A

Build Specification
Engine Size 65 bhp ! ! ! !
74 bhp ! !

Converter Type SSL11 (2.8:1) ! ! ! !

SSS11 (2.78:1) !
WH11 (2.4:1) !

Pump Size 58 l/min (12.7 gal/min) ! ! ! ! ! !

(15.3 USA gal/min)

Fan Ratio 1 to 1 ! ! !
1 to 1.25 ! ! !

* Low Emission Engines

2CX 2CXU 2DX

2CXL 212SU

Engine Stall Speed

1 Converter only r.p.m. 2078 1576 2242

2 MRV r.p.m. 2121 2320

MRV (Loader) r.p.m. 2320
MRV (Excavtor) r.p.m. 2272

2 Converter + MRV r.p.m. 1825 1398 1852

(Loader)

Build Specification
Engine Size 66 bhp !
75 bhp ! !

Converter Type SSL11 (2.8:1) ! !

WH11 (2.4:1) !

9803/7110 Issue 6*
Section F Transmission Section F
1-3 Technical Data 1-3

Syncro Shuttle (cont'd)

Converter Pressures (in neutral) bar kgf/cm2 lbf/in2

Converter In at 50 deg.C 1000 rev/min 2.4 - 3.4 2.5 - 3.5 35 - 50

2000 rev/min 5.2 - 6.5 5.3 - 6.7 75 - 95
Converter In at 100 deg.C 1000 rev/min 1.3 - 2.0 1.4 - 2.1 20 - 30
2000 rev/min 5.2 - 5.9 5.3 - 6.0 75 - 85

Converter Out (measure at 50 deg.C and 2000 rev/min) 3.4 3.5 50 max

Converter Relief (Safety) Valve Pressure 6.5 6.7 95 max

Lubrication Pressures (in neutral)

At 50 deg.C 1000 rev/min 0.2 - 0.3 0.2 - 0.4 3.0 - 5.0

2000 rev/min 0.4 - 0.7 0.4 - 0.7 6.0 - 10.0
At 100 deg.C 1000 rev/min 0.1 - 0.2 0.1 - 0.2 2.0 - 3.0
2000 rev/min 0.3 - 0.6 0.3 - 0.6 4.0 - 8.0

Main Line Pressure (in neutral)

At 50 deg. C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150

2000 rev/min 10.7 - 11.7 10.9 - 12.0 155 - 170

At 100 deg.C 1000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150
2000 rev/min 9.3 - 10.3 9.5 - 10.5 135 - 150

Clutch Pressure (forward and reverse) †

At 50 deg. C 1000 rev/min 7.6 - 9.7 7.7 - 9.8 110 - 140

2000 rev/min 9 - 11 9.1 - 11.25 130 - 160

At 100 deg.C 1000 rev/min 7.6 - 9.7 7.7 - 9.8 110 - 140
2000 rev/min 7.6 - 9.7 7.7 - 9.8 110 - 140

† Note: The forward and reverse clutch pressures should always be the same as the mainline pressure less (a maximum of)
1.7bar (25lbf/in2; 1.8kgf/cm2). If the mainline pressure is in the lower part of the tolerance band, then the forward and reverse
clutch pressures should also be in the lower part of the tolerance band and vice versa.

Flow Rates (in neutral) litres/min UK gal/min US gal/min

Cooler at 50 deg.C 1000 rev/min 10.4 - 13.6 2.3 - 3.0 2.8 - 3.6
2000 rev/min 14.5 - 20.0 3.2 - 4.4 3.8 - 5.3

Cooler at 100 deg.C 1000 rev/min 10.2 - 12.5 2.3 - 2.8 2.7 - 3.3
2000 rev/min 22.7 - 26.1 5.0 - 5.7 6.0 - 6.9

Pump at 50 deg.C 1000 rev/min 11.0 - 15.0 2.5 - 3.3 2.9 - 4.0
2000 rev/min 22.5 - 29.5 5.0 - 6.5 6.0 - 7.8

9803/7110 Issue 3
 Section F Transmission Section F
1-4 Technical Data 1-4

Tyres
Note: Wheel fixing on SD40 axle was changed from 8 stud to 4 stud at machine serial number 657150. Wheel fixing on SD40
Limited Slip Differential axle was changed from 8 stud to 4 stud at machine serial number 657159. The first machine fitted with
SD55 axles (5 stud fixing) was serial number 657628.

FRONT

Type Size Ply Pressure (Normal Duty) † Pressure (Heavy Duty) ††

bar lbf/in2 bar lbf/in2

Firestone Super Traction Lug 12.5 x 18 10 1.5 22 2.1 30

Goodyear Sure Grip Lug 12.5/80 x 18 10 2.5 36 3.5 51

Continental AS Farmer 12.5 x 18 10 1.75 26 2.55 37

Michelin X M27 335/80 R18 - 1.8 26 2.7 39

Dunlop SP PG7 385/55 R18 - 2.5 36 3.8 55

Goodyear SG Implement 12.5/80 x 18 10 2.5 36 3.5 51

Michelin X M27 405/70 R 20 - 1.4 20 2.4 34

REAR
*
Type Size Ply Pressure (Normal Duty) † Pressure (Heavy Duty) †††
bar lbf/in2 bar lbf/in2

Firestone Super Traction Lug 12.5 x 18 10 1.7 25 1.9 28

Traction S.G. Goodyear 12.5/80 x 18 10 2.25 33 2.5 36

Continental AS Farmer 12.5 x 18 10 1.75 26 2.0 29

Michelin X M27 335/80 R18 - 1.8 26 2.2 32

Dunlop SP PG7 385/55 R18 - 2.25 33 3.0 44

Goodyear SG Implement 12.5/80 x 18 10 2.25 33 2.5 365

Michelin X M27 405/70 R 20 - 1.4 20 1.8 26

† These tyre pressures are recommended for road travel and normal working conditions.

†† 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.

9803/7110 Issue 3*
Section F Transmission Section F
1-5 Technical Data 1-5

Product Changes

Axles

1 On both SD40 and SD 55 axles, JCB recommend that only the latest type friction and counter plates be used, refer to
General Technical Information, 061 (G20/N. Am.) and 057 (G19/N. Am.). Replace complete axle sets, parts are packed in
set unit quantities. See parts book for specific axle quantities. Plates must not be mixed, use in sets.

2 On SD 55 steer-drive axles, a new oil seal A was introduced for

the steer axle inner drive shaft, General Technical Information
066 (F103/N. Am.) refers.

3 On both SD40 and SD 55 axles, the ring dowel positions on the

annulus carrier have been altered so that now they are equally
spaced. Replacement annulus carrier with the old ring dowel
spacing and square section seals, (see step 3) is still available
for service use, if a hub swivel is changed to the later type ring
A
dowels it is not necessary to change both sides for this reason.

; ;;;
;;;;
4 On both SD40 and SD 55 axles, the brake piston seal changed from
an ‘O’ ring seal to a square section seal. For SD40 axles General
Technical Information 064 (F100/N. Am.) refers. For SD55 axles

;;;
;;;;
; ;;;
;;;;
General Technical Information 068 (F104/N. Am.) refers. The square
section seal type annulus brake piston can be visually identified as

;;;
;;;; ;;;
there is one seal groove in the piston B and one seal groove in the

;;;;
;;;
annulus carrier C. The ‘O’ ring seal brake parts have two seal
grooves in the brake piston shown at D. Square section type brake

;;;
;;;; ;;;
;;
;;;
pistons and brake annulus carriers must be fitted to both sides of
the axle when replacing ‘O’ ring type annulus carriers with square

;;
;;;; ;;;
type seals to ensure even braking.
B
5 On both SD40 and SD55 axles, a heavy duty circlip with the larger
groove on driveshafts was progressively introduced. The new circlip C

;;;; ;;;
will not fit the old driveshafts. To identify the different shafts
measure the groove width:
Standard 1.74 - 1.6mm Heavy duty 2.35 - 2.15mm

;;;;
;;;
; ;;;
;;;;
General Technical Information 065 (F102/N. Am.) refers.

;;;;
;;;;
;;; ;;;
6 SD40 axles have changed from a seven ring dowel to a six ring

;;;;
;;;
dowel and have 3 brake piston back off bolts instead of 2.

;;;;
;;; ;;;
;;
;;;
7 SD55 have introduced a new axle which changed from ring dowel

;;
and Verbus Ripp bolt securing of the annulus carrier to the hub swivel

;;;; ;;;
to a splined annulus carrier and hub swivel with retaining plate. For

;;
Dismantle and Assembly procedure see page F/14-1 to 14-4. D
D

9803/7110 Issue 1
Section F Transmission Section F
2-1 2-1

Towing Procedure
General 5 Release the parking brake.

! CAUTION a If the engine can not be run, proceed as follows:

Towing a machine too far or too fast can damage the
transmission. Do not tow the machine further than one ! DANGER
mile. Use a trailer for greater distances. When towing do Chock the front and rear wheels to prevent the machine
not travel faster than 25 km/h (15 mph). from moving as it is necessary to work under the
machine to release the parking brake. When the brake
Use towing chains with two towing vehicles. One towing has been manually released, as described below, it will
vehicle should be coupled to the front of the disabled be impossible to apply the parking brake.
machine. The other towing vehicle should be coupled to 2-2-7-12
the rear of the disabled machine, to provide braking
power. i Gain access to the parking brake housing A
mounted on the rear face of the gearbox.
The towing vehicle(s) must have enough pulling and ii Remove brake centre bolt B and spacer C.
braking power to move and stop the machine. iii Retain the spacer.
2-2-7-11 iv Screw bolt B back into the housing until the bolt
head just touches the housing.
Preparation for Towing
! CAUTION
1 Block the wheels securely before preparing the
machine for towing. Do not remove the blocks until the Do not over tighten, it is only necessary to overcome the
* spring force.
machine is hitched to the towing vehicle.

2 Select neutral gear. The brake has been released and the machine is now
ready for towing.
3 The backhoe and stabilisers must be in their transport
positions and secured. The loading shovel must be When towing is completed, and before unhitching the
raised to 900 mm (3 ft) above the ground and blocked. towing vehicle, reverse the above procedure to re-apply
This gives room to connect the towing chains. the parking brake. Apply sealant to bolt B and tighten
to a torque of 56 Nm (41.3 lbf ft).
If the engine can not be run, the backhoe, stabilisers
and loading shovel must be hoisted into their transport b Alternatively, if the engine can be run, operate the
positions and secured. parking brake control to release the brake. In this
situation it will be necessary to run the engine
4 Attach towing chains from the front towing vehicle to throughout towing. Stop the engine to re-apply the
the disabled machine front attachment points and the parking brake before unhitching the towing vehicle.
rear vehicle to the disabled machine rear frame.
6 When towing is complete, block the wheels before
unhitching the machine from the towing vehicles.

BC

S182250

9803/7110 Issue 3*
Section F Transmission Section F
3-1 3-1

A B
C

E
D

F G

5154A
H J

9803/7110 Issue 1
Section F Transmission Section F
3-2 3-2

Synchromesh - Description
The gearbox is fitted with 'Blocking Pin' synchromesh, As the speeds are synchronised the radial load on the
comprising the following parts. blocker pin and the synchro hub is reduced. This allows the
synchro hub to slide freely along the blocker pin and engage
SYNCHRO HUB (A) controls the operation of the its dog teeth with second gear, see diagram J.
synchromesh unit and gear selection, the selector fork fitting
into the outer groove. Internal dog teeth link the selected
gear to the drive shaft. Through the synchro hub centre are
two sets of holes for the blocker pins (C) and the split
energiser pins (D), spaced alternately.

SYNCHRO RINGS (B) are rigidly joined by the blocker pins,

with the split energiser pins held, in counterbores, between
the two synchro rings.

BLOCKER PINS (C) have a narrow neck in the centre,

against which the synchro hub transmits radial drive during
gear changes. The edges of the blocker pin neck and their
mating synchro hub holes are designed so that, as the radial
loads are reduced, the synchro hub can slide over the
shoulder of the blocker pin.

SPLIT ENERGISER PINS (D) take the initial axial load of the
synchro hub on the shoulder of the split energiser pin neck.
As the axial load reaches approximately 400 N (40.8 kg; 90
lb) the internal springs allow the split energiser pin to
collapse and the synchro hub to move axially.

SYNCHRO CUPS (E) take the frictional drive from the

synchro ring on their inner faces. The synchro cups are
5171
splined to drive their respective gears whilst synchronisation
is taking place.

SYNCHROMESH - OPERATION

Diagram F shows the gearbox with first gear engaged.

Synchro ring B is in contact with synchro cup E and the
synchro hub dog teeth are linking first gear to the shaft gear.
In this position the split energiser pins D are 'collapsed'.

When selecting second gear the synchro hub A slides along

the split energiser pins until the pin recess and the synchro
hub flange are in line. At this point the split energiser pins
open and the synchro rings are moved by the synchro hub
pushing on the split energiser pin shoulder.

Initial contact between the synchro ring and the synchro cup
starts to synchronise the speed of the shaft and second
gear. The rotational force of the synchro ring is taken by the
blocker pin against the edge of the synchro hub hole, as at
G.

As the axial load on the synchro hub increases, the split

energiser pin 'collapses' and the conical faces of the
blocking pin and synchro hub hole come into contact, as at
H.

Further increases in the axial loads increase the frictional

grip of the synchro ring and the synchro cup, causing the
shaft and gear speeds to synchronise.

9803/7110 Issue 1
 Section F Transmission Section F
4-1 Fault Finding 4-1

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
1 Poor engine condition. 1 Check and if necessary repair engine.
2 Low oil level. 2 Top up system.
3 Worn pump. 3 Check flow and if necessary repair or renew pump.
4 Torque converter damage. 4 Check and if necessary repair or renew torque converter.
5 Low mainline pressure. 5 See fault 'Low Mainline Pressure'.
6 Clutches slipping. * 6 See fault 'Low Clutch Pressure'.
7 Internal leakage. 7 a) Check internal cored galleries and casting for porosity.
* b) Check condition of seals.
8 High stall speeds. 8 See fault 'High Stall Speeds'.
9 Low stall speeds. 9 See fault 'Low Stall Speeds'.
10 Overheating. 10 See fault 'Overheating'.

LOW MAINLINE PRESSURE (in neutral)

Possible Cause Remedy
1 Worn pump. * 1 Check flow and if necessary repair or renew pump.
2 Blocked suction strainer. 2 Clean suction strainer.
3 Pressure maintaining valve sticking/leaking. 3 Free off or renew valve.
4 Oil aerated (foaming). 4 a) Internal leakage (cored galleries) - inspect/repair
transmission.
b) Dirty suction strainer - clean strainer.
c) High oil level - drain to proper level.
d) Incorrect grade of oil - drain then refill with correct oil.
5 Oil leak through parking brake on/off circuit. 5 a) Check external pipework for parking brake circuit.
b) Check parking brake (pressure) circuit - refer to parking
brake fault finding procedure on page F/4-6.
c) Disconnect parking brake and re-check.

* HIGH STALL SPEEDS (Forward & Reverse Clutches)

Possible Cause Remedy
1 Damaged converter blades. 1 Check and if necessary renew converter.
2 Clutches slipping. * 2 See fault 'Low Clutch Pressure'.
3 Internal leakage. 3 a) Check internal cored galleries and casting for porosity.
* b) Check condition of seals.

* LOW STALL SPEEDS (Forward & Reverse Clutches)

Possible Cause Remedy
1 Poor engine condition. 1 Check and if necessary repair engine.
2 Torque converter reaction member clutch slipping. 2 Check and if necessary renew torque converter.

LOW CONVERTER OUT PRESSURE

Possible Cause Remedy
1 Low mainline pressure. 1 See fault heading 'Low Mainline Pressure'.
2 Converter internal leakage. 2 Check and if necessary renew converter.
3 Converter relief valve faulty. 3 Check and if necessary repair relief valve.
* 4 Restriction in converter feed. 4 See item 10 in fault 'Overheating'

LOW PUMP FLOW

Possible Cause Remedy
1 Low oil level. 1 Top up system.
2 Blocked suction strainer. 2 Clean suction strainer.
* 3 Worn pump. 3 Repair or renew pump.

9803/7110 Issue 3*
Section F Transmission Section F
4-2 Fault Finding 4-2

Syncro-Shuttle Gearbox - Hydraulic (cont'd)

HIGH CONVERTER OUT PRESSURE
Possible Cause Remedy
1 Oil cooler/lines blocked. 1 Clean cooler, free blockage.
2 Converter in pressure incorrect 2 Check converter in pressure correct
3 Converter relief valve faulty. 3 Check and if necessary repair relief valve.

LOW LUBRICATION PRESSURE

Possible Cause Remedy
1 Low mainline pressure. 1 See fault heading 'Low Mainline Pressure'.
2 Oil cooler/lines blocked. 2 Clean cooler, free blockage.
3 Ruptured lubrication line. 3 Repair line.
4 Converter internal leakage. 4 Check and if necessary renew converter.
5 Converter relief valve faulty. 5 Check and if necessary repair or renew relief valve.
6 Leak at pump to case joint (indicated by low cooler flow) 6 Check and if necessary repair or replace as necessary.
7 Restriction in converter feed 7 See item10 in fault 'Overheating'

LOW CLUTCH PRESSURE AND/OR CLUTCH SLIPPING

Possible Cause Remedy
1 Low mainline pressure. 1 See fault heading 'Low Mainline Pressure'.
2 Worn pump. 2 Check flow and if necessary repair or renew pump.
3 Blocked restrictor orifice in F/R solenoid valve block. 3 Remove F/R solenoid and clear restriction in solenoid
(Both F/R clutches will indicate low pressure). valve block.
4 Clutch seals worn. 4 Confirm with a clutch leak test, if required renew clutch
seals
5 Clutch piston rings worn. 5 Confirm with a clutch leak test, renew piston rings.
6 Mechanical failure. 6 Strip and rebuild clutch, renew parts as required.

LOW COOLER FLOW

Possible Cause Remedy
1 Converter relief valve faulty. 1 Check and if necessary repair or renew relief valve.
2 Leak at pump to case joint . 2 Check and if necessary repair or replace as necessary.
3 Worn pump. 3 Check flow and if necessary repair or renew pump.
4 Internal leakage. 4 a) Check internal cored galleries and casting for porosity.
b) Check condition of seals.
5 Restriction in converter feed. 5 See item 10 in fault 'Overheating'.

OVERHEATING
Possible Cause Remedy
1 Low oil level. 1 Top up system.
2 High oil level. 2 Drain oil to correct level.
3 Trapped or kinked hoses in cooler system. 3 Renew or repair hoses.
4 Low converter out pressure and flow rate. 4 Repair or renew the converter relief valve.
5 Oil cooler blocked. 5 Clean cooler.
6 Operating in wrong gear range. 6 Select correct gears to suit working conditions.
7 Water system overheating. 7 Rectify water system problems, eg radiator, cooler lines,
low water level etc.
8 Oil aerated (foaming). 8 See fault 'Low Mainline Pressure', item 4.
9 Clutch piston(s) sticking on return stroke. 9 Check and repair clutch piston(s) and seal(s).
10 Cored galleries on front housing pump mounting * 10 Replace front housing (or rectify existing housing).
face wrong depth (indicated by excessively low
pressure and flow on converter out cooling line).
11 Leakage across pump mounting face and front case. 11 Check for damaged surface on both components and
loose pump mounting bolts.

9803/7110 Issue 4*
Section F Transmission Section F
4-3 Fault Finding 4-3

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. Ensure that the correct quantity and grade of oil is used and that there are no
obvious leaks.

A If the transmission is noisy, start at check 1.

B If the transmission is overheating, start at check 4.

C If the transmission will not pull, start at check 12.

D If there is no drive in one or both directions, start at check 17.

E If the transmission is jumping out of gear, start at check 29.

F If the transmission is sticking in gear, start at check 39.

G If ratios are 'crash changing', start at check 41.

CHECK ACTION

1 Is there noise when selecting direction? YES: Check 3

NO: Check 2

2 Is there noise when running with direction selector YES: Check 9

in neutral and ratio selector in a gear? NO: Check 19

3 Is there air in the hydraulic system? YES: Continue running to expel air.
NO: Check 4

4 Is the fluid level correct? YES: Check 5

NO: Check level only when machine is cold and top-up as
required.

5 Are the oil passages restricted? YES: Clear the restriction.

NO: Check 6

6 Is the suction strainer restricted? YES: Remove and clean strainer.

NO: Check 7

7 Is pump pressure as specified? YES: Check 9

NO: Check clutch pressure maintenance valve is free to
operate.

8 When flow testing pump, is output low? YES: Renew pump.

NO: Check converter sprag clutch for wear or slip.

9 Does the noise continue when direction selector YES: Check 10

is in forward or reverse? NO: Check 11

10 Is transmission misaligned? YES: Renew mountings and check position.

NO: Check 'converter out' pressure and flow.

11 Are the pump bushes worn? YES: Renew

NO: Check converter for wear or cooler for restriction to
flow.

12 Is the transmission not pulling in one direction only? YES: Check 16

NO: Check 13

13 Is the transmission not pulling in both YES: Stall test machine, Check 14.
Forward and Reverse? NO: Check 16

9803/7110 Issue 3
Section F Transmission Section F
4-4 Fault Finding 4-4

Syncro Shuttle Gearbox - Mechanical (cont'd)

CHECK ACTION

14 Is 'converter in' pressure as specified? YES: Check 15

NO: Inspect converter relief valve for damage. Check
cooler bypass relief valve pressure setting.

15 Is pump being driven by converter? YES: Check pump pressure.

NO: Renew damaged parts.

16 Are clutch sealing rings damaged? YES: Tap pressure gauge into clutch feed lines to monitor
pressure.
NO: Check clutch plates for damage.

17 Is there drive in one direction only? YES: Check 19

NO: Check 18

18 Is the start switch in the run position and supplying YES: Check 19
current to the neutral start relay? NO: Rectify.

19 Is the fault only when the transmission is hot? YES: Dismantle solenoid and check components.
NO: Check microswitches, relay and wiring loom.

20 Is the noise a growl, hum or grinding? YES: Check gears for damage or wear.
NO: Check 21

21 Is the noise a hiss, thump or bumping? YES: Check bearings for damage or wear.
NO: Check 22

22 Is the noise a squeal? YES: Check free running gears for seizure.
NO: Check 23

23 Is the noise present when in neutral or when in gear? NEUTRAL: Check 24

IN GEAR: Check 27

24 Is the countershaft or its bearings worn or damaged? YES: Renew damaged parts.
NO: Check 25

25 Is there excessive backlash in the gears? YES: Adjust by checking shaft end float.
NO: Check 26

26 Is the mainshaft pilot bearing worn? YES: Renew.

NO: Check gear teeth for scuffing.

27 Is the mainshaft rear bearing worn? YES: Renew.

NO: Check 28

28 Are the sliding gear teeth worn or damaged? YES: Renew gears.
NO: Check 29

29 Are the selector forks loose? YES: Tighten screws.

NO: Check 30

30 Are the selector fork pads or grooves in gears worn? YES: Renew worn parts.
NO: Check 31

31 Are the dog gear teeth worn? YES: Renew.

NO: Check 32

32 Are the selector rod detent springs broken? YES: Renew.

NO: Check 33

9803/7110 Issue 1
Section F Transmission Section F
4-5 Fault Finding 4-5

Syncro Shuttle Gearbox - Mechanical (cont'd)

CHECK ACTION

33 Are the selector rods worn or damaged? YES: Renew.

NO: Check 34

34 Are the selector fork pads out of position? YES: Reposition or renew (check interlock).
NO: Check 35

35 Is there excessive end float in gears or shafts? YES: Adjust.

NO: Check thrust washers and mating faces.

36 Is the synchroniser bronze worn? YES: Renew synchro pack.

NO: Check 37

37 Are steel chips embedded in the bronze? YES: Continue using, chips will either embed below bronze
or be rejected.
NO: Check 38

38 Are the synchroniser components damaged? YES: Renew.

NO: Check free running gears for seizure or damage.

39 Are the sliding gears tight on the splines? YES: Free or renew.
NO: Check 40

40 Are chips wedged between splines of shaft YES: Remove chips.

or gear? NO: Ensure that clutch is disengaged when dump pedal is
pressed.

41 Are steel chips embedded in the bronze? YES: Continue using, chips will either embed below bronze
or be rejected.
NO: Check 42

42 Are the synchroniser spring pins damaged? YES: Renew synchro.

NO: Check 43

43 Is the synchroniser bronze worn? YES: Renew synchro.

NO: Check blocker pins.

9803/7110 Issue 1
Section F Transmission Section F
4-6 Fault Finding 4-6

Parking Brake
PARKING BRAKE INOPERATIVE BUT TRANSMISSION FUNCTIONS IN FORWARD AND REVERSE

CHECK ACTION

1 Is distance spacer fitted to centre bolt (B, page F/2-1)? YES: Check 2.
NO: Fit spacer.

2 Is the parking brake solenoid spool sticking? YES: Free off or renew valve.
NO: Check 3.

3 Put the starter switch in 'IGN' position. Disengage the YES: Dismantle parking brake and check condition.
parking brake, is there a voltage reading at the parking NO: Check 4.
brake feed wire?

4 Put the starter switch in 'IGN' position. Is there a voltage YES: Renew parking brake relay.
reading at the parking brake solenoid feed wire? NO: Check switch and wiring.

PARKING BRAKE PERMANENTLY ENGAGED

CHECK ACTION

1 Is the parking brake solenoid spool sticking? YES: Free off or renew valve.
NO: Check 2.

2 Put the starter switch in 'IGN' position. Disengage the YES: Check 4.
parking brake, is there a voltage reading at the parking NO: Check 3.
brake feed wire?

3 Put the starter switch in 'IGN' position. Is there a voltage YES: Check 4.
reading at the parking brake solenoid feed wire? NO: Check switch and wiring.

4 Has the parking brake been dismantled recently? YES: Dismantle and check for correct build.
NO: Check 5.

5 Is the transmission main line pressure correct? YES: Check 6.

NO: See Hydraulic Fault Finding Procedures, starting at
page F/4-1.

6 Is the main line pressure correct with the parking brake YES: Dismantle parking brake and check condition.
circuit isolated? NO: See Hydraulic Fault Finding Procedures, starting at
page F/4-1.

9803/7110 Issue 1
Section F Transmission Section F
6-1 Front Axle 6-1

A E D

C
B

S175691

9803/7110 Issue 1
Section F Transmission Section F
6-2 Front Axle 6-2

Removing and Replacing

! WARNING
A raised and badly supported machine can fall on you.
Position the machine on a firm, level surface before
raising one end. Ensure the other end is securely
chocked. Do not rely solely on the machine hydraulics or
jacks to support the machine when working under it.

Disconnect the battery, to prevent the engine being

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

Removing
Replacing
! WARNING 1 Replacing is the reverse of the removal sequence.
Raised loader arms can drop suddenly and cause
serious injury. Before working under raised loader arms, 2 Apply JCB Lock & Seal to the threads of bolts A.
fit the loader arm safety strut.
GEN3-2
Torque Settings
1 Using Tool No. 892/00822 remove bolts A to
Item Nm kgf m lbf ft
disconnect the propshaft from the axle (refer to Page
A 40-48 4.08-4.90 29.5-35.4
31 - 1).
B 680 69 500
2 Disconnect the brake pipes from the axle swivel hubs,
blank off the exposed connections.

3 Disconnect the hydraulic pipes from the steer ram,

blank off all exposed connections.

4 Loosen the road wheel retaining nuts B.

5 Make sure that the rear wheels are blocked, raise the
loader arms and install the safety strut G. Engage the
parking brake.

6 Prop the machine on each side as shown at C.

7 Remove the front road wheels.

8 Position a jack underneath the balance point (see Note)

of the axle and support the axle weight.

Note: Because the drivehead assembly is offset, the balance

point of the axle is not the centre of the axle. Attach a
'cradle' to the jack that will partially embrace the axle.

9 Remove nut D and pivot pin retaining bolt E.

10 Use puller (tool no. 992/00800) and remove the pivot

pin F.

11 Lower the jack so that the axle is clear of the mounting

yoke and remove the axle.

9803/7110 Issue 1
Section F Transmission Section F
8-1 Rear Axle 8-1

F
D S175641

9803/7110 Issue 1
Section F Transmission Section F
8-2 Rear Axle 8-2

Removing and Replacing

! WARNING
A raised and badly supported machine can fall on you.
Position the machine on a firm, level surface before
raising one end. Ensure the other end is securely
chocked. Do not rely solely on the machine hydraulics or
jacks to support the machine when working under it.

Disconnect the battery, to prevent the engine being

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

Removing Replacing
1 Replacing is the reverse of the removal sequence.
1 Using Tool No. 892/00822 remove bolts A to
disconnect the propshaft from the axle (refer to Page
2 Apply JCB Lock & Seal to the threads of bolts A.
31 - 1).

2 Disconnect the brake pipes from the axle swivel hubs,

blank off the exposed connections. ! CAUTION
Bleed the brake system before driving the machine.
3 Disconnect the hydraulic pipes from the steer ram, BRAK 1-6

blank off all exposed connections.

Torque Settings
4 Loosen the road wheel retaining nuts B.
Item Nm kgf m lbf ft
5 Make sure that the front wheels are blocked, use the A 20.9 - 23.7 2.13 - 2.42 15.4 - 17.5
stabiliser legs to raise the rear end of the machine. B 680 69 500
Engage the parking brake. D 476 49 351

6 Prop the machine on each side as shown at C.

7 Remove the rear road wheels.

8 Position a jack underneath the balance point (see Note)

of the axle and support the axle weight.

Note: Because the drivehead assembly is offset, the balance

point of the axle is not the centre of the axle. Attach a
'cradle' to the jack that will partially embrace the axle.

9 Remove nuts D, bolts E and washers F.

10 Lower the jack and remove the axle.

9803/7110 Issue 1
Section F Transmission Section F
11 - 1 Front and Rear Axles 11 - 1

S175651

9803/7110 Issue 2
 Section F Transmission Section F
11 - 2 Front and Rear Axles 11 - 2

Drive Head - Dismantling Drive Head - Assembly

The following procedures apply to both the SD40 and SD55 Pinion Depth (see Note)
axles; the illustrations show a typical axle.
Place new pinion head bearing assembly on a flat surface
1 Drain the oil from the drive head. Remove the and position bearing cup 892/00174 over the bearing.
propshaft. Measure gap A (e.g. 0.20 mm) and add this to the cup depth
stamped on the tool (e.g. 30.01 mm) to obtain the bearing
2 To remove the drive head it is necessary to withdraw depth.
both drive shafts from the axle.

3 Remove the drive head carrier screws 1. Mark the

installation position of drive head carrier 2 relative to
the axle housing.

4 Remove the drive head carrier from the axle housing.

5 Pull out the roll pins 3 and remove the castellated nuts
4. Remove the outer races of bearings 5 and 6 from the
drive head carrier bores. S184400

6 Remove bearing cone 5.

From the face of the pinion, obtain the etched deviation
7 Remove differential assembly 8 from carrier. figure (e.g. + 2) which is in units of 0.01 mm. If positive, add
this to the bearing depth; if negative, subtract from the
8 Loosen the differential case half bolts 7 and pull the bearing depth.
case halves 8A and 8B apart. Remove the axle bevel
gears 9, the differential bevel gears 10, trunnion pins 11 Obtain the deviation figure (e.g. —1) stamped on the
and thrust washers 12 from the case halves. differential housing bolt flange. If negative, add to bearing
depth; if positive, subtract from bearing depth.
9 Remove the thrust washers 13 from both case halves.
Subtract the total of the above figures from the standard
10 Pull off the bearing 6 from case half 8A. value of 31.19 mm. The result will be the thickness of shims
required behind the pinion head bearing cup.
11 Remove the screws 14 and separate the crown wheel
15 from the case half 8A. Example (all dimensions in millimetres)

12 Remove pinion nut 16 and washer 17. Use Service Tool Cup depth 30.01
892/00812 to prevent drive flange 18 from rotating. Gap A +0.20
Bearing depth 30.21
13 Remove the drive flange. Pinion deviation (+ 2) +0.02
Housing deviation (- 1) +0.01
14 Drive pinion shaft 20 out of drive head carrier 2. Total 30.24

15 Prise shaft seal 19 out of the bore. Standard value 31.19

Less Total above 30.24
16 Remove taper roller bearing 21 and tap out the outer SHIM THICKNESS 0.95
bearing race.
Note: See page F/12-1 for general guidance on crownwheel
17 Tap out the outer race of bearing 22 from the opposite and pinion adjustment.
bearing housing and remove the drive pinion shim(s)
* 23.

18 Remove spacer 24 from drive pinion 20. Prise taper

roller bearing 22 to raise it sufficiently to insert bearing
pullers. Pull the bearing from the pinion shaft.

9803/7110 Issue 3*
Section F Transmission Section F
11 - 3 Front and Rear Axles 11 - 3

S175651

9803/7110 Issue 2
 Section F Transmission Section F
11 - 4 Front and Rear Axles 11 - 4

Drive Head - Assembly (cont'd)

The following procedures apply to both the SD40 and SD55 7 Fit crownwheel 15 using new Verbus Ripp bolts 14
axles; the illustrations show a typical axle. tightened to 94 Nm (69 lbf ft, 9.59 kgf m).

Note 1: Both the crownwheel 15 and pinion 20 and the 8 Locate crownwheel assembly (without bearings) into
bevel gears 9 and 10 are matched and should be renewed housing.
as sets if any of their components are damaged or
excessively worn. The two differential housing halves 8A and 9 Drive bearing cones 5 and 6 onto differential case
8B are also matched. Do not use unmatched halves. spigots. Lightly oil the bearings then fit their bearing
cups and castellated nuts 4 into drive head carrier 2.
Make sure all bearings are lightly oiled before fitting and Do not fit the roll pins 3 at this stage.
setting. Make sure bearings are rotated whilst being set. 10 Adjust castellated nuts 4 to give an increase in input
pinion rolling torque of between 1.36 Nm - 2.5 Nm (12
1 Select shims 23 required for pinion depth setting and fit lbf in - 22 lbf in) more than that recorded in Step 4.
behind new bearing cup 22. (See Pinion Depth Setting
Procedure, page F/11-2) 11 Measure the backlash between crownwheel 15 and
pinion 20, which should be 0.13 mm - 0.20 mm (0.005
2 Fit new pinion head bearing cone 22 onto pinion 20. in - 0.008 in). Adjust castellated nuts 4 by equal
amounts when altering backlash. When backlash and
* Note 2: SD55 axles with a round drive head (see item 2 on preload are both correct, fit roll pins 3.
page F/11-11) may have been fitted with either a collapsible
or solid spacer 24. The preferred option is a solid spacer, 12 Check tooth marking as per page F/12-1. If incorrect,
see Solid Spacer Installation. In the absence of special adjust.
tools or a solid spacer a collapsible spacer may be fitted. All
other dirve heads should be fitted with collapsible spacers. 13 Apply JCB Multi-gasket to the mating faces of drive
The procedure is described in steps 3 and 4 following. head carrier 2 and the axle casing. Fit the drive head
carrier to the axle casing with the crownwheel towards
3 Fit a new collapsible spacer 24 onto pinion 20. Lightly the short drive shaft. Fit securing bolts 1 and tighten to
oil pinion head bearing 22. Lightly oil pinion tail bearing 56 Nm (42 lbf ft, 6 kgf m).
21 and fit the bearing. Using a suitable drift tap the tail
bearing fully into position in the carrier. Locate the 14 Assemble both driveshafts and hub assemblies (refer to
pinion in carrier 2. (Before inserting, ensure that the page F/13-4).
pinion matches crownwheel 15.) Insert a new oil seal
19 into housing. Pack grease between the seal lips. Fit Re-fill the hubs and differential with the correct grade of
drive flange 18 using a new stake nut 16 and washer oil. Refit the propshaft (see page F/31-1).
17.

* Note 3: Later axles have a combined stake nut and washer.

If this is fitted in service, the separate washer must be
discarded.

4 Tighten stake nut 16 until end float is almost zero, then

check the seal drag torque is between 0.40 Nm - 0.75
Nm (3.54 lbf in - 6.64 lbf in). Continue to tighten the
stake nut to collapse spacer and give a rolling torque of
1.7 Nm - 2.8 Nm (15 lbf in - 24.8 lbf in) (excluding seal
drag). Record the rolling torque figure obtained. Rotate
flange 18 in each direction to bed in the bearings before
measuring. Stake the nut when the pre-load is correct.

* Note 4: If the specified rolling torque is exceeded, the

collapsible spacer will be distorted. Renew the spacer and
start again.

5 Assemble the trunnion pins 11, bevel gears 9 and 10

and their thrust washers 12 and 13 into differential half
case 8A (see Note 1 above).

6 Position differential half case 8B onto half case 8A,

aligning the match-mark letters (see Note 1 above).
Apply JCB Lock and Seal to the threads of bolts 7, then
fit and torque tighten to 28 Nm (21 lbf ft, 3 kgf m).
Check the gears for free rotation.

9803/7110 Issue 4*
Section F Transmission Section F
11 - 5 Front and Rear Axles 11 - 5

9803/7110 Issue 1
Section F Transmission Section F
11 - 6 Front and Rear Axles 11 - 6

Drive Head with Limited Slip Differential -

Dismantling (SD40 AXLES)

11 Separate the two halves of the differential assembly

! WARNING and remove trunnion pins 11, side gears 14, planet
A raised and badly supported machine can fall on you. gears 12, thrust washers 13, pressure plates 18,
Position the machine on a firm, level surface before counter plates 16, friction plates 17 and shims 15.
raising one end. Ensure the other end is securely
chocked. Do not rely solely on the machine hydraulics or 12 Check the condition and security of bushes 29 (see
jacks to support the machine when working under it. Note below).

Disconnect the battery, to prevent the engine being Note: Later type differential assemblies are not fitted with
started while you are beneath the machine. bushes 29; instead, the differential case halves 7A and 7B
GEN-1-1 are machined so that they support the driveshafts.

1 Drain oil from the axle hubs.

2 Remove the planet gear carrier, brake pressure plate,

brake friction plates and brake counter plates from both
hub assemblies and withdraw both drive shafts. (Refer
to page F/13-2 for details of hub, drive shaft and brake
dismantling.)

3 Remove the prop shaft. (Refer to page F/31-1 for

details.)

4 Drain oil from the differential casing and remove

securing bolts 1. Lift drive head carrier 2 from the
casing.

5 Drive out roll pins 3 and unscrew castellated nuts 4 and

4A. Remove and discard bearing cups 5. Drive off
bearing cones 6 and discard.

6 Remove the differential assembly from the drive head

when bearings 6 have been removed from both sides.

7 Using Service Tool 892/00812, remove drive flange 21

and drive out pinion 22 complete with collapsible
spacer 23. Remove oil seal 24 and pinion tail bearing
25. Drive pinion head bearing cone 26 from the pinion.

8 Remove pinion head bearing cap 27 with its shims 28.

9 Using heavy duty socket 892/00819, unscrew Verbus

Ripp bolts 8 and discard. Remove crownwheel 9.

10 Mark the two halves of the differential assembly for

subsequent assembly. Remove bolts 10.

9803/7110 Issue 2*
Section F Transmission Section F
11 - 7 Front and Rear Axles 11 - 7

9803/7110 Issue 1
 Section F Transmission Section F
11 - 8 Front and Rear Axles 11 - 8

Drive Head with Limited Slip Differential - 8 Determine Pinion Depth Setting (See Note 1)
Assembly (SD40 AXLES) a Place new pinion head bearing assembly on a flat
surface and position bearing cup 892/00174 over
Make sure all bearings are lightly oiled before fitting and the bearing. Measure gap A (e.g. 0.20 mm) and add
setting. Make sure bearings are rotated whilst being set. this to the cup depth stamped on the tool (e.g.
30.01 mm) to obtain the bearing depth.
1 Assemble trunnion pins 11, side gears 14, with
pressure plates 18, counter plates 16, friction plates 17,
planet gears 12 and thrust washers 13 into the
crownwheel half of differential assembly 7A.

DO NOT fit shims 15 at this point.

2 Align the two halves of the differential assembly with

the marks made during dismantling. Assemble using
bolts 10.
S184400
3 Using a dial test indicator, with two screwdrivers or
suitable levers, gently apply pressure to slide gear 14
away from the trunnion pins 11, as shown below. b From the face of the pinion, obtain the etched
Measure and note the end-float of the side gear. deviation figure (e.g. + 2) which is in units of 0.01
mm. If positive, add this to the bearing depth; if
4 Turn the differential assembly over and repeat step 3 negative, subtract from the bearing depth.
for the second side gear.
c Obtain the deviation figure (e.g. -1) stamped on the
*5 Dismantle the differential assembly. Add shims 15 to differential housing bolt flange. If negative, add to
give end-float of between: bearing depth; if positive, subtract from bearing
New plates - 0.1 and 0.2 mm (0.004 and 0.008 in). depth.
Old plates - 0.2 and 0.5 mm (0.007 and 0.020 in).
d Subtract the total of the above figures from the
6 Repeat steps 2, 3 and 4. If the end-float is correct, standard value of 31.19 mm. The result will be the
tighten bolts 10 to 56 Nm (41 lbf ft). thickness of shims required behind the pinion head
bearing cup.
7 Fit crownwheel 9 using new Verbus Ripp bolts 8
tightened to 94 Nm (70 lbf ft). Example (all dimensions in millimetres)

Cup depth 30.01

Gap A +0.20
Bearing depth 30.21
Pinion deviation (+ 2) +0.02
Housing deviation (- 1) +0.01
Total 30.24

Standard value 31.19

Less Total above 30.24
SHIM THICKNESS 0.95

Note 1: See page F/12-1 for general guidance on

crownwheel and pinion adjustment.

Note 2: Crownwheel 9 and pinion 22 are matched and the

side gears 14 and planet gears 12 are matched. These
S171530 components should be renewed as pairs if either is
damaged or excessively worn.

9 Select shims 28 required for pinion depth setting and fit

behind new bearing cup 27.

10 Press new pinion head bearing cone 26 onto pinion 22

using press 892/00179 with adapters 992/07608 and
992/07609.

9803/7110 Issue 3*
Section F Transmission Section F
11 - 9 Front and Rear Axles 11 - 9

9803/7110 Issue 1
Section F Transmission Section F
11 - 10 Front and Rear Axles 11 - 10

Drive Head with Limited Slip Differential -

Assembly (SD40 AXLES)
11 Fit a new collapsible spacer 23 onto pinion 22. Lightly
oil pinion head bearing 26 and locate the pinion in the
housing. (Before inserting, ensure that the pinion
matches crownwheel 9). Lightly oil pinion tail bearing 25
and fit the bearing. Using a suitable drift, tap the tail
bearing fully into position in the housing. Insert a new
oil seal 24 into the housing. Pack grease between the
seal lips. Fit drive flange 21 using a new stake nut 19
and washer 20.

Note 3: Later axles have a combined stake nut and washer.

If this is fitted in service, the separate washer must be
discarded.

12 Tighten stake nut 19 to collapse spacer 23 until the end

float is almost zero, then check the seal drag torque is
between 0.40 Nm - 0.75 Nm (3.54 lbf in - 6.64 lbf in).
Continue to tighten the stake nut to collapse spacer 23
and give a rolling torque of 1.7 Nm - 2.8 Nm (15 lbf in -
24.8 lbf in) (excluding seal drag). Rotate flange 21 in
each direction to bed in the bearings before measuring.
Stake the nut when the pre-load is correct.

Note 4: If the specified rolling torque is exceeded, the

collapsible spacer will be distorted. Renew the spacer and
start again.

13 Locate differential assembly (without bearings) into

drive head.

14 Drive bearing cones 6 onto spigots, lightly oil the

bearings and fit bearing cups 5 and castellated nuts 4.
Do not fit the roll pins 3 at this stage.

15 Adjust castellated nut 4 on the crownwheel side until

backlash is 0.13 mm to 0.20 mm (0.005 in to 0.008 in).

16 Adjust castellated nut 4A until there is no end-float and

no pre-load, ensuring that bearings are bedded in by
rotating in each direction. Tighten nut 4A by a further 4
castellations to set pre-load, ensuring that correct
backlash is maintained. Fit roll pins 3.

17 Apply JCB Multi-gasket to the mating surfaces of drive

head carrier 2 and the axle casing. Fit the drive head
carrier to the axle casing with the crownwheel towards
the long driveshaft. Fit securing bolts 1 and tighten to
56 Nm (40 lbf ft).

18 Reassemble both driveshafts and hub assemblies (refer

to page F/13-4). Refill the hubs and the differential with
the correct grade of oil. Refit the propshaft (see page
F/31-1).

9803/7110 Issue 2*
Section F Transmission Section F
11 - 11 Front and Rear Axles 11 - 11

Drive Head with Limited Slip Differential -

Dismantling (SD55 AXLES)

S155180

9803/7110 Issue 1
 Section F Transmission Section F
11 - 12 Front and Rear Axles 11 - 12

Drive Head with Limited Slip Differential -

Dismantling (SD55 AXLES)
The numerical sequence shown on the illustration is 10 Rotate side gears 15 to eject planet gears 13 and thrust
intended as a guide to dismantling. washers 14. Lift out side gears, pressure plates 19,
counter plates 17, friction plates 18 and shims 16.
For assembly the sequence should be reversed.
11 Check the condition and security of bushes 30 (see
! WARNING Note below).
A raised and badly supported machine can fall on you.
Note: Later type differential assemblies are not fitted with
Position the machine on a firm, level surface before
bushes 30; instead, the differential assembly is machined so
raising one end. Ensure the other end is securely
that it supports the driveshafts.
chocked. Do not rely solely on the machine hydraulics or
jacks to support the machine when working under it.

Disconnect the battery, to prevent the engine being

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

1 Remove the planet gear carrier, brake pressure plate,

brake friction plates and brake counter plates from both
hub assemblies and withdraw both drive shafts. (Refer
to page F/13-2 for details of hubs, driveshafts and
brakes dismantling.)

2 Remove the propshaft.

3 Drain oil from differential casing and remove securing

bolts 1. Discard gasket 3. Lift drivehead 2 from casing.

Note: Item 3 is not fitted on later machines, instead JCB

Multi-gasket sealant is used.

4 Drive out roll pins 4 and unscrew castellated nuts 5 and

5A. Remove bearing cups 6.

5 Identify the manufacturer's marks on the drive head

casing 2 and the bearing caps 2A for subsequent
assembly.

Remove bolts 2B and remove the differential from the

drivehead. Remove bearings 7.

6 Using Service Tool 892/00812, remove drive flange 22

*
and drive out pinion 23 complete with spacer 24.
Remove oil seal 25 and pinion tail bearing 26. Drive
pinion head bearing cone 27 from the pinion.

7 Remove pinion head bearing cup 28 with its shims 29.

8 Unscrew Verbus Ripp bolts 9 using heavy duty socket

892/00819 and remove crownwheel 10.

9 Remove bolt 11 and drive out trunnion pin 12.

9803/7110 Issue 2*
Section F Transmission Section F
11 - 13 Front and Rear Axles 11 - 13

Drive Head with Limited Slip Differential -

Assembly (SD55 AXLES)

S155180

9803/7110 Issue 1
Section F Transmission Section F
11 - 14 Front and Rear Axles 11 - 14

Drive Head with Limited Slip Differential -

Assembly (SD55 AXLES)
1 Fit side gears 15, with pressure plates 19, counter 8 Determine Pinion Depth Setting (See Note 1)
plates 17 and friction plates 18 into differential case 8.
a Place new pinion head bearing assembly on a flat
Note: Do not fit the shims 16 at this point. surface and position bearing cup 892/00174 over
the bearing. Measure gap A (e.g. 0.20 mm) and add
Position planet gears 13 and thrust washers 14 until this to the cup depth stamped on the tool (e.g.
they are engaged with side gears and diametrically 30.01 mm) to obtain the bearing depth.
opposed. Rotate side gears until planet gears and
washers align with trunnion pin bore.

2 Drive in trunnion pin 12 until bolt 11 can be located.

3 Using a dial test indicator, with two screwdrivers or

suitable levers, gently apply pressure to side gear 15
away from the trunnion pins 12 as shown. Measure and
note the end-float of the side gear.

S184400

b From the face of the pinion, obtain the etched

deviation figure (e.g. + 2) which is in units of 0.01
mm. If positive, add this to the bearing depth; if
negative, subtract from the bearing depth.

c Obtain the deviation figure (e.g. -1) stamped on the

differential housing bolt flange. If negative, add to
bearing depth; if positive, subtract from bearing
depth.

d Subtract the total of the above figures from the

standard value of 31.19 mm. The result will be the
thickness of shims required behind the pinion head
bearing cup.

Example (all dimensions in millimetres)

S171590
Cup depth 30.01
Gap A +0.20
Bearing depth 30.21
Pinion deviation (+ 2) +0.02
Housing deviation (- 1) +0.01
4 Turn the differential assembly over and repeat step 3 Total 30.24
for the second side gear.
Standard value 31.19
5 Dismantle the differential assembly. Add shims 16 to Less Total above 30.24
give end-float between 0.1 and 0.2mm (0.004 and SHIM THICKNESS 0.95
0.008in.).
Note 1: See page F/12-1 for general guidance on
6 Repeat steps 2, 3, and 4. If the end float is correct. crownwheel and pinion adjustment.
Remove bolt 11 apply JCB Lock and Seal to threads of
bolt then fit and tighten to 28 Nm (20 lbf ft). Note 2: Note: Both the crownwheel 10 and pinion 23 and
the side gears 15 and planet gears 13 are matched and
7 Fit crownwheel 10 using new Verbus Ripp bolts 9 should be renewed as pairs if any of their components are
tightened to 94 Nm (70 lbf ft). damaged or excessively worn.

9 Select shims 29 required for pinion depth setting and fit

behind new bearing cup 28.

9803/7110 Issue 1
 Section F Transmission Section F
11 - 15 Front and Rear Axles 11 - 15

Drive Head with Limited Slip Differential -

Assembly (SD55 AXLES)
10 Press new pinion head bearing cone 27 onto pinion 23 16 Adjust castellated nut 5A until there is no end-float and
using press 892/00179 with adapters 992/07608 and no pre-load, ensuring that bearings are bedded in by
992/07609. rotating in each direction. Tighten nut 5A by a further 4
castellations to set pre-load, ensuring that correct
* Note 3: Round drive heads may have been fitted with either backlash is maintained. Fit roll pins 4.
a collapsible or solid spacer 24. The preferred option is a
solid spacer, see Solid Spacer Installation. In the absence 17 Using a new gasket 3 (see Note 7), fit differential to axle
of special tools or a solid spacer a collapsible spacer may casing with crownwheel towards long driveshaft. Fit
be fitted. All other drive heads should be fitted with securing bolts 1 and tighten to 56 Nm (40 lbf ft).
collapsible spacers. The procedure is described in steps 11 Reassemble both driveshafts and hub assemblies and
and 12 following. re-fill hubs and differential with the correct grade of oil.
Refit the propshaft.
11 Fit a new collapsible spacer 24 onto the pinion 23.
Lightly oil pinion head bearing 27 and locate the pinion * Note 7: On later machines, the gasket 3 is replaced by JCB
in the housing. (Before inserting, ensure that the pinion Multi-gasket.
matches the crownwheel 10.) Lightly oil pinion tail
bearing 26 and fit the bearing. Using a suitable drift tap
the tail bearing fully into position in the housing. Insert a
new oil seal 25 into housing. Pack grease between the
seal lips. Fit the drive flange 22 using a new stake nut
20 and washer 21.

* Note 4: Later axles have a combined stake nut and washer.

If this is fitted in service, the separate washer must be
discarded.

12 Tighten the stake nut 20 to collapse spacer 24 until end

float is almost zero, then check the seal drag torque is
between 0.40 Nm - 0.75 Nm (3.54 lbf in - 6.64 lbf in).
Continue to tighten the stake nut to collapse spacer 24
and give a rolling torque of 1.7 Nm - 2.8 Nm (15 lbf in -
24.8 lbf in)(excluding seal drag). Rotate flange 22 in
each direction to bed in the bearings before measuring.
Stake the nut when the pre-load is correct.

* Note 5: If the specified rolling torque is exceeded, the

collapsible spacer will be distorted. Renew the spacer and
start again.

13 Fit bearing caps 2A using bolts 2B tightened to 165 Nm

(121 lbf ft). Make sure the correct manufacturer's marks
are aligned.

Locate differential assembly (without bearings) into

drivehead.

* Note 6: Drivehead casing 2 and bearing caps 2A are

matched and should be renewed as a complete assembly if
damaged or worn.

14 Drive bearing cones 7 onto spigots, lightly oil the

bearings then fit bearing cups 6 and castellated nuts 5.
Do not fit the roll pins 4 at this stage.

15 Adjust castellated nut 5 on crownwheel side until

backlash is 0.13 mm - 0.20 mm (0.005 in - 0.008 in).

9803/7110 Issue 3*
Section F Transmission Section F
12 - 1 Front and Rear Axles 12 - 1

Crown Wheel and Pinion - Adjustment

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. After every repair, check the
markings to verify settings.

Correct tooth marking.

Pinion too deeply in mesh.

Decrease the shim thickness between the pinion inner

bearing cap and the axle casing. Move the crown wheel
towards the pinion to correct the backlash.

Pinion too far out of mesh.

Increase the shim thickness between the pinion inner

bearing cup and the axle casing. Move the crown wheel
away from the pinion to correct the backlash.

Note: Crown wheel teeth will fail prematurely if run in this

condition.

9803/7110 Issue 1
 Section F Transmission Section F
12 - 2 Front and Rear Axles 12 - 2

Renewing the Pinion Oil Seal

The pinion oil seal 4 may be renewed without removing the 4 Fit the coupling yoke, its washer and a new stake nut:
axle from the machine.
4.1 Using Service Tool 892/00812, tighten the nut to
! WARNING 200 Nm (148 lbf ft; 20.4 kgf m).
A raised and badly supported machine can fall on you.
4.2 Measure the rolling torque. The reading should be
Position the machine on a firm, level surface before
0.5 to1Nm (0.37 to 0.74lbf ft; 0.05 to 0.1kgf m)
raising one end. Ensure the other end is securely
more than that recorded in Step 1 (see Note).
chocked. Do not rely solely on the machine hydraulics or
jacks to support the machine when working under it.
4.3 If necessary, progressively torque tighten nut to
achieve correct rolling torque.
Disconnect the battery, to prevent the engine being
started while you are beneath the machine.
GEN-001 Note: If the rolling torque figure (new pinion seal fitted)
exceeds the reading recorded in step 1 by 1Nm (0.74 lbf ft;
0.1 kgf m) or more, then the collapsible spacer mounted on
1 Remove the roadwheels and uncouple the axle the axle pinion MUST be renewed.
propshaft. Measure the axle rolling torque and record
the reading. 4.4 Stake the nut using a square ended staking tool.

2 Using Service Tool 892/00812, remove the drive flange 5 Refit the roadwheels and couple the propshaft.
1 together with its stake nut 2 and washer 3.

Note: Stake nut 2 is now a combined nut and washer.

* Therefore washer 3 should be discarded. (T.I. 035
(F47/N.Am.) refers.)

3 Remove the seal 4 and fit a new one. Pack between the
lips of the new seal with grease before fitting.

S203310

9803/7110 Issue 3*
Section F Transmission Section F
13 - 1 Front and Rear Axles 13 - 1

S175632

9803/7110 Issue 3
 Section F Transmission Section F
13 - 2 Front and Rear Axles 13 - 2

Axle Hub and Driveshaft - Dismantling DO NOT mix the two different types of friction plates.

* The following procedures apply to both the SD40 and SD55 *

axles; differences between the two types of axle are 8 Remove brake piston back-off bolt 13A and spring 13B
indicated in the text and illustrations. For SD55 splined axle (2 or 3 off each, see Product Changes page F/1/5).
see page F/14-1. Carefully withdraw the brake piston 13 from its housing,
if removal is necessary. A hydraulic hand pump can be
1 Drain oil from the axle hub, remove screws 1. used to force the piston out of the housing, or if the
brakes system is still connected use the brake pedal.
2 Using a soft-faced mallet, tap the planet gear carrier 2 Remove and discard O-rings 14 and 15.
to 'crack' the joint between the carrier and bearing
carrier 19, then lever the planet gear carrier off the 9 SD40 AXLES:
bearing carrier. Remove and discard 'O' ring 3 (see Remove external circlip 16 and spacer 17.
Note).
SD55 AXLES:
Note: Later type axles use sealant (part number 4102/0933) Remove brake plate carrier C and spacer D.
in place of the ‘O’ ring.
10 Remove Verbus Ripp bolts 18. These bolts are very
3 SD40 AXLES: tight and care must be taken not to distort the bolt
Remove a planet gear 4 only if it is defective. Note that heads. Use as short an extension bar as possible.
a planet gear can only be renewed as an assembly,
which comprises the pinion, the bearing 5 and two 'L' 11 Using special tool (part number 892/00833) as jacking
shaped circlips 6. To remove a planet gear, first remove screws, jack the annulus assembly 21, 22 and 23 off
the external circlip 7, then pull off the planet gear. the bearing carrier 19. Ensure that the ring dowels 20
remain either in the axle arm or the annulus carrier 21.
SD55 AXLES:
Remove a planet gear 4 only if it is defective. Note that Note: Fretting between the hub swivel and annulus carrier
a planet gear can only be renewed as an assembly, mating faces might be evident; this condition is normal, do
which comprises the pinion, the bearing 5 and two 'L' not attempt to repair. If the hub swivel and annulus carrier
shaped circlips 6. To remove a planet gear, first remove are to be re-used, the carrier must be assembled in the
the external circlip 7, then pull off the planet gear. same angular position it was removed; match mark the hub
swivel and carrier before removing the carrier.
Remove circlip A, sun gear B.
12 Remove internal circlip 22 to separate the annulus ring
4 The driveshaft thrust pad 8 is drilled and tapped M6 for 23 from the annulus carrier 21.
removal purposes.
13 Pull off the bearing carrier 19 together with the outer
5 Remove circlip 9 and brake pressure plate 10. Remove wheel bearing cone and cup 24. Withdraw the inner
shims X. bearing cup from the inboard side of the carrier.

6 There are three counterplates 11 and two friction plates 14 Pull off the inner wheel bearing 25.
12. If the brake pack is to be re-used, note the
positions of the plates before removing them. 15 Remove combination seal 26.

7 Wear limit of friction plates 12 is to the depth of 16 Disconnect the track rod and steering ram from the axle
circumferential grooves X. Check all plates for flatness steer knuckles.
and damage. (Grooving of the counterplates 11 is
normal.) Renew the brake pack complete if worn or Note: The top and bottom trunnions are very similar (bottom
damaged. Do not renew individual plates. trunnion not illustrated), the only difference being that shims
(if required) 29 are fitted to the top trunnion only.

17 Mark position of top and bottom trunnions 28, remove

bolts 27 and remove trunnions. Retain shims 29 (if
fitted) with top trunnion. Withdraw the hub carrier 30.

Note: Trunnions may be removed easily and without

damage to the shims by pumping grease through the grease
nipple.

18 Remove the top and bottom trunnion seals 31 and

bearings 32.
S203890
19 Withdraw drive shaft 33 from the axle casing. Prise out
Note: Later type axles have 'paper' friction plates, these can drive shaft inner oil seal 34. Remove bearing 35 using
be readily identified because they do not have radial slots. tool 892/00225.

9803/7110 Issue 5*
Section F Transmission Section F
13 - 3 Front and Rear Axles 13 - 3

S175632

9803/7110 Issue 3
 Section F Transmission Section F
13 - 4 Front and Rear Axles 13 - 4

Axle Hub and Driveshaft - Assembly (10 lbf) more than the reading recorded at Step 6.
9 Connect the track rod and steering ram to the axle
steer knuckles.
* The following procedures apply to both the SD40 and SD55
axles; differences between the two types of axle are
indicated in the text and illustrations. For SD55 splined axle 10 Lightly oil the inner wheel bearing 25 and its cup, then
see page F/14-1. fit them into the bearing carrier 19.

Note: The top and bottom trunnions are very similar (bottom 11 Fit a new combination seal 26 into the bearing carrier.
trunnion not illustrated), the only difference being that shims
29 (if required) are fitted to the top trunnion only. A204250
Y
1 Tap the drive shaft inner bearing 35 into position in the
hub swivel driveshaft bore.

2 Fit new oil seal 34. Pack grease between lips of seal.

3 Fit driveshaft 33, taking care to locate inner end into

splines of differential gears.

4 Press new top and bottom trunnion oil seal 31 into

position on trunnion 33, followed by bearing 32. Grease
bearing and oil seal before fitting to axle.

5 Locate hub swivel 30 and fit bottom trunnion 28. Apply

JCB Lock and Seal to threads of bottom trunnion bolts
27 and then torque-tighten bolts to : One of two types of combination seal are used:
a) The seal with a plain casing as shown above must
SD40 AXLES - 56 Nm (42 lbf ft, 6 kgf m). be greased before fitting. Ensure the seal enters
SD55 AXLES - 98 Nm (72 lbf ft, 10 kgf m). squarely and that the chamfered face of the seal is
below the end of the bore of the bearing carrier as
Fit top trunnion and leave top trunnion bolts finger tight. shown at Y.

6 Attach a spring balance to track rod swivel as shown

and note the reading. Tighten the top trunnion bolts 27 A198470
to eliminate end float but no bearing pre-load, ie no X
increase in spring balance reading.

S160251

7 Measure gap at top trunnion and subtract 1 mm (0.040

b) The later type with the locating lip as shown above
in) to give shim thickness (bearing pre-load). For
must not be lubricated before fitting. Drive the seal
example:
squarely into the carrier until the locating lip is flush
Gap = 1.55 mm (0.061 in)
as at X.
less 1.00 mm (0.040 in)
Shim = 0.55 mm (0.021 in)
Note: After assembling the bearing carrier to the swivel hub,
make sure that there is sufficient clearance between the hub
Note: If the gap measures 1mm, then no shim is required.
and seal (type X). If unsure, fit the same type of seal as
originally fitted.
8 Refit top trunnion. Apply JCB Lock and Seal to the top
trunnion bolt threads, fit and tighten to:
12 Install the cup of outer wheel bearing 24 into the
SD40 AXLES - 56 Nm (42 lbf ft, 6 kgf m). bearing carrier 19. Grease the bore of the seal and the
SD55 AXLES - 98 Nm (72 lbf ft, 10 kgf m). surface of the stub.

Check spring balance reading which should be 4.5 kgf 13 Fit the bearing carrier 19 onto the hub swivel 30.

9803/7110 Issue 3*
Section F Transmission Section F
13 - 5 Front and Rear Axles 13 - 5

Axle Hub and Driveshaft - Assembly

14 Lightly oil the bearing race of outer wheel bearing 24. vi Remove the planet gear carrier 2 and tighten M14
Fit the bearing onto the axle arm. Rotate the carrier 19 Verbus Ripp bolts 18 to 320 Nm (236 lbf ft, 33 kgf
(and therefore the bearings) during fitting. m).

15 Assemble the annulus ring 23 to the annulus carrier 21. vii Temporarily refit the planet gear carrier 2, DO NOT
Secure with circlip 22. fit the sun gear. Use a spring balance and cord
wrapped around the planet carrier flange as shown.
16 Fit annulus assembly in the same angular position as Pull the spring balance so that the hub rotates, do
removal (see Note, page F/13-2, step 11) using new several times to let the seal bed in and record the
'Verbus Ripp' bolts 18. Do not fully tighten bolts but reading.
allow the bearing carrier to rock slightly.

17 Check the bearing carrier rolling force:

SD40 AXLES
i Use a spring balance and cord wrapped around the
planet carrier bolts as shown. Pull the spring
balance so that the hub rotates, do several times to
let the seal bed in and record the reading.

S136070

To get the rolling force, subtract seal drag rolling

force (see step 17 v) from reading obtained at this
step, the result should be 2 to 22 N; (0.4 to 5 lbf;
0.2 to 2.2 kgf).
S205370
If the resulting figure is outside these limits check;
the seal 26 is fitted correctly; and/or renew
ii Tighten M14 Verbus Ripp bolts 18 to 320 Nm (236 bearings 24 and 25.
lbf ft, 33 kgf m).
vii Remove the planet gear carrier 2.
iii Use a spring balance and cord wrapped around the
planet carrier bolts as shown. Pull the spring 18 SD40 AXLES
balance so that the hub rotates, do several times to Fit spacer 17 and external circlip 16.
let the seal bed in and record the reading.
SD55 AXLES
To get the rolling force, subtract seal drag rolling Fit spacer D and brake plate carrier C.
force (see step17 i) from reading obtained at this
step, the result should be 13.6 to 150N; (3 to 34lbf; 19 Lubricate new seals 14 and 15 with hydraulic oil and fit
1.4 to 15.3kgf). them into their grooves in the brake piston 13 and
annulus carrier 21. Make sure they seat squarely in their
If the resulting figure is outside these limits check; grooves.
the seal 26 is fitted correctly; and/or renew
bearings 24 and 25. * 20 Carefully press the piston 13 all the way into its
housing. Fit brake piston back-off springs 13B and
SD55 AXLES bolts 13A (2 or 3 off each, see Product Changes page
iv Temporarily refit the planet gear carrier 2, DO NOT F1/5). Torque tighten 13A to 5Nm. 3.5lbf ft. 0.5kgf m.
fit the sun gear.
21 Assemble the friction plates 12 and counterplates 11
v Use a spring balance and cord wrapped around the onto the driveshaft and annulus ring 23. If the original
planet carrier flange as shown. Pull the spring brake pack is being re-used, return the plates to their
balance so that the hub rotates, do several times to original positions (see 'Dismantling', Step 6.) Soak new
let the seal bed in and record the reading. friction plates in JCB Special Gear Oil before assembly.

9803/7110 Issue 4*
 Section F Transmission Section F
13 - 6 Front and Rear Axles 13 - 6

Axle Hub and Driveshaft - Assembly

* 22 Add shim(s) X and assemble the brake pressure plate
10 with its chamfer towards the brake pack. Make sure
the shim(s) fit between items 10 and 11. The shim(s)
should give a gap of 1.5 mm to 1.8mm (0.060 to 0.070
in.). This can be measured by putting a dial test
indicator (DTI) on the end face of item 10 and
pressurising the brakes, or alternatively, use feeler
gauges in between items 10 and 9. When the correct
gap has been achieved fit circlip 9.

23 SD55 AXLES ONLY

Fit sun gear B and circlip A.

24 Press the driveshaft thrust pad 8 (chamfered side

lowermost) into the recess in the planet gear carrier 2.

25 Fit new planet gears 4 in place of any that were

removed. (See Step 3 in 'Dismantling'.) Secure with
circlip 7.

Note: Large radius at end of bearing bore fits onto pin first.

26 Fit new 'O' ring 3 (see Note).

Note: Later type axles use sealant (part number 4102/0933)

in place of the ‘O’ ring.

Fit the planet gear carrier 2 onto the bearing carrier 19,
ensuring that the two tapped holes W in the planet gear
carrier are aligned with their mating holes in the bearing
carrier. (The tapped holes are diametrically opposite
one another). Ensure that the planet gear carrier butts
fully against the bearing carrier.

Note: Do not strike the centre of the planet gear carrier 2

when fitting as this may dislodge the driveshaft thrust pad 8.

27 Fit screws 1 and torque-tighten to 56 Nm (41.3 lbf ft,

5.71 kgf m).

28 Fill the axle hub with oil.

9803/7110 Issue 3*
Section F Transmission Section F
14 - 1 Front and Rear Axles 14 - 1

31

S303742

9803/7110 Issue 2
 Section F Transmission Section F
14 - 2 Front and Rear Axles 14 - 2

SD55 Splined Hub and Drive Shaft Dismantling

! WARNING 13 Remove circlip 19 to separate annulus ring from

Make the machine safe before getting beneath it. Park annulus carrier. Remove brake seal 20 from hub swivel.
the machine on level ground. Make sure the engine is
stopped, the parking brake engaged and the 14 Remove brake piston back off bolt 21A and spring 21B
transmission is in neutral. Disconnect the battery. Chock (3 off each). Carefully withdraw brake piston 21 from its
both sides of all four wheels. housing. A hydraulic hand pump can be used to force
5-3-2-1 the piston out of the housing.

1 Disconnect track rod and steering rams. Remove plug 1 * Note: Fretting will be evident between retaining plate 15 and
and drain oil from hub. annulus carrier 17 due to relative movement of the annulus
carrier on the hub spline - this is normal and not detrimental
Note: If track rod is to be removed completely, identify R.H. to the operation of the axle.
and L.H. ends to ensure correct assembly.
15 Remove and discard seals 22 and 23. Inspect the
2 Remove screws 2. housing bore for damage and scoring. Nicks or cuts in
the seals may be responsible for loss of brake fluid.
3 Lever off the planet gear carrier 3 at the levering points.
Remove and discard the 'O' ring 4. 16 Pull off bearing carrier 24 together with the outer
bearing 25.
4 Remove planet gears 5 only if defective. Note that
gears can only be removed as assemblies, which 17 Pull off inner bearing 26.
comprise the gear, the bearing and two 'L' shaped
circlips. To remove a planet gear, first remove the 18 Remove seal 27.
external circlip 6.
Note: The top and bottom trunnions are very similar (bottom
5 Pull off the planet gear 5. trunnion not illustrated).

6 The driveshaft thrust pad 7 is drilled and tapped M6 for 19 Mark position of top and bottom trunnions 33, remove
removal purposes. bolts 32 and remove trunnions. Withdraw the hub
carrier 30.
7 Remove circlip 8 to allow the sun gear 9 to be slid off
the drive shaft. 20 Remove the top and bottom trunnion seals 34 and
bearings 35.
8 Remove circlip 10 to allow the brake pack assembly to
be slid off the driveshaft. 21 Withdraw drive shaft 31 from the axle casing. Prise out
drive shaft inner oil seal 29. Remove bearing 28 using
9 Remove brake pressure plate 11, counter plates 12 and tool 892/00225.
friction plates 13.
* Note: If the brake pack is to be re-used, note the positions
32
of the plates before removing. Ensure pistons are removed
and cleaned. Fit new seals when the brakes are fitted.
33
10 Examine friction plates, wear limit is to the depth of the
grooves. Check all plates for flatness and damage. 30
Some scoring of the counterplates is normal. Renew
the brake pack complete if worn or damaged. Do not
renew individual plates.
* 34
Note: Excessive wear of the brake and counter plates can
indicate sticking brakes or possible residual pressure in the
braking system. See Section G, Residual Brake System 35
Pressure.

11 Remove Verbus Ripp bolts 14 and remove retaining

plate 15.

12 Remove brake seal 16 then mark the relationship

between the annulus carrier 17, annulus ring 18 and
hub swivel 30, remove the annulus carrier 17 with
annulus ring 18 from the hub swivel 30.

9803/7110 Issue 2*
Section F Transmission Section F
14 - 3 Front and Rear Axles 14 - 3

31

A303742

9803/7110 Issue 2
 Section F Transmission Section F
14 - 4 Front and Rear Axles 14 - 4

SD55 Splined Hub and Drive Shaft Assembly

1 Tap the drive shaft inner bearing 29 into position in the 12 Lubricate and fit new seal 22 onto the piston 21 and
hub swivel driveshaft bore. seal 23 into the annulus carrier 17. Make sure they seat
squarely in their grooves.
2 Fit new oil seal 28. Pack grease between lips of seal,
see Salvage/Repair, Drive Shaft Oil Seal. 13 Carefully press the piston 21 all the way into the
annulus carrier housing 17. Fit brake back off springs
3 Fit drive shaft 31, taking care to locate inner end into 21B and bolts 21A (3 off).
the splines of the differential gears.
* 14 Align relationship marks made on dismantling.
4 Press new top and bottom trunnion oil seal 34 into Assemble the annulus ring 18 to the annulus carrier 17.
position on trunnion 33, followed by bearing 35. Grease Secure with the circlip 19. Make sure the two blanking
bearing and oil seal before fitting to axle. plugs X are fitted to the annulus carrier. Apply JCB
Threadlocker and Sealer to the threads.
5 Locate hub swivel 30 and fit bottom trunnion. Apply
Threadlocker and Sealer to threads of trunnion bolts 32 * Note: Inspect the inside of the annulus carrier and piston for
and then torque tighten bolts. marks. Any signs of scoring where the seal contacts can
cause leaks.
6 Fit top trunnion 33, apply Threadlocker and Sealer to
threads of trunnion bolts 32 and then torque tighten 15 Fit annulus assembly onto splined hub, check that
relationship mark aligns. Push the annulus assembly
32 onto the splined hub until the splines of the annulus
assembly are flush with the end of the splined hub. Fit
brake seal 16 onto hub swivel.
33
16 Measure seal drag rolling force, see page F/13-5 Step
30 17 iv to viii.

* 17 Torque tighten bolts 14 evenly.

18 Assemble the friction plates 13 and counterplates 12

34 onto the annulus carrier. If the original brake pack is
being used return the plates to their original positions as
35 noted during dismantling. Soak new friction plates in
JCB Special Gear Oil before assembly.

19 Add shims A and assemble the brake pressure plate 11

S303741
with its chamfer towards the brake pack. Make sure the
bolts. shims fit between items 11 and 12. The shims should
7 Lightly oil the inner wheel bearing race 26. Assemble give a gap of 1.5 mm to 1.8mm (0.060 to 0.070 in.). This
the bearing cup and bearing race into the bearing can be measured by putting a dial test indicator (DTI)
carrier 24. on the end face of item 11 and pressurising the brakes,
* or alternatively, use feeler gauges in between items 10
8 Fit combination seal 27 into the bearing carrier 24 so and 12. When the correct gap has been achieved fit
that the chamfer faces the hub swivel. Do not circlip 10.
disassemble seal or use excessive force when fitting,
see Salvage/Repair. 20 Bleed the brake system. Gently apply the brakes and
release the pressure with the engine running. Check the
9 Lightly oil the outer wheel bearing race 25. Assemble piston activates and retracts correctly, and does not
the bearing cup and bearing race into the bearing stick in the applied position before fitting the hub
carrier 24. Fit bearing carrier onto axle stub. carrier.

Note: The bearing carrier must be fully supported during the Note: if the brake piston has not retracted, the brake seal or
fitting operation; do not allow any weight to rest on the piston assembly may have been assembled incorrectly.
bearings, otherwise the inner bearing will be displaced and Alternatively, there may be residual hydraulic brake pressure
damage the seal. holding the piston in the applied position - Release the brake
bleed nipple with the engine running and check if the piston
10 Fit retaining plate 15, make sure the brake galleries retracts when the pressure is released. See Section G -
align. Secure using new bolts 14 and tighten until the Residual Brake System Pressure. Investigate the cause if
annulus assembly just rocks. the piston remains in the applied position.
*
11 Fit new brake seal 20 to hub swivel. Make sure the
blanking screws Z are fitted. Apply JCB Threadlocker
and Sealer to threads.

9803/7110 Issue 2*
Section F Transmission Section F
14 - 5 Front and Rear Axles 14 - 5

21 Press the drive shaft thrust pad 7 (chamfered side

lowermost) into the recess in the planet carrier 3.

22 Fit new planet gears 5 in place of any that were

removed during dismantling. Secure with circlip 6.

23 Slide the sun gear 9 onto the drive shaft and secure
with circlip 8. Fit a new 'O' ring 4 in place of the one
discarded during dismantling.

24 Fit the planet carrier 3 onto the bearing carrier 24

ensuring that the two tapped holes are in line with
those on the bearing carrier. Fit and tighten screws 2
after applying JCB Threadlocker and Sealer to the
threads.

25 Reconnect steer arms.

26 Fit drain plug 1 and fill hubs with correct grade oil.

Torque Settings
Item Nm kgf m lbf ft
1 70-100 7.1-13.8 51.5-73.75
2 56 5.71 41.3
14 166 16.9 122
21A 5 0.5 3.5
32 98 10 72

9803/7110 Issue 1
Section F Transmission Section F
17 - 1 Front and Rear Axles 17 - 1

Solid Spacer Installation

Note: Solid spacer setting tools are required for this job (see 10 Remove adapter B and sleeve A. Fit new oil seal,
Service Tools, Section 1). grease between seal lips before fitting. Before fitting the
flange, check that the bearing end of the flange is not
1 Install pinion and bearings into the drive head casing. fretted and renew the flange if required. Clean any oil
Install largest e.g. 13.6 mm solid spacer X (refer to from the splines of the flange and the shaft. Run an
illustration in Front and Rear Axles, Pinion Depth (see even 2 mm diameter bead of JCB Threadlocker and
Parts Catalogue for part number) and fit pinion tail Sealer around the outer end of the shaft spline. Fit the
bearing (lightly oiled). Do not fit the oil seal at this stage. flange using a new stake nut.

2 Fit special tool sleeve A and special pinion shaft

adapter B and tighten to 50 Nm. If sleeve A is not
available, use the drive flange instead.

3 Fit special bracket C to the drive head housing using

two M12 x 20 nuts and bolts. Fit special tool support
pillar Y so that the fork end engages in adapter B. Y
Ensure that fork Y is centrally located on adapter B. If
necessary, re-align bracket C to suit.
B
4 Fit dial test indicator (DTI) Z. Ensure that the DTI is
mounted on the drive head and not on bracket C. C A
5 Set torque wrench E to 35 Nm and measure the end
float while rotating the shaft.

6 To select the right size spacer F, subtract the end float

obtained at step 5 from the solid spacer size (e.g. 13.6
mm). Also subtract 0.06 mm to allow for theoretical
bearing tolerance and pre load. The result is the size of
342780
spacer to be fitted. If there is no spacer of this size, fit
the next closest size spacer. 11 Progressively torque tighten retaining nut to 300 Nm.
Provided the correct size spacer has been selected the
Example rolling torque should be between 2.3 and 3.4 Nm
including seal drag.
Temporary spacer size 13.60
Subtract end-float 0.52 Note: The nut tightening torque can be increased to a
Total 13.08 maximum of 390 Nm provided that the rolling torque does
Subtract tolerance & preload 0.06 not exceed the maximum of 3.4 Nm.
Result 13.02
12 Finally stake the nut into the slot.
(No spacer available this size, use next closest size
spacer i.e. 13.00)

7 Remove sleeve A and fit correct size spacer. Take care

to avoid damaging the outer bearing.
E
8 Fit sleeve A. Initially tighten adapter B to no more than
50 Nm to protect against bearing damage while spacer
selection is verified. Check there is no end float and Z
pinion is free to turn smoothly by hand. Then check that
rolling torque is less than 2.0 Nm. If the rolling torque
exceeds 2.0 Nm, check that the shaft has been
assembled correctly.

9 If rolling torque measured at 8 is too high, fit the next

larger size spacer. If rolling torque is too low, fit the 342790
next smallest size spacer. If a correct spacer is not
available from the range, check that drive head is
assembled correctly.

9803/7110 Issue 1
 Section F Transmission Section F
31 - 1 Propshafts 31 - 1

Propshafts
Removing and Replacing
X
When Removing

Before removing propshafts always mark both companion

flanges and also mark the sliding joints prior to removal.

When Replacing

Upon assembly, after lubricating sliding joints with JCB MPL

Grease, align the shafts against identification marks Y
previously made or, in the case of a shaft being renewed,
use the manufacturer's alignment markings.

* Retaining straps C stretch with use, therefore these straps

must always be replaced with new ones.

Apply JCB Lock and Seal to threads of all flange bolts.

Z
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.

S189610
* The propshaft must have both ends exactly on the same
plane as shown at X. The yokes must not be at right angles
as at Y or at an intermediate angle as at Z.

Torque Settings

Item Nm kgf m lbf ft

1 21 2.1 15
2 77 7.8 57

S204000

9803/7110 Issue 3*
Section F Transmission Section F
41 - 1 Syncro Shuttle 41 - 1

M 25

S204680

9803/7110 Issue 2
 Section F Transmission Section F
41 - 2 Syncro Shuttle 41 - 2

Dismantling
1 Drain the oil from the casing into a suitable container by 11 Press out brake operating piston 26 from the end cover
removing the drain plug 1 and sealing washer 2. 24 by removing the piston housing centre bolt 28 and
Discard the sealing washer. spacer 29 and screwing in an M10 x 30 bolt to press
out the piston. Remove and discard the piston 'O' ring
2 Remove suction strainer retaining bolts 3 and remove 27. Remove the M10 x 30 bolt and refit the original bolt
the strainer 4. Remove and discard the strainer cap and spacer.
gasket 5.
12 30 k.p.h. Gearbox
3 Remove and discard the oil filter. Remove counter plates 31 (10 off), friction plates 32 (9
off), annular pressure plate 33, reaction pins 34 (3 off)
and the disc spring assembly 35 from the brake casing.

12A 20 k.p.h. Gearbox

Remove brake pressure plate 30, counter plates 31 (7
off), friction plates 32 (6 off), annular pressure plate 33,
reaction pins 34 (3 off) and the disc spring assembly 35
from the brake casing.

13 Remove the adaptor block assembly retaining

setscrews 10 (4 off) and remove the block 11. Remove
and discard the gasket 12.

14 Remove the casing retaining bolts 36.

15 Screw a lifting eye into a brake housing bolt hole. Using

a suitable hoist, lift the rear casing 37 away from the
front casing 38. Pry bars may be used at the points
provided to assist in 'cracking' the joint. Remove and
discard the face 'O' rings 39 and 40.

S203970

4 Position the gearbox with the rear casing 37

uppermost.

5 Unscrew capscrews 6 and remove spacers 7 (4 off).

Remove the solenoid valve assembly 8. Retain the
spacers (4 off) but discard the 'O' rings 9 (4 off).

6 Remove output yoke stake nuts 13 using service tool

892/00812. Discard the stake nuts. Remove washers 14
and yokes 15 from the output shaft 16.

7 Remove and discard the output shaft oil seals 17.

8 Remove the gear change turret retaining bolts 18 (4 off).

Remove the turret 19 and gasket 20. Discard the
gasket.

9 Remove the brake feed pipe 21.

*
10 30 k.p.h. Gearbox
Remove the brake end cover retaining bolts 22 (4 off)
and 23 (2 off) and remove the end cover 24. Remove
and discard the end cover gaskets 25 and spacer M.
*
20 k.p.h. Gearbox
Remove the brake end cover retaining bolts 22 (4 off) S203991
and 23 (2 off) and remove the end cover 24. Remove
and discard the end cover gasket 25.

9803/7110 Issue 2*
Section F Transmission Section F
41 - 3 Syncro Shuttle 41 - 3

S204210

9803/7110 Issue 1
 Section F Transmission Section F
41 - 4 Syncro Shuttle 41 - 4

Dismantling (Cont'd)
16 Remove the output shaft assembly 41. 29 Remove the pump and shaft from the pump case.

17 Remove locking screws 42 (2 off) from selector forks 44 30 Remove the bearing cups located in the rear casing
and 45. using a slide hammer.

18 Remove the detent plugs 46, springs 47 and balls 48 (2 Assembly

off each).
Note: All bearings must be lightly oiled before assembly.
19 Slide selector shafts 49 from selector forks 44 and 45. Make sure all components are thoroughly clean and renew
all 'O' rings.
20 Remove taper plug 50 from the casing. Thread a piece
of thin looped wire to the bottom of the RH selector 1 Clean the mating faces of front casing 38 and rear
shaft locating hole. Using a small diameter screwdriver casing 37.
through the taper plug hole, push the baulk roller 51
into the wire loop. Carefully withdraw the baulk roller. 2 Fit new bearing cups into front and rear casings using a
bearing dolly.
21 Remove the layshaft assembly 52.
3 Fit the idler shaft 60 using a soft faced hammer.
22 Remove the main shaft assembly 53.
4 Fit the idler gear assembly (thrust washers 56, thrust
23 Remove the reverser unit 54. See page 42-1 for bearing 57, needle roller bearing 59, idler gear 58,
Dismantling and Assembly instructions. thrust washers 56, thrust bearing 57 and spacer 55).

24 Remove spacer 55, thrust washers 56, thrust bearing * Note: Later type assemblies have the thrust bearings 57 and
57, idler gear 58, needle roller bearing 59, thrust the thrust washers 56 replaced by ‘PPA’ (plastic) type
washers 56 and thrust bearing 57 from idler shaft 60. washers (2 off - one each side of the idler gear).

* Note: Later type assemblies have the thrust bearings 57 and 5 Fit the reverser unit 54.
the thrust washers 56 replaced by ‘PPA’ (plastic) type
washers (2 off - one each side of the idler gear). 6 Fit the main shaft assembly 53.

25 Remove the idler shaft 60 using a slide hammer if 7 Fit the layshaft assembly 52.
necessary.
8 Fit the output shaft assembly 41.
26 Remove the bearing cups located in the front casing
using a slide hammer. 9 Thread the RH gear selector rod 49 through selector
fork 45 and into the casing. Secure with locking screw
27 Turn the gearbox into the horizontal position. 42. Torque tighten to 35 Nm (25.8 lbf ft).

28 Remove the pump assembly retaining bolts 61 (4 off) 10 Using a piece of looped wire, lower the baulk roller 51
and washers 62 (4 off) and withdraw the pump down the LH selector rod channel in the casing. When
assembly 63. Remove and discard 'O' ring 64. in position at the bottom, push the roller into position
using a small screwdriver through the taper plug hole
(item 50). Remove the wire and screwdriver. Fit the
taper plug 50 and torque tighten to 28 Nm (20.7 lbf ft).

11 Thread the LH selector rod 49 through selector fork 44

and into the casing. Secure with locking screw 42.
Torque tighten to 35 Nm (25.8 lbf ft).

12 Fit detent balls 48, springs 47 and plugs 46 (2 off each).

Torque tighten plugs to 35 Nm (25.8 lbf ft).

13 Screw a lifting eye into a brake housing bolt hole of the

rear casing 37. Using a suitable hoist, lift the rear
casing into position over the front casing 38. Carefully
lower the rear casing onto the front casing, ensuring
that the locating pegs are fully engaged. Secure the
casings with six equally spaced bolts 36. Torque
tighten to 56 Nm (41.3 lbf ft). Remove the lifting eye.

S203980

9803/7110 Issue 2*
Section F Transmission Section F
41 - 5 Syncro Shuttle 41 - 5

Assembly (Cont'd)
14 Clean the parking brake mating face. 20 Calculate the required shim thickness.

15 Using service tool kit Pt No. 993/59400, fit base plate A Example:
onto the parking brake mating face and secure with
socket head set screws B. Torque tighten to 56 Nm a End Float Tolerance : 0.03 to 0.08 mm. (Identical
(41.3 lbf ft). clearance for all shafts.)

16 Pass the adaptor C through the large diameter hole in b Measured End Float : 0.20 mm
the base plate and screw into the end of the layshaft.
c To give an end float within the tolerance, subtract
17 Fit the lever arm pegs D into the adaptor annular space. 0.05mm from dimension at para. b for the required
Position the lever unit mounting blocks E on the base shim thickness,
plate and secure with bolts F. Tighten the bolts. e.g., 0.20 - 0.05 = 0.15 mm.

18 Fit a magnetic base dial test indicator (DTI) G onto the 21 Remove the bolts F securing the lever unit mounting
base plate with the pin resting on the top of the blocks E and remove the lever unit. Unscrew and
adaptor. remove the adaptor C.

19 Measure layshaft end float as follows (refer to view W): 22 Remove taper plug 67.

a Using a torque spanner on the nut of the lever unit 23 Fit the short extension H to the adaptor C.
as shown, apply a torque of 30 Nm (22.1 lbf ft)
clockwise while turning the output shaft backwards 24 Using a lever, put the gearbox in gear.
and forwards using a turning handle. Zero the DTI.
25 Screw the adaptor into the end of the main shaft. Fit the
b Apply a torque of 30 Nm (22.1 lbf ft) anti-clockwise lever arm pegs D into the adaptor annular space.
while turning the output shaft backwards and Position the lever unit mounting blocks E in the
forwards using a turning handle. Take the layshaft appropriate position on the base plate A and secure
end float reading from the DTI. with bolts F. Tighten the bolts.

26 Fit a magnetic base DTI G onto the base plate with the
pin resting on the top of the adaptor.

27 Measure main shaft end float and determine shim

thickness by repeating steps 19 and 20. Refer to view
X.

S204020

S204030

9803/7110 Issue 1
Section F Transmission Section F
41 - 6 Syncro Shuttle 41 - 6

Assembly (Cont'd)
28 Temporarily refit taper plug 67. 39 Clean the mounting face of the flywheel housing. Mount
the DTI on the face with the probe resting on the end of
29 Remove short extension from adaptor. the reverser unit shaft. Firmly press the reverser unit
shaft in to take up any shaft end float. Zero the DTI.
30 Fit the rear output yoke 15, washer 14 and stake nut Refer to view Z.
13. Torque tighten to 350 Nm (258.2 lbf ft).
40 Screw a threaded bolt or rod into the threads exposed
31 Fit the output yoke adaptor J and secure with bolts K. when oil inlet adaptor 65 was removed, until it touches
Torque tighten to 22 Nm (16.2 lbf ft). Screw the adaptor the end of the reverser unit shaft.
C into the yoke adaptor extension L until tight.

32 Fit the lever arm pegs D into the adaptor annular space.
Position the lever unit mounting blocks E in the
appropriate position on the base plate A and secure
with bolts F. Tighten the bolts.

33 Fit a magnetic base DTI G onto the base plate with the
pin resting on the top of the adaptor.

34 Measure the output shaft end float and determine shim

thickness by repeating steps 19 and 20. Refer to view
Y.

S204050

S204010 * 41 Screw bolt or rod in further (approx. 10 Nm; 7.4 lbf ft)
whilst turning output shaft. Stop when increasing
resistance is felt. DO NOT overtighten. Take the DTI
reading.

42 Calculate the required shim thickness as detailed in

step 20.
35 Remove the lever unit, adaptor, base plate and output
yoke adaptor. 43 Remove bolt or rod and the DTI. Temporarily refit oil
inlet adaptor 65 and sealing washer 66.
36 Remove the rear stake nut 13, washer 14 and output
yoke 15. 44 Turn the gearbox into the vertical position, with the rear
casing upwards.
37 Remove oil inlet adaptor 65 and sealing washer 66 from
the rear casing. 45 Screw a lifting eye into a brake housing bolt hole. Using
a suitable hoist, lift the rear casing 37 away from the
38 Turn the gearbox into the horizontal position. front casing 38. Pry bars may be used at the points
provided to assist in 'cracking' the joint. Turn the rear
casing over.

9803/7110 Issue 2*
Section F Transmission Section F
41 - 7 Syncro Shuttle 41 - 7

Assembly (Cont'd)
46 Using a bearing puller, remove the layshaft bearing cup 53 If any measurement is outside the tolerance, remove
from the rear casing. Referring to the shim thickness rear casing, see step 45. Using a bearing puller, remove
calculation for the layshaft 52, fit the required shims the bearing cap(s) of the shaft(s) outside the tolerance.
into the rear casing. Using a bearing dolly, refit the Add or remove shim(s) to bring the measurement(s)
layshaft bearing cup. within the tolerance. Using a bearing dolly, refit the
bearing cup(s) into the rear casing.
47 Repeat step 46 for the main shaft 53, output shaft 41
and reverser unit 54. 54 Remove the front case 'O' rings 39 and 40 and clean
the sealant from the front case mating face.
48 Turn the rear casing over.
55 Repeat steps 49 to 52 inclusive. The end float
49 Fit the face 'O' rings 39 and 40 into the front case measurements should now be within the tolerance for
mating face recesses. all shafts. If any measurement is still outside the
tolerance, repeat step 53.
50 Apply a bead of sealant to the front case mating face,
smoothing the sealant around the 'O' ring areas. * 56 Turn the gearbox into the horizontal position. Fit new
'O' ring 64 to the oil pump assembly. Refit the oil pump
51 Screw a lifting eye into a brake housing bolt hole of the assembly and secure with new washers 62 and bolts
rear casing 37. Using a suitable hoist, lift the rear 61. Torque tighten to 28 Nm (20.7 lbf ft). Make sure that
casing into position over the front casing 38. Carefully the pump rotors rotate.
lower the rear case onto the front case, ensuring that
the locating pegs are fully engaged. Secure the casings
with bolts 36. Torque tighten to 56 Nm (41.3 lbf ft).
Remove the lifting eye.

S203980

57 Pack the cavity between the lips of both front and rear
output shaft oil seals 17 with grease and fit the seals.

58 Fit the front and rear output yokes 15 and secure with
washers 14 and new stake nuts 13. Do not fully tighten.
Align the front and rear output yokes.

Note: Fit the output yokes so that the staking slot can be
reached when the stake nut is fully tightened.
S203991
59 Fit the gear change turret 19 with a new gasket 20 and
52 Repeat end float measurements, as detailed in steps 15 secure with setscrews 18. Torque tighten to 56 Nm
to 36 inclusive, to check that end float on all shafts (41.3 lbf ft).
remains within the tolerance of 0.03 to 0.08 mm.
60 Fit oil inlet adaptor 65 with new sealing washer 66 into
the rear casing. Torque tighten to 102 Nm (75.2 lbf ft).

61 Fit taper plug 67. Torque tighten to 56 Nm (41.3 lbf ft).

9803/7110 Issue 2
 Section F Transmission Section F
41 - 8 Syncro Shuttle 41 - 8

Assembly (Cont'd)
62 30 k.p.h. Gearbox 65 Torque tighten the brake end cover retaining setscrews
Position the output yokes so that the staking slots are 23 and 22 to 56 Nm (41.3 lbf ft) and the brake feed pipe
accessible. Assemble the parking brake in the following 21 nuts to 22 Nm (16.2 lbf ft).
order: disc springs 35 (see note), annular pressure plate
33, reaction pins 34 (3 off), and, alternately, counter 66 To check that the brake releases, remove brake cover
plate 31 (10 off) and friction plates 32 (9 off). centre setscrew 28 and spacer 29. Refit the setscrew
without spacer. Screw in setscrew whilst attempting to
62A 20 k.p.h. Gearbox turn one of the gearbox output yokes. When the yoke
Position the output yokes so that the staking slots are begins to turn the brake has released. Unscrew the
accessible. Assemble parking brake in the following setscrew whilst turning an output yoke until the yoke
order: disc springs 35 (see note), annular pressure plate cannot be turned. This confirms that the brake is on.
33, reaction pins 34 (3 off), alternately, counter plates Refit the spacer 29 to the setscrew and refit to the
31 (7 off) friction plate 32 (6 off), and pressure plate 30. brake cover. Torque tighten to 56 Nm (41.3 lbf ft).

Note: Make sure that the disc springs 35 are installed the 67 Fit adaptor block assembly 11 and new gasket 12 to
correct way, as shown below. the rear casing. Secure with setscrews 10 and torque
tighten to 10 Nm (7.4 lbf ft).
35
68 Fit new 'O' rings 9 to the underside of solenoid valve 8.
Fit solenoid onto the adaptor block assembly 11,
ensuring that 'O' rings remain in position in solenoid
base. Secure solenoid using spacers 7 and cap screws
6 (4 off). Torque tighten to 5.8 Nm (4.3 lbf ft).

69 Fit a new gasket 5 to a clean suction strainer 4 and

A204620
insert into the casing. Apply JCB Lock and Seal to the
threads of setscrews 3 (2 off) and torque tighten to 10
Nm (7.4 lbf ft).
63 30 k.p.h. Gearbox
Fit new 'O' ring 27 to brake piston 26. Fit piston into
brake end cover 24. Fit new gaskets 25 and spacer M
(see Note). Fit the cover and loosely secure with
setscrews 23 (2 off) and 22 (4 off).

* Note: Two sizes of spacer M are available; when assembled,

the reaction pin 34 must protrude above the spacer by 2.1 to
3.7 mm (0.082 to 0.146 in.). Select the appropriate size
spacer M to achieve this dimension.

2.1 to 3.7 mm
M
(0.082 to 0.146 in)

34 S203970

S221440
70 Torque tighten the output yoke stake nuts 13 to 350
Nm (258.2 lbf ft). Stake the nuts using a square ended
63A 20 k.p.h. Gearbox staking tool.
Fit new 'O' ring 27 to brake piston 26. Fit piston into
brake end cover 24. Fit a new gasket 25 onto the brake 71 Fit drain plug 1 with new sealing washer 2. Torque
end cover mounting face. Fit the cover and loosely tighten to 102 Nm (75.2 lbf ft).
secure with setscrews 23 (2 off) and 22 (4 off).
72 Fit a new oil filter.
64 Assemble the brake feed pipe 21 between the brake
housing and the rear cover.

9803/7110 Issue 2*
 Section F Transmission Section F
42 - 1 Reverser Unit 42 - 1

Dismantling
1 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.

2 Turn the assembly over and knock the clutch shaft on a

wooden block to loosen the clutch end bearing 2.
2
Remove the bearing using pullers.
3
3 Remove the thick thrust washer 3, thrust bearing 4 and
thin thrust washer 5.
*
Note: Later type assemblies have the thrust bearing 4 and A
the thin thrust washer 5 replaced by a single ‘PPA’ (plastic)
S221460
type washer A.

4 Withdraw the gear and splined hub assembly 6 and the

needle roller bearing 7.

5 Remove the thin thrust washer 8, thrust bearing 9 and

thick thrust washer 10.
*
Note: Later type assemblies have the thrust bearing 9 and
the thin thrust washer 8 replaced by a single ‘PPA’ (plastic)
type washer.

S204120

9803/7110 Issue 2*
Section F Transmission Section F
42 - 2 Reverser Unit 42 - 2

Dismantling (Cont'd)
6 Remove the clutch friction/counter plate retaining
circlip 11.

7 Remove pressure end plate 13.

Note: If the reverser unit has been previously dismantled,

shims 12 may be fitted.

8 Remove clutch friction plates 14 (4 off) and counter

plates 15 (4 off). Keep plates together in sets, DO NOT
mix with those from other clutches.

Note: 2DX machines and later 2CXL/Farm Master machines

have five friction plates and 5 counter plates.

9 Remove the disc spring assembly 16.

S204110

9803/7110 Issue 3
 Section F Transmission Section F
42 - 3 Reverser Unit 42 - 3

Dismantling (Cont'd)
10 Position clutch assembly in a suitable press to
compress the piston spring then remove circlip 17.

S145000

11 Lift off spring retaining plate 18.

12 Remove spring 19 and oil baffle plate 20.

* Note: Later type assemblies do not have a separate oil

baffle plate 20 fitted. Instead, they have a new type piston
that incorporates the oil baffle as an integral part of the
piston.

13 Turn the assembly over and knock the clutch shaft on a

wooden block to loosen the piston 21.

Note: If the piston does not loosen, hand pump air down the
shaft oil inlet hole.

14 Remove the piston 21. Remove and discard the piston

'O' ring 22 and shaft 'O' ring 23.

15 Make sure that the piston liner 24 is secure and is a

tight fit on the piston.

16 Dismantle the opposite clutch assembly (torque

converter end) by repeating steps 1 to 15 and
observing the following notes.

Note: The clutch shaft has only one piston ring seal 1 fitted
at this end.

Note: Spacer A is fitted on the clutch shaft after the needle

roller bearing 7. The spacer may be fitted at either end of the
needle roller bearing.

S204100
S204090

9803/7110 Issue 2*
 Section F Transmission Section F
42 - 4 Reverser Unit 42 - 4

Assembly
The assembly procedure is the reverse of the dismantling 10 Pack clutch end bearing with JCB MPL Grease and
procedure. press the bearing onto clutch shaft.

Make sure all components are thoroughly clean prior to 11 Fit piston ring seals.
assembly. Renew all 'O' rings.
12 Assemble the opposite clutch assembly (torque
1 Lubricate the piston 21 with hydraulic oil and press fully converter end) by repeating steps 1 to 11.
into bore of clutch housing.

2 Fit oil baffle 20, spring 19 and spring retaining plate 18.

3 Compress spring and fit circlip 17.

4 Fit four counter plates 15 and four friction plates 14

alternately, starting with a counter plate.

* Note: 2DX machines and later 2CXL/Farm Master machines

have five friction plates and 5 counter plates.

5 Fit pressure end plate 13 and clutch friction/counter

plate retaining circlip 11.

6 Using a dial test indicator as shown, measure the end

float of the pressure end plate 13, which should be 2.0
to 3.3 mm (0.079 to 0.130 in). If necessary, fit shim 12
between the retaining circlip and pressure end plate to
correct end float inaccuracies.

7 Fit thrust washers 10 and 8 and thrust bearing 9.

Note: Later type assemblies have the thrust bearing 9 and

the thin thrust washer 8 replaced by a single ‘PPA’ (plastic)
type washer (see step 5, Dismantling). The ‘PPA’ washer
must be installed NEXT to the gear and hub assembly.

8 Align teeth of clutch plates using a thin rod or

screwdriver. Fit gear and splined hub assembly 6.

9 Fit needle roller bearing 7, thrust washers 5 and 3 and

thrust bearing 4.

Note: Later type assemblies have the thrust bearing 4 and

the thin thrust washer 5 replaced by a single ‘PPA’ (plastic)
type washer (see step 3, Dismantling). The ‘PPA’ washer
must be installed NEXT to the gear and hub assembly.

S191420

9803/7110 Issue 3*
Section F Transmission Section F
44 - 1 Syncro Shuttle 44 - 1

Torque Converter
Replacing

Ensure that flywheel face, drive plate, and hardware are

clean and free from burrs or other surface imperfections. 2 A
When Replacing
1
1 Offer drive plate 1 to the torque converter.

2 Place the torque converter alignment tool A over the

torque converter spigot, make sure that the tool
locates in two of the converter bolt holes as shown. It
is important to note that the converter drive tube
must be protected against damage or contamination S267910
at all times.

3 Fit four of the M10 flanged bolts 2 and torque tighten

to 84 Nm (62 lbf ft). Remove the alignment tool and fit
the remaining two retaining bolts 2.

4 Offer the torque converter and drive plate assembly

to the flywheel, bolt the drive plate to the flywheel
(use only 3 bolts). Check the converter run-out as
shown at B, which should not exceed 0.38mm (0.015
in.).

Note: In the unlikely event that the run-out exceeds 0.38 mm

(0.015 in.), remove the converter and check the spigot for
B
burrs, remove the drive plate and rotate it 180° on the torque
converter, repeat steps 2 to 4.

5 Remove the torque converter and drive plate

assembly from the flywheel.
S161470
6 Install the torque converter with its drive plate
assembly onto the transmission input shaft, make
sure that the dogs on the converter pump drive shaft
engage with the recesses in the pump, also take care 3
not to damage the oil seal.

7 Rotate the engine flywheel so that one bolt hole is in

a six O' clock position.
2
8 Rotate the torque converter and drive plate assembly
so that one bolt hole is in a six O' clock position.

9 Install the transmission/torque converter assembly to

the engine.
1
10 Remove the access plate from the bottom of the
engine flywheel housing and through the access hole
fit and hand tighten one M8 flanged bolt (item 3) in
the six 'O' clock position

11 Rotate the flywheel until the next bolt hole is

accessible, fit and hand tighten the next bolt 3.
Repeat the operation until all bolts are fitted. Finally
torque tighten bolts 3 to 44 Nm (32 lbf ft), rotating the
flywheel each time to align bolts 3 with access hole.
Refit access plate. A265990

9803/7110 Issue 1
Section F Transmission Section F
45 - 1 Syncro Shuttle 45 - 1

E
D B
G
C
J F
H S205690

A
S204870

S204890 X Z
Y
9803/7110 Issue 1
Section F Transmission Section F
45 - 2 Syncro Shuttle 45 - 2

Pressure and Flow Testing If testing the complete transmission, the following
procedures are listed in a logical sequence and should
Before completing any of the transmission pressure/flow therefore be completed in the same sequence. Also, refer to
tests, make sure that the oil level is correct and at normal the fault finding procedures at the beginning of the
operating temperature. transmission section for reference to specific tests.

All gauges etc used in the following pressure/flow tests are Mainline Pressure
shown in Section 1.
1 Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure
gauge to test connector A.
! WARNING 2 Start engine and run at 1000 rev/min. With the
Fine jets of hydraulic oil at high pressure can penetrate transmission in neutral the pressure gauge will show
the skin. Do not use your fingers to check for hydraulic the Mainline Pressure which should be as shown in
oil leaks. Do not put your face close to suspected leaks. Technical Data, page F/1-2.
Hold a piece of cardboard close to suspected leaks and
then inspect the cardboard for signs of hydraulic oil. If 3 Repeat step 2 and note gauge readings with engine
hydraulic oil penetrates your skin, get medical help running at 2000 rev/min.
immediately.
HYD 1-1
4 Stop engine and remove test gauge.

If the mainline pressure is low, refer to the fault 'Low

! WARNING Mainline Pressure' on page F/4-1 for a list of possible
Take care when disconnecting hydraulic hoses and reasons. A high reading could indicate a faulty pressure
fittings as the oil will be HOT. maintenance valve.
Trans 1-2

Clutch Pressure (Forward Clutch Given in Example)

! WARNING 1 Stop engine, connect a 0-20 bar (0-300 lbf/in2) pressure

DO NOT go underneath the machine with the engine gauge to test connector B (item C for reverse clutch).
running. Switch off the engine, apply the parking brake
and chock both sides of all wheels before going 2 Start engine and run at 1000 rev/min. With parking
underneath the machine. brake and footbrake firmly applied, select Forward, the
Trans 2-1 pressure gauge will show the Clutch Pressure which
should be as shown in Technical Data, page F/1-2.
TEST POINTS Note: If the mainline pressure is in the lower part of the
tolerance band (see Technical Data, page F/1-2), then the
A - Mainline pressure forward and reverse clutch pressures should also be in the
lower part of the tolerance band and vice versa.
B - Forward clutch pressure
3 Repeat step 2 and note gauge readings with engine
C - Reverse clutch pressure running at 2000 rev/min.
D - Converter inlet/converter relief valve pressure 4 Stop engine and remove test gauge.
E - Converter outlet pressure If the clutch pressure is low, the clutch could be leaking. A
leaking clutch is easier to detect when the engine is running
F - Pump flow (remove filter and fit adapters) at idle. With the engine at idling speed, check the mainline
pressure and then check the clutch pressure as described
G - Lubrication pressure above, if the clutch pressure is 1.7 bar (25 lbf/in2) less than
the mainline pressure, then the clutch is probably leaking.
H - Cooler flow (flowmeter in line from transmission to Refer to the fault 'Low Clutch Pressure' on page F/4-2
cooler) before dismantling the clutch.
J - Load Valve A high reading could indicate a faulty pressure maintenance
valve.

9803/7110 Issue 1
Section F Transmission Section F
45 - 3 Syncro Shuttle 45 - 3

Pressure and Flow Testing

Pump Flow Converter Relief (Safety) Valve Pressure

1 Stop engine, remove transmission filter F, and screw 1 Connect a 0-10 bar (0-145 lbf/in2) pressure gauge to
adapter X (892/00304) on to the threaded spigot. Fit test point D.
test adapter Y (892/00301) and secure with adapter Z
(892/00302). Connect flowmeter W (892/00229). 2 Fit a load valve J into the converter out line.

2 Start engine and run at 1000 rev/min. With the CAUTION: Make sure the load valve is in the OPEN position
transmission in neutral the flowmeter will show the (the adjusting knob screwed fully out) before starting the
Pump Flow which should be as shown in Technical following pressure test. If the load valve is not fully open,
Data, page F/1-3. damage to the converter seals will be incurred.

3 Repeat step 2 and note gauge readings with engine CAUTION: DO NOT allow the pressure to exceed 7.6 bar
running at 2000 rev/min. (110 lbf/in2) or damage to the converter seals will be caused.

4 Stop engine and remove test adapters, refit filter. 3 Start the engine and run at 1000 rev/min. With the
transmission in neutral, slowly screw down the load
If the pump flow is low, refer to the fault 'Low Pump Flow' on valve J whilst observing the gauge reading which
page F/4-1. should rise to the Converter Relief (Safety) Valve
setting as specified in Technical Data, page F/1-2.
Converter Out Pressure/Oil Cooler Flow Rate
4 If the reading is higher than specified then the converter
1 Stop engine, connect a 0-10 bar (0-145 lbf/in2) pressure relief valve is faulty. A low reading indicates a leaking
gauge and flowmeter (see note) into the converter out pump seal or a faulty converter relief valve.
line as shown at E and H respectively.
5 Stop engine, remove test gauges and refit hoses to
Note: The flowmeter must have a low back pressure, original position.
otherwise an incorrect reading will be obtained.

2 Run the engine at 1000 rev/min with transmission in Lubrication Pressure

neutral. The pressure gauge indicates the Converter
Out Pressure and the flowmeter indicates the Oil 1 Stop engine, connect a suitable pressure gauge into
Cooler Flow Rate, both readings should be as the return line from the oil cooler to the transmission as
specified in Technical Data, pages F/1-2 & F/1-3. shown at G.
3 Repeat step 2 and note gauge readings with engine 2 Start the engine and run at 1000 rev/min. With the
running at 2000 rev/min. transmission in neutral the pressure gauge will indicate
the Lubrication Pressure which should be as specified
4 Stop engine, remove test gauges and refit hoses to in Technical Data, page F/1-2.
original position.
3 Repeat step 2 and note gauge readings with engine
If the pressure is low, refer to the fault 'Low Converter Out running at 2000 rev/min.
Pressure' on page F/4-1 for a list of possible reasons. A high
pressure together with low flow could be caused by a 4 Stop engine and remove pressure gauge.
blocked oil cooler.

Converter In Pressure

1 Stop engine, connect a 0-10 bar (0-145 lbf/in2) pressure

gauge to test point D.

2 Start the engine and run at 1000 rev/min. With the

transmission in neutral the pressure gauge will show
Converter In Pressure which should be as shown in
Technical Data, page F/1-6. A high or low reading could
indicate a faulty converter relief valve, or a problem with
the pump.

3 Remove pressure test gauge.

9803/7110 Issue 1
Section F Transmission Section F
45 - 4 Syncro Shuttle 45 - 4

Torque Converter Stall Test

Note: Before completing the torque converter stall test, 3 If engine speeds are higher than the stated figures
make sure that the mainline and clutch pressures are check the transmission for clutch slippage or internal
correct. If the pressures are incorrect, the clutches could leakage.
slip, causing premature wear of the clutch friction plates.
If engine speeds are below the stated figures either the
Also, make sure that the machine neutral circuit pressure engine is losing power and should be
(including steer circuit) is correct (14 bar; 200 lbf/in2 serviced/overhauled or the torque converter reaction
maximum). member clutch is slipping.

1 Ensure that the engine and transmission are at normal To check the engine, make sure the main relief valve is
working temperature. Run engine at maximum speed set correctly, select Neutral, open throttle fully and
and check the No Load Speed (High Idle Speed - operate an excavator service to 'blow off' the main
U.S.A). See Engine Technical Data for correct figure; relief valve. Engine speed should fall to slightly above
adjust if necessary. the Maximum Governed Speed (see Engine Technical
Data). If engine speed is correct the torque converter is
2 Apply parking brake A and footbrake firmly B, select faulty.
4th Speed Forward and open throttle C fully. Engine
speed should be as specified at Torque Converter Stall Note 1: The engine can also be checked by doing a stall test
in Transmission Technical Data. Select Reverse and and 'blowing off' the main relief valve simultaneously. The
repeat test. speed should be as stated on page F/1-2 ('Engine Rev/Min
at Converter Stall + MRV Operating').
DO NOT stall the converter for longer than 30 seconds or
the transmission fluid will overheat. Note 2: Maximum Governed Speed is a datum figure only.
It cannot be adjusted or checked with the engine installed in
the machine.

B C

S181851

9803/7110 Issue 1
Section F Transmission Section F
50 - 1 Power Take Off Clutch 50 - 1

Description of Operation
The drive for the compressor is transmitted by constant mesh from gear A through idler gear B onto the power take off clutch
gear C. Gear A is mounted on the input reverser shaft D and is driven via the torque converter. The converter has an additional
integral splined spigot when compared to a 'standard' converter, this additional spline is used to directly drive gear assembly A
via gear E.

The constant meshing gears will freely rotate until the PTO clutch solenoid F is energised. When the solenoid is energised,
pressurised oil is diverted via a solenoid spool G to the power take off clutch pack assembly H. The clutch pack works on a
similar principle to the standard 'reverser' clutch found in the standard syncro shuttle transmission, that is the pressurised oil
enters the clutch and forces a piston against the friction/counter plate assembly J. Because the friction/counter plates are now
compressed drive is transferred from the clutch gear C, through the friction/counter plate assembly to the PTO drive yoke K.

When the solenoid is de-energised, the friction/counter plates are released by spring pressure and the constant meshing gears
will once again freely rotate (with no drive being transmitted).

A212860

9803/7110 Issue 1
Section F Transmission Section F
50 - 2 Power Take Off Clutch 50 - 2

A212880

F G
SECTION THROUGH A - A
H

C
K J

A212870

9803/7110 Issue 1
Section F Transmission Section F
51 - 1 Power Take Off Clutch 51 - 1

27 19
21
20 28
18
26
17

25
24
23 16
22

32
31
29 30

34 35

33 36

38
3
2 37

7
8 9 10
1
11
12 15
14
13
6

5
4
S212380-1
39

9803/7110 Issue 1
Section F Transmission Section F
51 - 2 Power Take Off Clutch 51 - 2

Removal and Replacement Dismantling and Assembly

Removal Idler Assembly
Note: If the PTO clutch is to be dismantled, the coupling nut
4 should be loosened before the clutch is removed from the The idler assembly (items 33 - 37) can be dismantled after
gearbox. the PTO clutch has been removed and must be assembled
before the PTO is replaced. Withdraw shaft 33 using an
Disconnect the hydraulic pipe connection from the PTO impulse extractor screwed into the M12 tapped hole in the
housing. Plug the exposed connections to prevent ingress of end of the shaft, then remove the remaining components via
dirt. the PTO cavity. Assembly is the reverse of the dismantling
sequence.
Loosen and remove the 8 bolts 1 which secure the PTO
housing 2 to the gearbox. Dismantling

Carefully lift the PTO clutch from the gearbox. Remove and Follow the numerical sequence on the illustration to
discard gasket 3. dismantle the unit, noting the points listed below.

Replacement Use suitable screws, inserted into the threaded holes

provided, to remove the brake piston 10.
Replacement is the reverse of the removal procedure.
Dowels 9 (3 off) should be removed if they are loose, to
Torque tighten bolts 1. prevent losing them.

When fitting nut 4, torque tighten as indicated then split the Bearing 18 will either remain on the clutch shaft or in its
nut sleeve axially using a square ended staking tool. (This housing in the gearbox when the clutch is removed.
operation may be easier performed after the clutch has been
replaced in the gearbox.) Dismantling of the clutch assembly 7 will be easier if it is
secured in a soft-jawed vice, coupling end lowermost.
Torque Settings
Thrust washer 28 and ring 27 should be removed using a
Item bearing puller applied to thrust washer 28. Discard ring 27.
1 56 Nm 41 lbf ft 5.7 kgf m Take care not to damage the clutch housing and the oil
4 350 Nm 258 lbf ft 35.7 kgf m holes in the end of the shaft when using the puller.

Note: Do not attempt to lever off these components. Always

use the correct tool.

The clutch pack comprises alternate friction plates 24 and

counter plates 25, beginning and ending with a friction plate.
The pack is sandwiched between two spacers 23 and 26,
and secured by circlip 22. Retain these items as a set for
assembly.

Note that the clutch housing cannot be removed from the

shaft.

Discard all seals and O rings.

9803/7110 Issue 1
Section F Transmission Section F
51 - 3 Power Take Off Clutch 51 - 3

27 19
21
20 28
B 18
26
17

25
24
23 16
22

32
31
29 30

34 35

33 36

38
3
2 37

7
8 9 10
1
11
12 15
14
13
6

5
4
S212380-1
39

9803/7110 Issue 1
Section F Transmission Section F
51 - 4 Power Take Off Clutch 51 - 4

Dismantling and Assembly (continued)

Inspection Brake Operation

Thoroughly clean all components. Ensure that all oil ways With the assembly mounted on the gearbox, check the
are clear. operation of the clutch brake as follows:

Inspect generally for damage. Check for scoring inside the With no electrical power or pressure connected, check that
piston housing and at the oil feed end of the shaft. Polish out the coupling 6 is free to rotate.
if necessary.
With air pressure connected to the solenoid valve 39 and the
Check the operation of the non-return valve located in piston solenoid de-energised, check that the coupling cannot be
30. rotated (i.e. brake on).

Check the clutch pack for damage and excessive wear. With air pressure connected and the solenoid energised,
Replace the complete set of friction and counter plates if check that the coupling can be rotated back and forth as far
necessary. Do not mix plates from different clutch packs. as the gear backlash allows (i.e. brake off).

Check the condition of brake disc 8. Renew if necessary. Note: The solenoid can be damaged if it is connected the
wrong way round. Ensure correct polarity before applying
Assembly power.

Assembly is basically the reverse of the dismantling

sequence, but please note the following.

Use new seals and O rings. Lightly oil components before

installing them.

Pack the cavity between the lips of seal 13 with grease

before assembly.

Thrust washer 28 should be installed using a bearing press,

ensuring that the plate is pressed squarely onto its shoulder
on the shaft. Ring 27 should similarly be installed using a
bearing press.

When installing the clutch pack, ensure that the

friction/counter plates are installed in the correct sequence,
see Dismantling. Note that there are seven friction plates
24, and six counter plates 25. Use the pinion assembly 19 to
align the inner teeth of the friction plates.

Lightly oil bearings 15, 18 and 21 before installing and rotate

them during setting.

After assembly, and using an airline, check that the clutch

operates smoothly and that there is endfloat.

Measure the clutch pack end float using two screwdrivers as

shown at B. The clutch pack endfloat should be 1.3 - 3.6
mm. If incorrect, check for damage, correct assembly and
that the correct number of clutch plates have been installed.
Note that shims are not necessary.

Fitting nut 4 may be easier performed after the clutch has

been replaced in the gearbox, see Removal and
Replacement.

Torque Settings

Item
39 47-54 Nm 35-40 lbf ft 4.8-5.5 kgf m

9803/7110 Issue 1
Section F Transmission Section F
55 - 1 Transfer Gearbox 55 - 1

Removal and Replacement

Removal Replacement

Remove plug A and drain the oil into a container. Replacement is the reverse of the removal procedure.

Support the gearbox and remove the top 2 bolts C, remove Clean and grease the gearbox drive splines and driveshafts.
propshaft guard, not shown.
Align the power take off gearbox driveshaft.
Remove lower bolt C and lift the gearbox clear of the
machine. * Make sure the gearbox fits flush and makes contact with
mounting brackets D, use shim/washers as required.

Make sure the WARNING label on the PTO guard is in good

condition and is legible.

Fit drain plug A, use a new seal.

Fill the gearbox with the recommended oil through the

fill/level plug B.

Item Nm lbf ft kgf m

A/B 102 75 10.4

C
C

9803/7110 Issue 2*
Section F Transmission Section F
55 - 2 Transfer Gearbox 55 - 2

Dismantling and Assembly

Dismantling Assembly

Remove bolts 11 (9 off) and separate casing 1 and 2. Assembly is basically the reverse of the dismantling
sequence, but please note the following.
Dowels 14 (2 off) should be removed if they are loose to
prevent losing them. Use new seals and O rings. Lightly oil components before
installing them.
Remove circlip 9 and remove gear 3. Driveshaft 5 can now
be removed. Fit seals flush with the outer edge of casing, pack the cavity
between the lips of seals 10 and 6 with grease before
assembly.

Clean mating faces of casing 1 and 2, use JCB Multi-Gasket

to reseal.

Torque Settings

Item Nm lbf ft kgf m

11 56 41 5.7`

A303950

9803/7110 Issue 1
Section F Transmission Section F
60 - 1 Salvage/Repair 60 - 1

Drive Shaft Oil Seal (all JCB axles)

OLD SEAL V
Oil Seal Replacement
1 Inspect the drive shaft seal surface for wear or pitting Z
and if required, fit either a new shaft or the wear sleeve,
special bearing and seal, see Wear Sleeve Fitting. W
2 To determine the installation requirements for the new
seal, measure dimension V from shoulder W to circlip
Z.

If dimension V is 16 to 16.30 mm (0.63 to 0.64 in), fit the

new seal protruding by 2 mm (0.080 in).
If dimension V is 17.3 to 17.5 (0.68 to 0.69 in), fit the
new seal flush with the end of the housing.

3 Fit the seal using a flat plate or suitable fitting sleeve.

Take care not to damage or distort the seal housing
309540

NEW SEAL
V
Z
W

309550

9803/7110 Issue 1
Section F Transmission Section F
61 - 1 Salvage/Repair 61 - 1

Wear Sleeve Fitting

1 If during seal replacement drive shaft wear is found to 4 Fit new special size bearing C, the old circlip Z and new
be present, check the drive shaft diameter at X on an special size seal B1.
unworn section away from the seal track. If the
diameter is 46.165 to 46.145 mm (1.818 to 1.817 in) a 5 Fit drive shaft oil seal, see page F/60-1.
wear sleeve can be fitted. If the diameter is outside
these limits, the sleeve cannot be fitted successfully
and the shaft must be renewed. 6 Refit the drive shaft taking care not to damage the seal
when fitting the shaft. Complete the repair.

2 If the wear sleeve is to be fitted, remove burrs or rust 7 If the wear sleeve has to be removed from the shaft, use
using an oil stone or emery cloth, taking care not to the following method:
reduce the overall shaft size. Degrease the wear sleeve
and shaft, apply JCB Retainer (High Strength) to the Place the sleeve horizontally on an anvil or suitable hard
shaft. surface as shown at Y. Hammer the sleeve whilst
rotating the shaft until the sleeve becomes oval and will
Note: The sleeve must be expanded before fitting by heating slide off the shaft. Protect your eyes when hammering.
to 100 - 110 °C (212 - 230 °F). Take precautions to prevent Wear safety glasses or goggles.
the danger of personal injury by burning. Wear gloves and
protective overalls.

After pre-heating, use a suitable tube to press or tap the

the wear sleeve A onto the shaft, internal chamfered
end first, until fully located against the shaft shoulder.

Note: If the sleeve is not a tight fit on the shaft, the shaft
must be renewed.
X
3 Remove the old inner drive shaft seal, circlip and
bearing.

Y
Z

C
B1
A

263870

9803/7110 Issue 1
Section F Transmission Section F
62 - 1 Salvage/Repair 62 - 1

Axle and Gearbox Driveshaft Flange Seals

(all JCB axles)
Leaks can be caused by one or more of the following:

1 Oil seal not fitted square.

After fitting, measure the oil seal depth B in four places

as shown at A, if the depth varies by more than
0.50mm (0.0195in) carefully tap the new seal until
square or fit another seal.

2 Dirt ingress/contamination.

Dirt can enter an oil seal if the unit or flange is not

thoroughly cleaned before removal and before fitting a 311190
new seal. B
3 Oil seal damaged when fitting.
5 Damage to the seal housing when removing seal.
Check that the oil seal is not damaged, distorted or the
lips cut or torn. When fitting an oil seal use a suitable Take care when removing seals and avoid damaging
tool or tube that does not touch the seal lip and fully the housing. On the outer diameter small
supports the casing of the seal without distorting the scratches/marks can be cured by using a silicon
seal during fitting. Lubricate the seal’s external and sealant on the seal outer diameter. For excessive
internal diameters sparingly with JCB HP grease and damage fit a new component.
check the spring was not displaced during fitting.
6 Incorrect oil seal fitted
4 Poor seal yoke/flange surface finish.
Seals with internal diameter, 50mm (1.96in) and 55mm
When the leak is a seepage around the seal check and (2.16in) are available. Refer to the parts catalogue for
if none of the other points are evident check the correct part numbers, location. If in doubt measure the
yoke/flange surface carefully for damage. flange diameter D, (typical illustration).

Restoring Surface Finish

Light damage, scratches/marks of the surface finish

can be restored. (Marks or scratches barely visible by
eye can allow hot oil to leak past the seal).

If the surface is excessively damaged or worn, fit a new

component.

Restore by carefully polishing with 800 or finer grade

D
abrasive grit paper C.

Use clean hydraulic oil as a lubricant and cutting fluid

while polishing to prevent scoring or scratches.

The recommended procedure to polish a component is

to mount in a lathe, rotate at 100 RPM approx. and
gently apply a strip of 800 or finer abrasive grit paper
and a film of hydraulic oil.

Note: Take care if polishing by hand when finishing to keep

abrasive paper clean. Do not rotate the paper and the
component in such a way as to create scratches or a spiral 311210
mark, which could ‘screw’ a small oil film under the seal lip.

Thoroughly clean all parts before and after polishing.

C

311200

9803/3620 Issue 1
Section F Transmission Section F
63 - 1 Salvage/Repair 63 - 1

Hub and Driveshaft - Fitting Bearing

Carrier Combination Seal
C
Measure the dimension between the wheel bearing face Y
and the outer face of the wheel bearing carrier Z.

a) If the dimension is 25 to 26mm (A) fit the oil seal using

service tool (part number 892/00891) with the spacer
until the oil seal is level with the wheel bearing carrier
face Z. D
b) Prior to April 95 the distance will be 28 to 30mm (B).
For these axles fit the seal to a depth of 3mm by using
the service tool C (892/00891), without the spacer D.

Note: Fitting the latest type seal to an earlier axle (prior to S227760
April 95) without using the service tool will cause damage to
the seal. The previous type seal must not be fitted to the
later type wheel bearing carrier, (no chamfer at X), as the
seal will fail in service.

A
25 - 26 MM Z
X

B 28 - 30 MM
Z
X

9803/7110 Issue 1
Section G Brakes Section G
i i

Contents Page No.

Technical Data 1-1

Schematic Brake Circuit 2-1

* Brake Circuit Description

- 2CX Machines to Serial Number 658960 4-1
- 2CX & 2DX Machines from
Serial Number 658961 to 763230 and 481196 to 489723 See Section E, page 10-1
- 2CX, 2DX, 212SU From to Serial Number 489724 See Section E, page 10-2

Service Brakes
- Brake System Venting 5-1
- Residual Brake System Pressure 5-1
- System Pressure Test 6-1
- Brake Seal or Component Leakage 7-1
- Bleeding Procedure 8-1
- Dismantling and Assembly 8-1

Accumulator Charge Valve (Machines to Serial Number 658960)

- Removal and Replacement 10 - 1
- Dismantling and Assembly 11 - 1

Charge/PriorityValve (Machines from Serial Number 658961 to 763230 and 48196 on)
- Pressure Testing See Section E, page 22-1
- Removal and Replacement See Section E, page 22-2
- Dismantling and Assembly See Section E, page 22-4

* Foot Brake Valve from to serial No.657000 to 763230 and 481196 to 489723
- Removal and Replacement 12 - 1
- Dismantling and Assembly 12 - 2

* Foot Brake Valve - 2CX, 2DX, 212SU From to serial No. 489724
- Removal and Replacement 12 - 3
- Dismantling and Assembly 12 - 3

Parking Brake
- Testing the Parking Brake 16 - 1
- Dismantling and Assembly 16 - 1

9803/7110 Issue 5*
 Section G Brakes Section G
1-1 1-1

Technical Data

Service Brakes

Type JCB oil-immersed multi-plate disc high pressure brakes with hydraulic
accumulators for emergency application.
Actuation Hydraulic ON, spring OFF.
Location Front and rear axle hubs.
Friction Plates 2 per brake pack, i.e., 8 per machine.
Counter Plates 3 per brake pack, i.e., 12 per machine.
Accumulator Pressure 25 bar (363 lbf/in2).
Brake Circuit Operating Pressure
Cut-in 90 bar (1305 lbf/in2).
Cut-out 110 bar (1595 lbf/in2).

* Dual Circuit Brake Modulating Valve (2CX, 2DX, 212SU from machine serial number 489724)
Output pressure 2CX, 212SU 35 bar (508 lbf/in2)
Output pressure 2DX 50 bar (725 lbf/in2)

Parking Brake

Type Oil-immersed multi-plate disc.

Actuation Spring ON, hydraulic OFF.
Location Within the gearbox.
Friction Plates
30 k.p.h. Gearbox 9 off
20 k.p.h. Gearbox 6 off
Counter Plates
30 k.p.h. Gearbox 10 off
20 k.p.h. Gearbox 7 off

9803/7110 Issue 3*
 Section G Brakes Section G
2-1 2-1

* Schematic Brakes Circuit (Machines to Serial Number 658960)

Refer to page E/2-1 for a full machine circuit schematic.

Component Key

2 Pump and Priority Valve

8 Pressure Test Connector
13 Brakes Charge Valve
14 Accumulator
15 Brake Valve
16 Brake Pressure Switch
17 Front Brakes
18 Rear Brakes

Steer Load Sensing Line

To Steering Circuit

13
15 17

16 18
14
8
14
8
A183050-1

To Main Hydraulic Circuit

9803/7110 Issue 3*
 Section G Brakes Section G
2-2 2-2

* Schematic Brakes Circuit (Machines from Serial Number 658961 to 763230 and 481196 to
489723)
Refer to page E/2-3 for a full machine circuit schematic.

Component Key

2 Main Pump
8 Pressure Test Connector
13 Brakes Charge/Priority Valve
14 Accumulator
15 Brake Valve
16 Brake Pressure Switch
17 Front Brakes
18 Rear Brakes

8
G1 S 13

16
G2

EF P T LS A1 A2
Steer Load Sensing Line
To Steering Circuit

To Main Hydraulic Circuit 15

8
17
14

14 18
8

A231660

9803/7110 Issue 2*
Section G Brakes Section G
2-3 2-3

Schematic Brakes Circuit 2CX, 2DX and 212SU Machines from Serial Number 489722)

Refer to page E/10-2 for brake description and operation.

Component Key

P Main Pump
T Hydraulic tank
8 Pressure Test Connector
13 Brakes Charge/Priority Valve
14 Accumulator
15 Brake Valve
16 Brake Pressure Switch
17 Front Brakes
18 Rear Brakes

S 13 15
2 8
3 G1
EF
T F
P 02
LS
G2 C1 01 1 17
16
4
T1
B1
A1 A2
G

14 14

P2 B2

18

9803/7110 Issue 1
9803/7110

4-1

Section G
%

S206320

$
$
S188010
TO LOADER
VALVE

Brakes
FROM
$
PUMP TO TANK

A206330

Section G
A
E
Issue 2

4-1
S206340
9803/7110

4-2

Section G
Brake Circuit Description

* Note: On machines from serial number 658961 the When the brake pedal is pressed, the spool F in If there is a difference in the volume of oil required
steering priority valve and brake charge valve form brake valve 15 is moved against spring force. This by the front and rear brake packs (e.g if one brake
one complete assembly. Refer to Section E, page allows oil from the charged accumulators to the pack is worn more than the other), then
10-1 for a description of operation. brake packs 17 and 18 in the front and rear axle compensating spool C operates. The higher
hubs respectively. Because of the drop in pressure, pressure in the pilot line combined with spring force
Oil from the hydraulic pump enters the brake charge spool D is pushed back by spring force, ensuring moves the spool to allow sufficient oil into either
valve 13 at port A, opens one-way valve B, passes the accumulators are re-charged. brake pack to make up the difference. Once the
through compensating spool C to charge the pressure equalises, the spool C returns to its central
accumulators 14. position.

When the pressure in accumulators attains set Proportional braking effort between the front and
pressure, spool D is moved fully across by pilot rear brake packs (17 and 18 respectively) is
pressure to allow oil flow to the main machine achieved by the spring between the two spools F in
hydraulic circuit via port E, note that not ALL the oil 2 the brake valve 15, with the assistance of internal
flow is available to the accumulators. pilot line G.

Brakes
Steer Load Sensing Line
To Steering Circuit

A 13 15

F
17
D

B G

16 C 18
F
14
8

Section G
E 14
8
Issue 2*

4-2
A204930
To Main Hydraulic Circuit
Section G Brakes Section G
5-1 Service Brakes 5-1

Brake System Venting * Residual Brake System Pressure

Before disconnecting any part of the brake circuit, vent the If residual pressure is greater than the pressure required to
system as described below. It will be necessary to construct overcome the brake retraction springs in the axle, brake
a venting apparatus as shown below. piston retraction will not occur resulting in excessive heat
and wear of brake components.
1 Stop the engine, engage the parking brake, then lower
the loader and backhoe to the ground. If the residual pressure in the braking system is above 0.35
bar (5 lbf/in2) in the hot condition, the system should be
2 Operate the brake pedal a minimum of 30 times. checked to identify the cause of the problem.

3 Ensure that valve C is fully closed. Note: Pressure cannot build up in the hydraulic tank until the
oil is hot, or if the pressure is vented by removing the tank
4 Connect the test point adaptor A to one of the cap/breather.
accumulator test points X. Place the other end in a
suitable container. Checking for Residual Pressure

5 Slowly open the valve C and allow the accumulator to The following checks should be done with the engine
discharge fully. Close valve C. running and the oil at working temperature.

6 Repeat steps 3 - 5 for the other test point X. 1 Apply and release the brakes. Check the brakes release
immediately.
Key
2 If the brakes do not release immediately, place a
A Test point adapter container under the axle hub to catch any spilt oil.
B 0.25 in BSP hose Unscrew the bleed nipple on the axle hub to release any
C Hand operated valve residual pressure.

Note: The same effort should be needed to rotate the hub

with the bleed nipple either open or closed. If the problem
affects one hub only, strip and inspect the affected hub.

3 If the brakes release immediately after the bleed nipple

has been opened, residual pressure should be
suspected.

4 If the brakes do not release immediately, tighten the

bleed nipple and check the following:

(a) Foot brake valve adjustment and linkage

(b) Operation of the hydraulic tank breather
(c) Clear plastic return lines from foot valve are not
restricted
(d) Hydraulic tank not over-filled

X
X

C B

A239350
A230410

9803/7110 Issue 2*
 Section G Brakes Section G
6-1 Service Brakes 6-1

Brake System Pressure Testing

1 Charge Valve Operation

i Park the machine on firm level ground and lower

the attachments to the ground.

ii Apply the parking brake and stop the engine.

iii Connect a 0-400 bar (0-6000 lbf/in2) pressure

gauge to either brake pressure test connector A or
B on the accumulator block.

iv Start the engine. Monitor the pressure - it should

be between 90 and 110 bar (1303 and 1595 lbf/in2). S204950

v Monitor engine speed while repeatedly applying the

footbrake. When engine speed falls, check that the
pressure indication is 90 bar (1305 lbf/in2).

vi Release the footbrake and continue to monitor

engine speed. When engine speed rises, check that
the pressure indication is 110 bar (1595 lbf/in2).

If pressures are incorrect, renew the charge valve as no

adjustment is possible.

2 Accumulator Pressure

! WARNING
* A minimum of 30 applications of the service brake is
possible from the stored accumulator pressure. Before
removing an accumulator or disconnecting any part of
the brake hydraulic system, make sure that engine is
switched off and hydraulic pressure is fully discharged
as described in this manual.
BRAK 2-4

i Park the machine on firm level ground and lower A B

the attachments to the ground.

ii Apply the parking brake and stop the engine. Fully

* discharge the accumulators as described on page 5 - 1.
S188010
iii Connect a 0-400 bar (0-6000 lbf/in2) pressure
gauge to brake pressure test connector A on the
accumulator block.

iv Start the engine and allow to idle for 2 minutes, the

pressure should be between 90 and 110 bar (1303
and 1595 lbf/in2).

v Stop the engine and apply the footbrake 2-3 times,

the pressure should slowly fall, if the pressure falls
rapidly to below 30 bar (435 lbf/in2) the
accumulator could be at fault (see following steps).

vi Repeat operations i to v for pressure test connector

B. If pressure decays on one accumulator but is
steady on the other, swop the accumulators and
repeat operations. If the pressure still decays on
the same accumulator, renew that accumulator.

vii If pressure decays on the other accumulator, the

charge valve is faulty and should be renewed.

9803/7110 Issue 3*
Section G Brakes Section G
7-1 Service Brakes 7-1

Brake Seal or Component Leakage

The most common reason for internal piston seal leakage is The following areas identify where leakage can commonly
a build-up of axle contamination from excessive brake wear occur.
caused by extended service periods. This allows metal
particles to build-up on the sealing surfaces causing scoring Low Pressure:
and allowing low pressure leaks.
A Swivel to annulus carrier sealing O rings and sealing
There are two types of internal leakage that can occur within surfaces.
the axle and hub:
B Brake piston seals.
(a) Low Pressure Leaks - Seal damage, or scoring to seal
component surfaces. C Annulus carrier to swivel sealing O ring surfaces.

(b) High Pressure Leaks - Mechanical leakage through a D Piston and annulus carrier sealing surfaces (porosity,
porous casing, or blanking screw threads. scores, nicks & scratches etc.).

Note: The low pressure leak test should be performed first. High Pressure:
Low pressure leaks are difficult to find using a high pressure
test - seals and other components can distort and form a E Blanking screws (x2) - missing, loose or no thread
seal under pressure. sealant used.

F Porosity through casing from internal galleries.

G Blanking screws (x2) - missing, loose or no thread

sealant used.

H Annulus carrier to piston seals sealing surfaces.

G
B

316000 H C
D 316010

9803/7110 Issue 1
Section G Brakes Section G
7-2 Service Brakes 7-2

Brake Seal or Component Leakage (cont.)

The following procedure explains how to check if a brake 5 After approximately 1/2 hour, check if the level has
seal or component is severely damaged/perished, or if the dropped below the original marked line, if it has then
seal has a small cut or nick. The test must only be done check the brake component for slight nicks, cuts, leak
when the axle is COLD. paths or generally for wear.

6 Repeat steps 2 to 5 for the opposite brake piston seal.

! WARNING
Before working on the brake system make sure the 7 Reconnect all brake pipes and bleed the brake system
machine is on level ground and chock all four wheels. as recommended on page G/8-1.
BRAKE 1-4

Test For a High Pressure Leak

! WARNING
Do not drive the machine with any part of its brake Check for severe piston seal damage:
system disconnected. When the following test has been
completed reconnect all brake pipes and bleed the brake 1 Remove and cap brake piston feed pipe J.
system using the recommended procedure.
BRAKE 2-1 2 Fill the brake piston housing with JCB Light Hydraulic
Fluid.
Test For a Low Pressure Leak
3 Install a hand pump fitted with a 0 - 40 bar (0 - 600
Check for small cuts or nicks in the piston seal: lbf/in2) pressure gauge to port M.

1 Remove and cap brake piston feed pipe J. Note: The hand pump MUST be filled with JCB Light
2
Hydraulic Fluid. DO NOT exceed 69 bar (1000 lbf/in ).
2 Install an adapter fitted with a piece of clear tube to the
brake piston port K. 4 Use the hand pump to generate a pressure in the brake
piston housing.
Note: The tube must be kept vertical during the test, use
tape to attach the tube to the side of the machine. 5 If the pressure falls off rapidly, or if no pressure reading
can be obtained, a seal is severely damaged and needs
3 Fill the tube until approximately three quarters full with replacing, or a leak path exists.
JCB Light Hydraulic Fluid.
6 Remove planet hub and identify the source of the
4 Using a suitable pen, mark the level line L of the brake leakage before proceeding any further.
fluid on the tube.

K
M

J J

159831 159832

9803/7110 Issue 1
Section G Brakes Section G
8-1 Service Brakes 8-1

Bleeding Procedure
Front Brakes

Bleed as follows:

a Attach tube to bleed screw A, ensuring that free end of

tube is immersed in hydraulic fluid contained in a
suitable jar.

b Open bleed screw A and apply one rapid stroke of the

brake pedal followed by three rapid short strokes from S204950
the pedal half way position. After the third short stroke
allow the pedal to return quickly to its stop.

c Continue bleeding normally until all air is expelled.

Close bleed screw A with the pedal fully depressed.

d Repeat the procedure for the other side.

Rear Brakes

Repeat front brakes procedure.

Dismantling and Assembly

The service brakes are located in the front and rear axles.
Instructions for dismantling and assembly are detailed under A
Front and Rear Axles - Axle Hub and Driveshaft in
Section F.

9803/7110 Issue 1
Section G Brakes Section G
10 - 1 Accumulator Charge Valve 10 - 1

Removal & Replacement

Removal Replacement

Replacement is a reversal of the removal sequence.

! WARNING
Make the machine safe before working underneath it.
! WARNING
Park the machine on level ground, lower the arms. Apply
the parking brake, put the transmission in neutral and Fine jets of hydraulic fluid at high pressure can penetrate
stop the engine. Chock both sides of all four wheels. the skin. Do not use your fingers to check for hydraulic
fluid leaks. Do not put your face close to suspected
Disconnect the battery, to prevent the engine being leaks. Hold a piece of cardboard close to suspected
started while you are beneath the machine. leaks and then inspect the cardboard for signs of
GEN-1-2 hydraulic fluid. If hydraulic fluid penetrates your skin, get
medical help immediately.
Removal INT-3-1-10/1

1 Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral. Make sure that the hoses are correctly installed. The hose
Lower the backhoe and loader end to the ground and connections are as follows:
stop the engine.
Port P (not stamped) = from the hydraulic pump
Port T (not stamped) = to the hydraulic tank
! WARNING Port EF (stamped) = to the loader valve block
A minimum of 10 applications of the service brake is Port G (stamped) = no hose - pressure switch port
possible from the stored accumulator pressure. Before Port A1 (stamped) = to the accumulator block
removing an accumulator or disconnecting any part of Port A2 (stamped) = to the accumulator block
the brake hydraulic system, make sure that engine is
switched off and hydraulic pressure is fully discharged. Torque tighten the valve retaining bolts B to 28 Nm (21 lbf
BRAK 2-2
ft).
2 Operate the foot brake pedal several times to vent
After replacement check the pressure settings (see page
residual hydraulic pressure.
G/6-1).
3 Disconnect all hydraulic hoses from the valve block and
plug all orifices to prevent ingress of dirt. Label each
hose before disconnecting, this will ensure correct re-
fitting.

4 Remove the electrical connector A.

5 Loosen and remove the three valve retaining bolts B.

S204950

A1

A
G
EF P

S206340

9803/7110 Issue 1
SXXXXXX
Section G Brakes Section G
11 - 1 Accumulator Charge Valve 11 - 1

S204960

9803/7110 Issue 1
Section G Brakes Section G
11 - 2 Accumulator Charge Valve 11 - 2

Dismantling Assembly
1 Remove nuts 1 and bolts 2. 1 Make sure all components are thoroughly clean prior to
assembly. Renew all 'O' rings and coat with JCB HP
2 Remove cover plate 3 along with 'O' rings 4 and 5. Grease on assembly.
Remove and discard the 'O' rings.
2 Fit 'O' rings 26 and 27 to check valve assembly 25
3 Remove plug 6 along with 'O' ring 7. Remove and making sure that 'O' rings fit correctly in grooves. Insert
discard the 'O' ring. filter 28 into recess of check valve. Locate assembly
into valve body making sure the filter locates in its seat
4 Carefully withdraw spool/damping orifice assembly 8 in the body without undue force. Tighten to the correct
and spring 9 from the valve body. torque.

5 Remove spring seat 10 along with 'O' ring 11. Remove 3 Fit new 'O' rings 23 and 24 to check valve assembly 22.
and discard the 'O' ring. Locate assembly and torque tighten.

6 Remove the complete relief valve assembly 12 using a 4 Locate pushrod 21 in its bore. Fit new 'O' rings 19 and
'C' spanner. Remove and discard 'O' rings 13,14, and 20, to check valve 18. Locate assembly and torque
17 and backing rings 14 and 16. tighten.

7 Remove check valve assembly 18 from valve body. 5 Fit 'O' rings 13, 15 and 17 and backing rings 14 and 16
Remove 'O' rings 19 and 20 and discard. to the relief valve assembly 12.

8 Carefully withdraw pushrod 21 from its bore. 6 Insert spool/damping orifice assembly 8 into valve
body.
9 Remove check valve assemblies 22 and 25 from valve
body. Remove all 'O' rings and discard. 7 Fit plug 6 and new 'O' ring 7 and torque tighten.

10 Remove and discard filter 28. 8 Insert spring 9 into spool bore.

Note: A new filter is supplied as part of the seal kit. 9 Locate spring seat 10 and new 'O' ring 11 over spring
and torque tighten.

Inspection 10 Fit new 'O' rings 4 and 5, to cover plate 3. Fit cover
plate to valve body using nuts 1 and bolts 2. Tighten to
1 Thoroughly wash all components. Apply hydraulic oil the correct torque.
immediately to prevent moisture collecting.
Torque Settlngs
2 Inspect all bores and 'O' ring grooves and make sure
that they are free from burrs. Item Nm kgf m Ibf ft
1 39 3.98 29
6 75-81 7.65-8.26 55-60
10 100-105 10.20-10.70 74-77
18 38-42 3.87-4.28 28-31
22 38-42 3.87-4.28 28-31
25 40-44 4.08-4.48 30-32

Note: If pressure switch A has been removed, when refitting,

torque tighten the switch to 60 Nm (44 lbf ft; 6.1 kgf m).

9803/7110 Issue 1
Section G Brakes Section G
12 - 1 Foot Brake Valve 12 - 1

* Brake Valve from machine serial number

657000 to 763230 and 481196 to 489723

Removal

1 Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral.
Lower the backhoe and loader end to the ground and
stop the engine.

! WARNING
A minimum of 10 applications of the service brake is
possible from the stored accumulator pressure. Before
removing an accumulator or disconnecting any part of
the brake hydraulic system, make sure that engine is
switched off and hydraulic pressure is fully discharged.
BRAK 2-2 S204950

2 Operate the foot brake pedal several times to vent

residual hydraulic pressure.

3 Disconnect all hydraulic hoses from the valve block and

plug all orifices to prevent ingress of dirt. Label each
hose before disconnecting, this will ensure correct re-
fitting.

4 Loosen and remove the two valve retaining bolts X.

C

Replacement D
Replacement is a reversal of the removal sequence.
Y
! WARNING F A
Fine jets of hydraulic fluid at high pressure can
penetrate the skin. Do not use your fingers to check for
hydraulic fluid leaks. Do not put your face close to
suspected leaks. Hold a piece of cardboard close to
E
suspected leaks and then inspect the cardboard for
signs of hydraulic fluid. If hydraulic fluid penetrates your B
skin, get medical help immediately.
INT-3-1-10/1

Make sure that the hoses are correctly installed. The hose X
connections are as follows:

Port A = to the rear brakes

Port B = to the front brakes
Port C = to the accumulator block
Port D = to the accumulator block S206320
Port E = plugged
Port F = to the hydraulic tank

Torque tighten the valve retaining bolts X to 16 Nm (12 lbf

ft).

After replacement check the brakes operate correctly.

9803/7110 Issue 3*
Section G Brakes Section G
12 - 2 Foot Brake Valve 12 - 2

* Brake Valve from machine serial number

657000 to 763230 and 481196 to 489723

Dismantling and Assembly

The foot brake itself is a non-serviceable item and should

not be dismantled. If it is suspect it must be renewed.

9803/7110 Issue 3*
Section G Brakes Section G
12 - 3 Foot Brake Valve 12 - 3

Brake Valve from machine serial number Dismantling and Assembly

489724 The foot brake valve is a non-serviceable item. If the unit is

faulty it must be renewed.
Removal

1 Park the machine on firm level ground, engage the

parking brake and set the transmission to neutral.
Lower the backhoe and loader end to the ground and
stop the engine.

! WARNING
A minimum of 10 applications of the service brake is
possible from the stored accumulator pressure. Before
removing an accumulator or disconnecting any part of
the brake hydraulic system, make sure that engine is
switched off and hydraulic pressure is fully discharged.
BRAK 2-2

2 Operate the foot brake pedal several times to vent S204950

residual hydraulic pressure.

3 Disconnect hydraulic hoses A, B, C, D, E from the valve

block X and plug all orifices to prevent ingress of dirt.
Label each hose before disconnecting, this will ensure
correct re-fitting.

4 Loosen and remove the two valve retaining

nuts/bolts/washers Y.

5 Carefully separate adjustable clevis Z from the valve

actuating shaft.

Replacement Y
1 Replacement is a reversal of the removal sequence.
Y
X C
A Z
! WARNING
Fine jets of hydraulic fluid at high pressure can
penetrate the skin. Do not use your fingers to check for
hydraulic fluid leaks. Do not put your face close to D
suspected leaks. Hold a piece of cardboard close to
suspected leaks and then inspect the cardboard for
signs of hydraulic fluid. If hydraulic fluid penetrates your
B
skin, get medical help immediately.
INT-3-1-10/1 E
2 Torque tighten the valve retaining bolts Y to 16 Nm (12
lbf ft).
3 Make sure that the hoses are correctly installed. The
hose connections are as follows:
Hose A (rear brakes) to valve port B1
Hose B (front brakes) to valve port B2
A335510
Hose C (hydraulic tank) to valve port T1
Hose D (accumulator block) to valve port P1
Hose E (accumulator block) to valve port P2
4 Adjust clevis Z to provide a clearance between it and
the valve actuating shaft of 0.5 mm.
5 Check the brakes operate correctly.

9803/7110 Issue 1
Section G Brakes Section G
16 - 1 Parking Brake 16 - 1

Testing the Parking Brake

! WARNING ! WARNING
Before testing the parking brake make sure the area If the machine starts to move during the following test,
around the machine is clear of people. immediately apply the foot brakes and reduce the engine
2-2-4-5 speed.
2-2-5-1
Test the brake on a level, dry surface. Make sure your seat
belt (when fitted) is securely fastened. 4 Test the brakes:

1 Raise the attachments. The attachments should already a Release the brake pedal.
be in one of the travelling positions. b If the machine has not moved, use the accelerator
pedal D to gradually increase the engine speed to
2 Make sure the parking brake is fully engaged. The 1600 RPM. The machine should not move.
parking brake is fully engaged when the button A is c Reduce the engine speed to idle and set the
pressed. forward/reverse lever to neutral.
d Set the gear lever to neutral.
3 Engage the drive:
5 If the machine moved during the test, refer to the
a Select third gear. Parking Brake Fault Finding procedures on page F/4-6.
b Push down hard on the brake pedal B and move the
forward/reverse lever C to forward (see note).
c Keep the brake pedal pushed down.

Note: An audible alarm will sound and a warning light will Dismantling and Assembly
show when the parking brake is engaged with the machine
in forward drive. The alarm will stop when neutral drive is The parking brake is integral with the Syncro Shuttle
selected. gearbox. Instructions for dismantling and assembly are
detailed under Syncro Shuttle Transmission - Gearbox in
Section F.

B D

S181851

9803/7110 Issue 1
Section K Engine Section K

Contents Page No.

Technical Data - 2CX Range of Machines
(including 210S & 210SU up to serial No. 762079) 1-1
Technical Data - 2DX Machines
(including 212S up to serial No. 762079) 1-2
Technical Data
- North American Machines only from serial No. 762080 1-3

9803/7110 Issue 3
 Section K Engine Section K
1-1 1-1

* Technical Data - 2CX Range of Machines

(including 210S & 210SU North American machines up to serial No. 762079)
Type 1004-4LR2 naturally aspirated
* Build Number AA50429 (65 BHP)
Number of cylinders 4
Bore and Stroke 100 mm (3.937 in) x 127.0 mm (5.00 in)
Swept Volume 3990 cm3 (243.5 in3)
Compression Ratio 16.5:1
Compression Pressure 20-34 bar (240-493 lbf/in2)
[maximum variation between cylinders - 3.5 bar (50 lbf/in2)]
Injection Sequence 1, 3, 4, 2
Valve Clearance - Hot or Cold
- inlet 0.20 mm (0.008 in)
- exhaust 0.45 mm (0.018 in)
Maximum Speed (no load) 2160 rev/min
Governed Speed 2000 rev/min
Idling Speed 820 rev/min

Fuel System

Injection Pump Type C.A.V., D.P.A., mechanically governed

Injection Pump Setting Code 2643C621/HM46L/850/7/2160
Injection Timing 16° ± 2° BTDC
Injection Setting Pressure 250 atm
Lift Pump Type AC Diaphragm

Induction System

Air Cleaner Type 2 stage, dry element

Max. Restriction (at which warning
light operates) 635 mm (25 in) H20

Lubrication System

Oil Pump Type Eccentric rotor

Oil Pressure (hot) at maximum speed 2.0 bar (30 lbf/in2) (minimum)

Cooling System

Coolant Pressure 0.48 bar (7 lbf/in2)

Coolant Temperature (normal) 80-85 °C (176 - 185 °F)
Temperature Warning Light operates at 98 °C (209 °F)

* Note: For further details of the engine refer to Engine Service Manual 9806/0100.

9803/7110 Issue 3*
 Section K Engine Section K
1-2 1-2

* Technical Data - 2DX Machines

(including 212S North American machines up to serial No. 762079)
Type 1000 Series, naturally aspirated
* Build Number AA50525 (75 BHP)
Number of cylinders 4
Bore and Stroke 100 mm (3.937 in) x 127.0 mm (5.00 in)
Swept Volume 4 litres (243 in3)
Compression Ratio 16.5:1
Compression Pressure 28 bar (400 lbf/in2)
[maximum variation between cylinders - 3.5 bar (50 lbf/in2)]
Injection Sequence 1, 3, 4, 2
Valve Clearance - Hot or Cold
- inlet 0.20 mm (0.008 in)
- exhaust 0.45 mm (0.018 in)
Maximum Speed (no load) 2320 - 2420 rev/min
Governed Speed 2200 rev/min
Idling Speed 750 rev/min

Fuel System

Injection Pump Type C.A.V., D.P.A., mechanically governed

Injection Pump Setting Code DM55L/1000/1/2420
Injection Timing 16.5° BTDC
Injection Setting Pressure 220 atm
Lift Pump Type AC Diaphragm

Induction System

Air Cleaner Type 2 stage, dry element

Max. Restriction (at which warning
light operates) 559mm (22 in) H20

Lubrication System

Oil Pump Type Eccentric rotor

Oil Pressure (hot) at maximum speed 2.0 bar (30 lbf/in2) (minimum)

Cooling System

Coolant Pressure 0.48 bar (7 lbf/in2)

Coolant Temperature (normal) 80-85 °C (176 - 185 °F)
Temperature Warning Light operates at 98 °C (209 °F)

* Note: For further details of the engine refer to Engine Service Manual 9806/0100.

9803/7110 Issue 2*
Section K Engine Section K
1-3 1-3

Technical Data - North American machines only from serial No. 762080
67 BHP (210S, 210SU, 210SL) 75 BHP (212S, 212SU)
Type 1004-40AJ, naturally aspirated 1004-42AR, naturally aspirated
Build Number AJ50686 AR50696
Number of cylinders 4 4
Bore 100 mm (3.937 in) 103 mm (4.055 in)
Stroke 127.0 mm (5.00 in) 127.0 mm (5.00 in)
Swept Volume 3.99 litres (243 in3) 4.23 litres (258 in3)
Compression Ratio 17.25:1 18.5:1
Compression Pressure 20 - 34 bar (300 - 500 lbf/in2) 20 - 34 bar (300 - 500 lbf/in2)
Maximum variation between cylinders 3.5 bar (50 lbf/in2) 3.5 bar (50 lbf/in2)
Injection Sequence 1, 3, 4, 2 1, 3, 4, 2
Valve Clearance - Hot or Cold
- inlet 0.20 mm (0.008 in) 0.20 mm (0.008 in)
- exhaust 0.45 mm (0.018 in) 0.45 mm (0.018 in)
Maximum Speed (no load) 2350 rev/min 2350 rev/min
Governed Speed 2200 rev/min 2200 rev/min
Idling Speed 800 rev/min 800 rev/min

Fuel System

Injection Pump Type DP202 DP202

Injection Pump Setting Code 2644F103/JG/1/2350 2644G002/RG/2350
Injection Timing 3° BTDC Dynamic 3° BTDC Dynamic
Injection Setting Pressure 294 bar (4263 lbf/in2) 294 bar (4263 lbf/in2)
Lift Pump Type AC Diaphragm AC Diaphragm

Induction System

Air Cleaner Type 2 stage, dry element 2 stage, dry element

Max. Restriction (at which warning
light operates) 559mm (22 in) H20 559mm (22 in) H20

Lubrication System

Oil Pump Type Differential rotor, gear driven Differential rotor, gear driven
Oil Pressure (hot) at maximum speed 280 Kpa (40 lbf/in2) 207 Kpa (30 lbf/in2)

Cooling System

Coolant Pressure 0.48 bar (7 lbf/in2) 0.48 bar (7 lbf/in2)

Coolant Temperature (normal) 85 - 90°C (185 - 194°F) 85 - 90°C (185 - 194°F)
Temperature Warning Light operates at 98°C (209°F) 98°C (209°F)

Note: For further details of the engine refer to Engine Service Manual 9806/2140.

9803/7110 Issue 1