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JCB Workshop Service Repair Manuals View and Download Instantly
JCB Service Repair Manuals
Welcome to JCB Service Repair Manuals below your find a extensive collection of JCB
Service Repair Manuals in PDF Format all available for Instant immediate download
to search for availability simply click on your specific JCB model(s) below.
JCB Service Repair Manuals

JCB Backhoe Service Repair Manuals
JCB Service 1CX, 208S Backhoe Loader Service Manual Shop Service Repair Book

JCB Service 2CX, 2DX, 210, 212 Backhoe Loader Service Manual Shop Repair Book

JCB Service 2CX, 210, 212 Backhoe Loader Service Manual Shop Repair Book
JCB Service 3CX, 4CX Backhoe Loader Workshop Manual Shop Service Repair
Workshop Book #1
JCB Service 3CX, 4CX, 214, 214E, 215, 217 Backhoe Loader Workshop Manual
Shop Service 3-CX, 4-CX Repair Book #2

JCB Service 3CX, 4CX, 214, 214E, 215, 217 Backhoe Loader Manual Shop Service
Repair Book #3

JCB Service 3CX, 4CX, 214, 214E, 215, 217 Backhoe Loader Manual Shop Service
Repair Book #4

JCB Service 3CX, 4CX Backhoe Loader Workshop Manual Shop Service Repair
Book #5

JCB Service 3DX Backhoe Loader Manual Shop Service Repair Book

JCB Service Midi CX Backhoe Loader Workshop Manual Shop Service Repair Book
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JCB Workshop Service Repair Manuals View and Download Instantly
JCB Excavators Service Repair Manuals
JCB Service 8052, 8060 Midi Excavator Workshop Manual Shop Service Repair
Book
JCB Service 8055, 8065 Midi Excavator Workshop Manual Shop Service Repair
Book
JCB Service 8085 Midi Excavator Manual Shop Service Repair Book
JCB Service 8027z, 8032z Mini Excavator Manual Shop Service 8027-z, 8032-z
Repair Book
JCB Service 802.7, 803, 804 Super & Plus Mini Excavator Manual Shop Service
Repair Book

JCB Service 801.4, 801.5, 801.6 Mini Tracked Excavator Manual Shop Service
Repair Book

JCB Service 8014, 8016, 8018 Mini Excavator Workshop Manual Shop Service
Repair Book

JCB Service 8025z, 8030z, 8035z Mini Excavator Manual Shop 8025-z, 8030-z,
8035-z Service Repair Book
JCB Service 8040z, 8045z Mini Excavator Workshop Manual Shop Service 8040-z,
8045-z Repair Book

JCB Service 8020 Mini Excavator Manual Shop Service Repair Book
JCB Micro, Micro Plus, Micro 8008 Excavator Manual Shop Service Repair Book

JCB Service 8080 Midi Excavator Manual Shop Service Repair Book

JCB Service 801.4, 801.5, 801.6 Mini Excavator Manual

JCB Service 8040Z, 8045Z Mini Excavator Manual Shop Service Repair Book

JCB Service 8013, 8015, 8017, 8018, 801 Gravemaster Mini Excavator Manual Shop
Service Repair Book

JCB Service 802, 802.4, 802 Super Mini Excavator Workshop Manual Shop Service
Repair Book

JCB JZ70 Service Manual JZ-70 Tracked Excavator WorkShop Service Repair Book

JCB JZ140 Tier 2 Service Manual JZ-140 Tier II Tracked Excavator WorkShop
Service Repair Book

JCB JZ140 Tier 3 Service Manual JZ-140 Tier III Tracked Excavator WorkShop
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JCB Workshop Service Repair Manuals View and Download Instantly
Service Repair Book

JCB JZ235, JZ255 Service Manual JZ-235, JZ-255 Tracked Excavator WorkShop
Service Repair Book
JCB JS130W, JS150W Service Manual Wheeled Excavator WorkShop Service Repair
Book

JCB JS130W, JS145W, JS160W, JS175W Service Manual Wheeled Excavator
WorkShop Service Repair Book
JCB JS130W, JS145W, JS160W, JS175W Auto Tier III Service Manual Wheeled
Excavator WorkShop Service Repair Book
JCB JS175W Auto Service Manual Wheeled Excavator WorkShop
JCB JS-200W Service Manual Wheeled Excavator WorkShop Service Repair Book
JCB Skid Steers Service Repair Manuals
JCB Service Robot 150, 165, 165HF Manual Skid Steer WorkShop Service Repair
Book
JCB Service Robot 160, 170, 170HF, 180T, 180T-HF Manual Skid Steer Workshop
Service Repair Book
JCB Service Robot 160, 170, 170HF, 180, 180HF, 180T, 180T-HF Manual Skid Steer
Shop Service Repair Book
JCB Service Robot 185, 185HF, 1105, 1105HF Manual Skid Steer Shop Service
Repair Book
JCB Service Robot 190, 190HF, 1110, 1110HF, 190T, 190T-HF, 1110T, 1110T-HF
Manual Skid Steer Workshop Service Repair Book
JCB Service Robot 190, 1110 Manual Skid Steer Shop Service Repair Book
JCB Wheel Loaders Service Repair Manuals
JCB Service Wheel Loading Shovel 406, 409 Manual Workshop Service Repair Book
JCB Service Wheel Loading Shovel 407B, 408B, 409B, 410B, 411B Manual Shop
Service Repair Book
JCB Service Wheel Loading Shovel 406, 407, 408, 409 Manual Workshop Service
Repair Book
JCB 403 Service Wheel Loading Shovel Manual 403 Workshop Service Repair Book
JCB Tracked Dumpster Service Repair Manuals
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JCB Workshop Service Repair Manuals View and Download Instantly
JCB Service Tracked Dumpster TD7, TD10, TD10SL, TD10HL Manual Shop Service
Repair Book
JCB Service Tracked Dumpster HDT5 Manual Shop Service Repair Book
JCB Utility Vehicles Service Repair Manuals
JCB Service Groundhog 6x4 Utility Vehicle Manual Shop Service Repair Book
JCB Service Groundhog 4x4 Utility Vehicle Manual Shop Service Repair Book
JCB ADT Dump Trucks Service Repair Manuals
JCB Service 714, 718 Articulated Dump Trucks Manual ADT Workshop Service
Repair Book

JCB Service 722 Articulated Dump Trucks Manual ADT Workshop Service Repair
Book
JCB Engine & Transmission Service Repair Manuals
JCB Service 444 Diesel Engine Manual Workshop Service Repair Manual

JCB Service DieselMax Tier 3 SE Diesel Engine Manual Workshop Service Repair
Manual
Duetz JCB Service 2011 Series Manual Duetz Diesel Engine Workshop Service
Repair Manual

JCB Transmission Service Manual JCB Complete Workshop Service Repair Manual
JCB Forklift Service Repair Manuals
JCB Service TELETRUK Forklift 2.0-D/G, 2.5-D/G, 3.0-D/G, 4X4 3.0D, 4X4 3.5D
Manual Workshop Service Repair Book



Excerpts from an JCB Service Manual

Section E Hydraulics Section E
'Husco' Loader Valve -Pressure Testing Unloader Valve

Make sure that the hydraulic oil is at working temperature,
i.e. 50°C (122°F).

Lower the backhoe bucket and loader shovel to rest on the ground; stop the engine; operate the control
levers to vent residual hydraulic pressure.

Make sure that the 'hydraulic speed control' facility is NOT switched on, otherwise the correct unloader
valve pressure cannot be obtained.
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If the machine has a front-mounted road breaker, ensure that the road breaker control valve lever is in
the 'off' position (lever down), otherwise the roadbreaker relief valve will operate and prevent unloader
valve pressure from being reached.

Connect a 0 -400 bar (0 -6000 Ibf/in2) pressure gauge to pressure test connector D on the loader valve,
(see Service Tools, Section 1).

2 With the engine running at 1500 revs/min, slowly operate arms raise or lower.
Note 1: The arms raise or lower service is specified because it has no auxiliary relief valve (A.R.V.).
Selecting this service ensures that the pressure vents through the un loader and not an A.R.V.

3 When the service reaches full travel, the gauge reading should rise slowly to unloading pressure then
fall back to zero. The maximum reading should be as specified in Technical Data.

4 If the pressure is incorrect, slacken locknut E and adjust cap F. Turn it clockwise to increase pressure
and anti-clockwise to decrease the pressure. When the pressure is correct, tighten the locknut.
If the correct pressure cannot be achieved, add or subtract shims as required, see page E/41-30 and
E/41-31 for shim description and location.

Note 2: The illustration shows the unloader pressure test connector D fitted to the loader valve block. On
some machines, there is a plug fitted at point D. The pressure test point in this instance is located next to
the steering priority valve, it is the same test point that is used to check the steering circuit pressures.

Hydraulic Speed Control (HSC)
The following procedure can be used to establish if the hydraulic speed control facility is working
correctly.

Connect a 0 -400 bar (0 -6000 Ibf/in2) pressure gauge to pressure test connector D (see note 2
opposite).

2 With the engine running at maximum speed, slowly operate arms raise, raise the pressure
toapproximately 137 bar (2000 Ibf/in2).

3 Make sure that the HSC rocker switch (mounted on the console) is in the OFF position.

4 Press the HSC control button (mounted on the loader control knob). The pressure gauge reading should
drop to zero (or near zero).

5 Repeat the above procedure but this time press the HSC rocker switch on (instead of the button on the
loader control knob). The pressure gauge reading should drop to zero (or near zero).

6 If there is no pressure drop at steps 4 and 5, then check the HSC hydraulic and electrical circuits for any
faults.

Section E Hydraulics Section E
42 -12
'Husco' Loader Valve -Pressure Testing
Shovel Ram Head Side A.R.V. (In Position)

Testing of A.R.V's on the machine should be avoided (use hand pump method as described on page E145-
1). However, the procedure described below is a secondary checking method which can be used if no
hand pump is available.
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Procedure

Make sure that the hydraulic oil is at working temperature,
i.e. 50°C (122°F).

Connect a 0 -400 bar (0 -6000 Ibf/in2) pressure gauge to test connector A on the loader valve. (See
Service Tools, Section 1.)
Run the engine at 1000 revs/min, hold the shovel ram fully open and check the maximum gauge reading,
which should equal the operating pressure shown in Technical Data. If necessary, adjust as detailed below
A.R.V. Adjustment

If the pressure is incorrect, the A.R.V. must be adjusted using the procedure described on pages E/45-1
to E/45-4.

Section E Hydraulics Section E
43 -3 Valves
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
Each of the identical load hold check valves 4R to 4W can be removed as shown at 4W. Make-up check
valve 4X is a smaller size but otherwise identical.
Ensure good condition of seating faces on poppets 4 and 8 and on the mating faces in the valve block.

Spools
Spools 4A, 4B, 4E and 4F are identical but must not be interchanged as they are matched to their bores.
Stabilizer spools 4C and 40 are identical to each other but different from the excavator spools.

All spools have the same centring and sealing components items 9 to 21.
To completely dismantle a spool, follow the sequence 9 to
21. To prevent spool rotation when turning screw 15, hold a rod through the eye end of the spool.
If only renewing the seals, dismantle as far as cap 14 then remove items 15 to 22 as an assembly.
Lubricate new seals with JCB Hydraulic Fluid and take care to prevent them from being damaged by the
sharp edges of the spool.
Apply JCB Lock and Seal to threads of screw 15.
Relief Valves

A.R.V's 4H to 4P appear identical but have various pressure settings (see page E/1 -1). Ensure that they
are correctly adjusted and fitted in their specified positions.
For dismantling and assembly procedure see page El43 -4.
Note: All hydraulic adapters that are installed together with a bonded sealing washer must also have
sealant (Loctite 577) applied to the threads of the adapter.
Torque Settings

Section E Hydraulics Section E
43 -4 Valves 43 -4
Excavator Valve -Relief Valves
Dismantling and Assembly

Eight A.R. v's are fitted at positions 4H to 4Q. These are identical in design but have various pressure
settings (see Technical Data).
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Note: Valve 4Q is only fitted to machines equipped with a Powerbreaker.
The numerical sequence shown on the illustration is intended as a guide to dismantling.
For assembly the sequence should be reversed.
When Dismantling

Dismantle sub-assembly 14 from item 1 using a special tool(see Service Tools, Section 1). The special
spanner locates in cross holes B.
Dismantle sub-assembly 14 into its component parts.
Make sure that small drilling A is not blocked.
Discard old and worn O-rings and back-up rings.
When Assembling
Renew all O-rings and back-up rings.

Lubricate O-rings and back-up rings with JCB Hydraulic Fluid.

Fit back-up ring 13 on the upper side of '0' ring 12 as shown in the inset.
Fit flat face of sleeve 9 against shoulder of poppet 10.
Torque tighten item 14 using the special tool (see Service Tools, Section 1), until its shoulder seats firmly
against item

Pressure test the valve using the procedure described on page E/45-1.
Torque Settings

Section E Hydraulics Section E
Hydraclamp Valve -from Serial Number 430001 (Sideshift 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. The following points MUST be avoided when dismantling and assembling the
valve:

• CONTAMINATION
• DAMAGE TO POPPET AND SEAT
• DAMAGE TO SEAL GROOVES

All or any of the above points may result in possible problems with the valve.

When removing '0' rings and seals, use an appropriately rounded tool that WILL NOT cause any damage
to the seal grooves. Discard ALL '0' rings DO NOT use worn or damaged items.
Note that the hydraclamp comprises two separate valve assemblies; 1) the check valve assembly (items 1
to 8); 2) the solenoid assembly (items 11 to 14).
When Dismantling
Loosen nut 1 (turn anti-clockwise) and then remove the check valve assembly from the valve block. If
required, the check valve assembly can be dismantled into its component parts (items 1 to 8).
Inspect the valve components for scratches, nicks or any other type of damage, particularly on the poppet
and seat faces. Replace with new if required.
When Assembling Renew all '0' rings. The parts microfiche will identify the correct seal kit part numbers
for items 2,4,6,10 and 14.
Lubricate parts with JCB Hydraulic Fluid before assembling. Make sure that all the parts move freely.
Ensure that the small drilling through the centre of item 3, is clear.
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Do not over-tighten the solenoid assembly, it may affect the operation of the solenoid, use the spanner
flats and torque tighten to figure indicated in the table below (items 11 and 13). For information, the
hydraclamp solenoid valve is the same type as the 'Hydraulic Speed Control' solenoid valve, shown on
page E/41-30.
Check the operation of the electric hydraclamp, see page E/11-4 for a description of operation.
Torque Settings
Install the A.R.V. sub-assembly into setting body 2.
Make sure that the adjusting pin 3 correctly locates in adjusting screw 9.
Make sure that the lock nut 10 correctly locates in the setting body socket -the anti-cavitation cone
should still be closed, as shown at B.

Install the AR.V. sub-assembly and setting body into
test block 1. Make sure that the assembly is installed in
the port marked 'RV' (relief valve).
Connect a hydraulic hand pump to port 'P' (pump) of the test block

1. Make sure that the hand pump is filled with JCB Hydraulic fluid.
Connect a 0 to 400 bar (O to 6000 Ibf/in2) pressure test gauge to port 'G' (gauge) of the test block 1.
Port 'T' (tank) can be left open when using a hydraulic hand pump.
Raise the pressure at the valve inlet using the hydraulic hand pump, when the AR.V. 'cracks' and oil
escapes from the port marked 'T' the pressure gauge will indicate the AR.V. setting.
If the AR.V. setting is correct, move to step 12.
If the AR.V. setting is not correct, move to step 8.
Use the hand pump to raise approximately 172 bar (2500 Ibf/in2) pressure at the valve inlet. Note:
Raising the pressure at the valve inlet locks the anticavitation cone C onto its seat, this allows the A.R.V.
adjusting screw lock nut 10 to be loosened (step 10). If the pressure is maintained move to step 10. If
the pressure falls off rapidly, or if no pressure can be obtained it is possible that the anti-cavitation cone
is not seating effectively, in this instance move to step 9.
If no pressure can be raised (see step 8) at the valve inlet, remove the A.R.V. assembly and install anti-
cavitation lock-out bung 6 in the port marked 'RV', make sure that the bung O-ring face seal D is facing
out. Re-fit the AR.V. assembly.
Note: The anti-cavitation lock-out bung seals and locks the AR.V. anti-cavitation function. The bung is
only suitable for the test block application and must NEVER be fitted to the excavator valve block.
The bung can be extracted using a 3/8 -16 UNC threaded bolt.
Release the AR.V. adjusting screw lock nut (see note):
Engage the nut at the end of setting body 2 using the slot in special spanner 4, turn the nut anti-
clockwise to release the AR.V. adjusting screw lock nut.
Note: Remember, it will not be possible to release the lock nut if there is not approximately 172 bar
(2500 Ibf/in2) pressure at the valve inlet.
Insert T -bar adjuster key 5 into adjusting pin 3. Push the adjusting pin down and make sure it has
engaged with the AR.V. adjusting screw. Rotate the T -bar clockwise to increase the pressure setting and
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anti-clockwise to decrease the pressure setting. After adjustment, use the slot in spanner 4 to lock the
AR.V. adjusting screw lock nut (see note).

Note: Remember, pressure must be maintained at the valve inlet to ensure the lock nut is tightened.




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