General Information 1
Care & Safety 2
Routine Maintenance 3
A
R
Attachments
Body & Framework B
Service
Manual Electrics C
Controls D
1CX, 208S
Backhoe Hydraulics E
Loader
Transmission F
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; ©
WATERLOO PARK, UTTOXETER,
STAFFORDSHIRE, ST14 5PA, ENGLAND
Brakes G
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9803/8550 issue 12 Engine K
,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.
9803/8550 Issue 1
,Colour Coding
The following colour coding, used on illustrations to
denote various conditions of oil pressure and flow, is
standardised throughout JCB Service Publications.
Blue: Neutral Circuit Pressure. Light Oil subjected to a partial vacuum due
Green: to a drop in pressure (cavitation).
Red: Pressure generated by the operation Yellow: Oil trapped within a chamber or line,
of a service. Depending on preventing movement of components
application this may be anything (lock-up).
between Neutral Circuit Pressure and
M.R.V. Operating Pressure.
Pink: Pressure that is above Neutral Circuit Orange: Oil pressure used in a controlling
Pressure but lower than that denoted device (servo).
by Red.
Green: Exhaust
, Section 1 General Information Section 1
i i
Contents Page No.
Identifying Your Machine 1-1
* Torque Settings
- Unsealed Hoses and Adapters 2-1
- ‘O’ Ring Face Seal System 2-3
- ‘Torque Stop’ Hose System 2-4
Service Tools
- Numerical List 3-1
- Electrics 4-1
- Hydraulics 4-2
Sealing and Retaining Compounds 5-1
9803/8550 Issue 2*
Care & Safety 2
Routine Maintenance 3
A
R
Attachments
Body & Framework B
Service
Manual Electrics C
Controls D
1CX, 208S
Backhoe Hydraulics E
Loader
Transmission F
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; ©
WATERLOO PARK, UTTOXETER,
STAFFORDSHIRE, ST14 5PA, ENGLAND
Brakes G
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9803/8550 issue 12 Engine K
,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.
9803/8550 Issue 1
,Colour Coding
The following colour coding, used on illustrations to
denote various conditions of oil pressure and flow, is
standardised throughout JCB Service Publications.
Blue: Neutral Circuit Pressure. Light Oil subjected to a partial vacuum due
Green: to a drop in pressure (cavitation).
Red: Pressure generated by the operation Yellow: Oil trapped within a chamber or line,
of a service. Depending on preventing movement of components
application this may be anything (lock-up).
between Neutral Circuit Pressure and
M.R.V. Operating Pressure.
Pink: Pressure that is above Neutral Circuit Orange: Oil pressure used in a controlling
Pressure but lower than that denoted device (servo).
by Red.
Green: Exhaust
, Section 1 General Information Section 1
i i
Contents Page No.
Identifying Your Machine 1-1
* Torque Settings
- Unsealed Hoses and Adapters 2-1
- ‘O’ Ring Face Seal System 2-3
- ‘Torque Stop’ Hose System 2-4
Service Tools
- Numerical List 3-1
- Electrics 4-1
- Hydraulics 4-2
Sealing and Retaining Compounds 5-1
9803/8550 Issue 2*
