ROBOT

160, 170, 170HF

Problem Solving
Click the problem on the contents list to
take you to the answer
 Open front Return
screen
Problem Solving
Contents

The following pages are extracted from the Robot 160, 170 Service Manual 9803/8520.
For more information, refer to the Service Manual.
Click on the appropriate title to go to the page. Start with Transmission or Loader Problems and Causes.

Transmission Problems Loader Problems

Transmission Problems and Causes Loader Problems and Causes
Checking for Faulty Pump or Motor CPPV Flow/Pressure Check
Checking Wheel Speed Bleeding the Hydraulic System
Machine Veers to One Side When Travelling Levelling Circuit Problem Solving
Transmission Pump Neutral Adjustment Main Relief Valve Pressure Test
Checking Motor Leakage Rate Loader Valve Dismantling and Assembly - Servo
Pump Main Pressure Test Points Loader Valve Dismantling and Assembly - Manual
Pressure Testing Main Relief Valves Suction Strainer Removal and Replacement
Checking Joystick Hydraulic Lines Changing Hydraulic Filter
Servo Joystick Dismantling and Assembly
Tyres and Wheels
Charge Pressure Checking and Adjustment - Servo
Charge Pressure Checking and Adjustment - Manual
Return to Idle Controls - Manual
Pump/Engine Coupling
Drive Motor Dismantling and Assembly
Adjusting Drive Chain Tension
Wheel Hub Assembly (Right Hand)
Drive Shaft Assembly (Left Hand)

9803/8520 Issue 1
Section E Hydraulics Section E
10 - 1 Problem Solving 10 - 1
CONTENTS

Hydrostatic Transmission
The purpose of this section is to help you trace transmission problems to a faulty unit (pump, motor, joystick etc). Once you have
traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the manual.

* Before you begin problem solving, read the Safety Information at the beginning of this manual.

* Make simple checks before say, stripping a major component.

* Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F).

* Whatever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.

* Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the
circuit.

PROBLEM CAUSE (servo machines) CAUSE (manual machines)

No drive in any direction 1, 2, 4, 10, 17 1, 2, 4, 17

No drive in either forward or reverse 1, 2, 6, 9, 11, 12 1, 2, 6, 9, 12
No spin turn either left or right 3, 4, 11, 12, 15 3, 4, 11, 15
No drive on one side 2, 5, 6, 9, 11, 12, 15, 16 2, 5, 6, 8, 9, 12, 15, 16
Machine will not travel in a straight line 3, 7, 9, 11, 12, 13, 14, 15 2, 8, 9, 12, 14, 15
Poor drive performance, no tractive effort 4, 5, 6 4, 5, 6
Machine creeps in neutral 7 8
Machine will not move at idle but
moves at max. revs. 4 4
Hydraulic fluid is overheating 1, 18, 19, 20 1, 18, 19, 20
Noise in transmission 16 16

KEY TO CAUSE REMEDY PAGE REF.

1 No oil in hydrostatic system or oil level too low Top-up as necessary.

2 Brake not released Check mechanism.

3 Tyres worn or pressure incorrect Check tyre pressures and condition. 3/9-2

4 Charge pressure low a Standard machines - Adjust charge pressure at Manual E26-4
transmission pump. Servo E29-4
b High-flow machines - Charge pressure is
controlled by the Priority Valve. Carry out flow check. E11-4
Check that transmission pump charge valve is disabled.

5 No or low pump output Check pump - carry out wheel speed check. E10-3 &
If one pump suspect, swop motor feed hoses and notice E10-4
if problem changes sides - if ‘yes’, pump related fault;
if ‘no’, motor related fault.

6 High pressure ‘loop’ relief valve/tow valve Check that valves have been re-tightened after towing.
open/set incorrectly Replace relief valve and re-check. E10-8

7 Pump neutral position set incorrectly Adjust servo neutral position. E10-6

8 Manual controls incorrectly set Adjust manual controls E25-2

..... continued

9803/8520 Issue 2
Section E Hydraulics Section E
10 - 1A Problem Solving 10 - 1A
CONTENTS

Hydrostatic Transmission (cont’d)

KEY TO CAUSE REMEDY PAGE REF.

9 Feed hose failure Check motor feed hoses.

10 No hydraulic feed to joystick Check for feed to joystick. E10-9

11 No hydraulic feed from joystick to pump Check for feed from joystick to pump. E10-9

12 Motor seal leakage Check motor case drain for confirmation of seal leakage E10-7
(compare one motor with the other). Check for shaft seal
leakage by checking chain case oil level.

13 Joystick inoperative Check joystick (plunger movement, leaking seals, etc.)

14 Chain tension Check chain tension. F5-2

15 Motor failure Inspect motor for damage. Repair as required. E36-1

16 Chain/sprocket damage Inspect chain and sprocket. Repair as required. F4-1

17 Pump/engine drive coupling failure Check coupling. E24-1

18 Oil temperature switch faulty Replace switch.

19 Restriction in oil cooler Carry out flow check. Check for damage to hoses and pipework.
Replace oil cooler.

20 Shuttle valve in motor defective Inspect motor and repair as required. E36-1

9803/8520 Issue 1
Section E Hydraulics Section E
10 - 2 Problem Solving 10 - 2
CONTENTS

X1 326680

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M2 M1 2a

Pb Pd 2b
Pa
2c
2d
P2 P1
M2a M1a
Pc Pe
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321360

X2

332940

9803/8520 Issue 1
Section E Hydraulics
10 - 3 Problem Solving
Checking for Faulty Pump or Motor
If the transmission operates or is faulty on one side only then
swop the motor feed hoses to check if the fault is with the
pump or motor. If, after the hose swop, the suspect motor
then operates the fault lies in the relevant pump unit. If the
motor still does not operate then the motor itself is faulty.
Proceed as follows:
1 Stop the engine.
2 Remove the seat and floorplate to expose the pump.
3 To ensure correct replacement after the test is complete,
mark the motor feed hoses A and B for the left hand
(upper) motor, C and D for the right hand (lower) motor.
4 Swop the motor feed hoses from one side to the other as
indicated in the illustration, i.e. swop hoses A and C then
swop hoses B and D.
Note: It may be found more convenient to use separate
additional hoses to extend the existing feed hoses.


9803/8520
Section E
10 - 3
CONTENTS
5 Restart the engine and re-check the operation of left and
right motors. Note that when the left motor is selected
the right motor should now drive and the left motor
should drive when the right motor is selected. If the
previously faulty motor now functions then the fault lies in
the relevant pump unit. If the motor still does not operate
then the motor itself is faulty.
 WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can
penetrate the skin. Do not use your fingers to check for
hydraulic fluid leaks. Do not put your face close to
suspected leaks. Hold a piece of cardboard close to
suspected leaks and then inspect the cardboard for
signs of hydraulic fluid. If hydraulic fluid penetrates your
skin, get medical help immediately.
INT-3-1-10/1
332950
Issue 1
Section E Hydraulics
10 - 4 Problem Solving
Checking Wheel Speed
The pump output and general efficiency of the drive system
may be checked by raising the machine off the ground and
checking the wheel speeds.
 WARNING
The following procedure requires the machine to be
disabled (wheels raised off the ground, attachment
disconnected etc.) while the work is carried out.
HYD 8-1/2
Place the machine safely onto blocks, so that all four wheels
are clear of the ground. Ensure that the machine is stable.
Stick a piece of reflective tape on a wheel rim. Start the
engine and run at maximum speed then operate the drive
control. Using a stroboscopic meter, measure the speed of
wheel rotation in each direction which should be 81 rev/min.
An allowance of 2% above this figure is permissible. Check
the speed of the wheels on the opposite side of the machine.
Note that excessive wheel speed may result in cooling
problems due to overheating of the hydraulic oil.

9803/8520
Section E
10 - 4
CONTENTS
* Maximum Displacement Adjustment - Servo Machines
If necessary the appropriate adjusting screws should be
screwed in 1/4 turn at a time until the correct wheel speed is
achieved. Stop the engine while adjustment is carried out.
1 Remove the seat and floorplate to expose the pump.
2 If the left hand wheels are rotating too fast, screw in
adjusters A (forward) or B (reverse) to achieve the
correct speed. If the right hand wheels are rotating too
fast, screw in adjusters C (forward) or D (reverse).
If all four wheels rotate slowly and cannot be corrected by
adjustment, the most likely cause would be internal wear of
the hydrostatic pump.
If the wheel speed is slow on one side only, the cause could
be a faulty servo or a faulty motor. Carry out procedure on
page E10-3 to determine which is faulty.
Following this procedure, further small adjustments may be
required to achieve correct straight line travel (see following
page).
* Maximum Displacement Adjustment - Manual Machines
If the correct wheel speed cannot be achieved, check that the
control linkage is correctly adjusted and giving maximum
pump swash.
If maximum pump swash is achieved and the wheel speed is
not correct, the pump or motor could be faulty. Carry out
procedure on page E10-3 to determine which is faulty.

332870
Issue 2*
Section E Hydraulics Section E
10 - 5 Problem Solving 10 - 5
CONTENTS

Machine veers to one side when travelling.

This condition may be corrected by adjusting the pump servo units or manual controls but before attempting this, carry out the
following preliminary checks.

Check tyre pressures The pressure of one tyre may be low or one or both tyres on one side of the machine may be
and condition new and the other tyres worn. In both these cases the rolling circumference of the tyres will be
unequal causing the machine to veer to one side.

Check chain tension Chains which are tensioned unequally will cause the machine to veer to one side. Always adjust
the tension on all four chains, never just one.

Check the servo joystick Check that the joystick spools are not sticking and are correctly operated by the lever.

Check the manual controls Check that the manual control linkage is not sticking. Lubricate if necessary.

Adjustment - Servo Machines

If the machine does not travel in a straight line, proceed as

follows:

Refer to illustration on previous page.

Fault

1 Machine veers excessively to left in forward travel Loosen locknut on adjuster screw C, screw in adjuster screw
1/4 turn and tighten locknut. Try machine. Keep adjusting 1/4
turn at a time until straight line travel is achieved.

2 Machine veers excessively to right in forward travel Proceed as for fault 1 but adjust screw A.

3 Machine veers excessively to left in reverse travel Proceed as for fault 2 but adjust screw D.

4 Machine veers excessively to right in reverse travel Proceed as for fault 3 but adjust screw B.

Adjustment - Manual Machines

Refer to Return to Idle Controls - Manual Pump.

Note: If the fault cannot be rectified by any of the above checks or adjustment, then either the pump or motor could be faulty. To
identify which, swop the motor feed hoses at the pump as described on page 10-3. If the machine now veers in the opposite
direction then the pump is faulty. If the machine continues to veer in the same direction the motor is faulty.

9803/8520 Issue 1
Section E Hydraulics
10 - 6 Problem Solving
Transmission Pump Neutral Adjustment
This procedure may be carried out if the machine creeps
when the drive control is in the neutral position.
Adjustment - Servo Machines
This fault may be due to an incorrect neutral setting of the
servo piston.
1 Identify which pump section requires adjustment.
If the machine veers to the left this could be caused by
either the right hand wheels moving forward or the left
hand wheels moving in reverse. Remember that pump
P1 drives the left hand motor and pump P2 drives the
right hand motor.
If the machine moves either straight ahead or behind
then both pump servos must be adjusted equally.
2 Stop the engine.
3 Remove the seat, seat base and pump cover.


P2

9803/8520
Section E
10 - 6
CONTENTS
4 If pump P1 requires adjusting, loosen locknut A and turn
the ‘neutral’ adjusting screw B 1/10 of a turn in the
required direction then re-tighten the locknut.
If pump P2 is to be adjusted, loosen locknut C and turn
adjusting screw D.
If the wheels are creeping forward, turn the adjusting
screws in an anti-clockwise direction (out). If the wheels
are creeping in reverse, turn the screws clockwise (in).
Note: This adjustment is very sensitive. Turn the adjusting
screw 1/10 of a turn at a time and re-check. A slight
movement when the wheels are raised is acceptable
provided that no movement occurs when the machine is
resting on the ground.
5 Start the engine and check that the wheels are
stationary.
6 Finally tighten locknuts A and C taking care to retain the
set position of adjusting screws.
7 Re-check for wheel movement.
Adjustment - Manual Machines
Refer to Return to Idle Controls - Manual Pump.
P1

332960
Issue 1
 Section E Hydraulics Section E
10 - 7 Problem Solving 10 - 7
CONTENTS

* Checking Motor Leakage Rate

If the motor speed is low and the pump output is normal, the
cause could be excessive internal wear in the motor which
would result in high leakage of oil into the motor casing. By 
measuring the amount of oil leaking from the motor casing
back to tank, it is possible to determine if the motor is worn.

1 Stop the engine.

2 Remove the seat and floorplate to expose the motors.


D
B
3 Connect a flowmeter into the motor drain hose A
(manual pump) or B (servo pump) at the tee connection C A
on top of the pump.

Note: On High-flow machines the motor drain hoses are

connected into the High-flow oil cooler feed hose at the back
of the machine.

4 Install a 0 - 400 bar (0 - 6000 lb/in2, 0 - 422 kg/cm2)

pressure gauge into the appropriate point on the pump to
measure the pressure generated in the motor feed line
324241
(see next page for pressure test points).

5 Start the engine and drive the machine forward against a


solid, immovable object as shown at C. Measure the
amount of oil expelled from the motor during one
minute’s operation.

At the maximum pressure of 385 bar (5582 lbf/in2) the normal

oil leakage should be approx. 17 l/min (3.75 UK gal/min, 4.5

US gal/min).

Note: The motor leakage at zero pressure is much less than

the rate at higher pressures. This is because at higher
pressures the motor flushing spool is actuated causing the oil
flow through the motor casing to increase. The figure quoted
above is the combined leakage and flushing flows.

If the flow rate is higher than normal, the motor should be

dismantled for repair.

324880A

332931

9803/8520 Issue 2*
Section E Hydraulics Section E
10 - 8 Problem Solving 10 - 8
CONTENTS

Pump Main Relief Pressure Test Points
Illustration X shows the servo pump. The upper view shows
the right hand side of the pump, the lower view shows the left
hand side of the pump.
Illustration Y shows the manual pump. The upper view shows
the underside of the pump, the lower view shows the left
hand side of the pump.
Testing Main Relief Valves
Whilst carrying out this test make sure the area around the
machine is clear of personnel.
1 Remove the seat and seat base. Install a 0 - 400 bar (0 -
6000 lb/in2, 0 - 422 kg/cm2) pressure gauge into the
appropriate point on the pump to measure the pressure
generated in the motor feed line.

A Left motor forward port 2 Servo machines:

B Left motor reverse port
C Right motor reverse port Raise the safety restraint to apply the parking brake and
D Right motor forward port prevent the machine from moving.

Note: Point D on the manual pump (illustration Y) is on the Manual machines:

right side of the pump.
Mark the relative positions of the two sections of the

 WARNING
Hydraulic Fluid
Fine jets of hydraulic fluid at high pressure can
penetrate the skin. Do not use your fingers to check for
hydraulic fluid leaks. Do not put your face close to
suspected leaks. Hold a piece of cardboard close to
suspected leaks and then inspect the cardboard for
signs of hydraulic fluid. If hydraulic fluid penetrates your
skin, get medical help immediately.
INT-3-1-10/1
safety restraint to parking brake link then disconnect the
link so that the restraint can be lowered without releasing
the parking brake.
3 Start the engine and run at max. revs. then operate the
transmission control to select the appropriate drive.
4 The gauge will show the relief pressure setting which
should be as shown in Technical Data.
If the pressure setting is incorrect, the appropriate valve
should be removed and a new one fitted. The valves are not
adjustable.

X B Y C

A B
D D A

C B 325410
C 327490

9803/8520 Issue 2
Section E Hydraulics Section E
10 - 9 Problem Solving 10 - 9
CONTENTS

Checking the Joystick Hydraulic Lines

If the machine does not respond to joystick movements, 4 Start the engine and observe the gauge reading which
check the hydraulic supply to and from the joystick as should show the transmission pump charge pressure
follows: (see Hydraulics Technical Data).

 WARNING
5 If the gauge shows no or little pressure it could indicate a
fault in the charge pressure relief valve in the hydrostatic
The following procedure requires the machine to be pump or the pressure reducing solenoid valve C.
disabled (wheels raised off the ground, attachment
disconnected etc.) while the work is carried out. 6 If the supply pressure is correct, check the feed hose to
HYD 8-1/2
the joystick for blockage.
1 Raise and block the machine so that the wheels are
7 Remove the tee piece and gauge and connect into each
clear of the ground. Stop the engine. Make sure the
servo feed line in turn, as shown at B.
machine is stable.
8 Start the engine and move the joystick lever to
2 Remove the seat and floorplate to access the hose
pressurise the relevant hose. The lever should be moved
connections A and B.
fully diagonally as shown below.
3 Insert a tee piece and 0 - 40 bar (0 - 600 lb/in2, 0 - 42
9 The pressure gauge should show transmission pump
kg/cm 2) pressure gauge into the supply hose at the
charge pressure with full joystick travel (see Hydraulics
loader valve at position A.
Technical Data).
Note: On High-flow machines the servo supply is taken from
10 If any readings are not correct, check the hoses for
the lower connection at the charge pressure priority valve.
blockage. If the hoses are clear the joystick should be
There are two connections, one for the transmission joystick
dismantled for repair.
and one for the loader joystick.

FWD
& (



) *
REV

&

* )
333070

332980

9803/8520 Issue 1
Section E Hydraulics Section E
11 - 1 Problem Solving 11 - 1
CONTENTS

Loader Circuit
The purpose of this section is to help you trace hydraulic problems to a faulty unit (valve, actuator, ram etc). Once you have
traced the faulty unit, refer to the appropriate dismantling, inspecting and test instructions given elsewhere in the manual.

To help identify circuits, valves, rams etc. mentioned in the problem solving procedures, refer to hydraulic schematic diagrams.

* Before you begin problem solving, read the Safety Information at the beginning of this manual.

* Make simple checks before say, stripping a major component.

* Make sure that the hydraulic fluid is at correct working temperature (50 °C, 122 °F).

* Whatever the fault, check the condition of the hydraulic fluid. Drain and replace if necessary.

* Be sure to remove ALL contamination and if possible identify its origin. It may be part of a component from elsewhere in the
circuit.

PROBLEM CAUSE (standard machines) CAUSE (High-flow machines)

Lack of power in all loader functions. 1, 2, 3, 4, 6, 7, 20 1, 2, 3, 4, 6, 7, 8, 20

All hydraulic rams slow to operate. 3, 4, 7 (servo only), 11, 13 3, 4, 8 (servo only), 11, 13

One hydraulic service fails to operate or 14, 15, 16, 17, 19 14, 15, 16, 17, 19
is slow to operate.

Engine tends to stall when hydraulics are under load. 3, 20 3, 8, 20

Valve spool sticking. 3, 21, 23, 24, 25, 26, 27, 28, 29, 30 3, 21, 23, 24, 25, 26, 27, 28, 29, 30

Ram creep. 15, 18 15, 18

Hydraulic oil becomes too hot. 5, 6, 12, 22 5, 6, 12, 22

Boom judders when used while machine is moving. 9 (servo only), 13 11, 13

KEY TO CAUSE REMEDY PAGE REF.

1 Insufficient hydraulic fluid. Check for leaks and top up as required.

2 Hydraulic leaks in system. Check hoses, replace as required.

3 Main relief valve (MRV) setting incorrect. Check and adjust as required. E21-1

4 Low loader pump flow. Check pump flow, if necessary service or replace pump.

5 Hydraulic filter clogged. Change hydraulic filter. 3/8-1

6 Charge filter by-pass valve leaking. Check condition of hydraulic filter. 3/8-1
Check operation of by-pass valve.

7 Charge pressure incorrect. Carry out charge pressure check. Manual E26-4
Servo E29-4

8 Charge pressure priority valve pressure Check pressure setting of charge pressure priority valve. E11-4
setting incorrect.

..... continued

9803/8520 Issue 1
 Section E Hydraulics Section E
11 - 2 Problem Solving 11 - 2
CONTENTS

KEY TO CAUSE REMEDY PAGE REF.

9 Servo pressure low Carry out charge pressure check. Check for blocked Manual E26-4
service feed hose or faulty joystick. Servo E29-4

10 Non priority pressure/flow low. Carry out charge pressure priority valve flow check. E11-4

11 Neutral circuit or low pressure lines leaking, Check pipe lines and replace as required.
damaged, trapped or kinked.

12 Restriction in neutral circuit lines. Check hoses and pipes, replace as necessary.

13 Air in hydraulic system Bleed system. E11-5

14 Service pipe lines leaking, damaged, Check hoses and pipes, replace as required.
trapped or kinked.

15 Ram or pipe lines from ram leaking. Check and rectify as required. E56-1

* 16 Valve spool not operating.
Check for leaks, rectify as required. Manual E41-2
Make sure that spool lock-out is operating (check for
faulty wiring, solenoid sticking, burr on spool, etc.)
Make sure that associated load hold Servo E40-2
check valve is operating.

On servo machines, check operation of

joystick and feed hoses.
On manual machines, check that control lever
and associated linkage is operating the spool,
rectify as required.

17 Valve spool not moving fully from Spool movement should be 5 mm (0.2 in)
neutral to full selection. On servo machines, check servo (charge) pressure. E26-3

18 Valve spool leaking Rectify, check for contamination. Manual E41-2

Servo E40-2

19 Piston rod bent. Replace piston rod. Check pressure setting of MRV. E56-1
Check that associated pivot pins are adequately greased.

20 Poor engine performance. Check engine performance. K1-1

21 Manual control linkage bent. Disconnect linkage. Repair linkage or renew.

22 Oil cooler obstructed. Remove debris from cooler fins.

23 Oil temperature abnormally high. Check for correct fluid, see Lubricants and
Capacities. Check oil cooler and grille for blockage.

24 Hydraulic fluid dirty. Clean tank strainer. If strainer badly clogged, drain and E61-1
flush hydraulic system then fill with clean hydraulic fluid.

25 Service pipe connection over tightened. Check tightness.

26 Valve housing twisted during installation. Loosen retaining bolts and tighten to correct torque. Manual E41-2
Servo E40-2

..... continued

9803/8520 Issue 2*
Section E Hydraulics Section E
11 - 3 Problem Solving 11 - 3
CONTENTS

KEY TO CAUSE REMEDY PAGE REF.

27 Bent spool. Dismantle control valve. Renew spool as necessary. Manual E41-2
Servo E40-2

28 Spool return spring broken. Renew as necessary. Manual E41-2

Servo E40-2

29 Spool return spring or cap out of alignment. Remove cap, check that spring is in correct position. Manual E41-2
Refit cap and torque tighten bolts. Servo E40-2

30 Temperature distribution within Warm up entire system before using service.

control valve not uniform.

9803/8520 Issue 1
Section E Hydraulics Section E
11 - 4 Problem Solving 11 - 4
CONTENTS

Charge Pressure Priority Valve Flow/Pressure Check (High-flow machines only)

1 Install a flow meter and 0 - 40 bar (0 - 600 lb/in2, 0 - 42 7 Operate a loader service and check that the priority line
kg/cm2) pressure gauge into the priority line from the pressure is not affected.
Charge Pressure Priority Valve (CPPV) lower port to the
transmission pump. 8 If the priority line pressure is below 16 bar (232 lb/in2; 16
kg/cm2) or the pressure is affected by loader operation
2 Place the machine safely onto blocks so that all four the CPPV or the gear pump could be faulty. To check
wheels are clear of the ground. Ensure that the machine which unit is faulty proceed as follows.
is stable.
9 Connect a flow meter and load valve into the non-priority
3 Start the engine and run at max. revs. then select drive. line from the CPPV upper port to the valve block.
Observe the reading on the pressure gauge then, using Alternatively the flow meter and load valve can be
the graph below, plot a vertical line from the pressure connected across the quick release couplings.
reading and check that the flow recorded on the
flowmeter is within the service limits set on the graph for Note: The machine must remain static during the following
that pressure. tests. If the transmission control levers are moved the motor
flushing flow will increase and the non priority rate will drop.
4 If the flow is outside the service limits suspect excessive
leakage within the hydrostatic system. Check that the 10 With the load valve open and the engine at max. revs,
hydraulic filter element is not blocked causing the by- the flow reading should be above 71 litres/min (15.6 UK
pass valve to open. gal/min; 18.8 US gal/min). If the flow reading is below
this figure the gear pump is faulty.
Note: The transmission pump charge pressure relief valve
must be disabled (see description on page E/3-5). On servo 11 Using the load valve, gradually increase the pressure in
machines screw adjustment in fully; on manual machines the the non-priority line. The flow and pressure readings
valve is shimmed and cannot be adjusted. should be as indicated in the table below.
DO NOT EXCEED 150 Bar (2175 lb/in2, 153 kg/cm2).
5 Lower the machine to the ground and repeat test in
paragraph 3 whilst driving the machine against a solid Table of Non-priority flow/Pressure
immovable object.
Pressure Flow
6 If the flow is outside the service limits suspect excessive bar lb/in2 kg/cm2 l/min UK gal/min US gal/min
leakage within the motors.
50 725 51 65 14.0 17.0
80 1160 82 61 13.5 16.0
100 1450 102 59 13.0 15.5
120 1740 122 57 12.5 15.0
140 2030 143 54 12.0 14.2
150 2175 153 53 11.5 14.0

US gal/min
0.5 2.4 5 7.4 10
25

Optimum
20 Pressure
Bar

Service
15 Limit

10
2 9 19 28 38
Litres/Min 340270

9803/8520 Issue 1
Section E Hydraulics Section E
11 - 5 Problem Solving 11 - 5
CONTENTS

Bleeding the Hydraulic System

It may be necessary to bleed the hydraulic system if major
components have been removed. Air in the system will result
in uneven loader operation.

1 Make up a hose loop with two quick release connectors

and connect across the two standard quick release
couplings A on the machine.

2 On High-flow machines connect a loop across the two

large quick release couplings B on the boom.

3 Start the engine and warm the hydraulic oil to normal

operating temperature.

4 Stop the engine. Remove the hydraulic tank filler cap.

Remove the seat and seat base.

5 Slacken hose connections at C (manual pump) and D


(servo pump).

6 Start the engine and operate all loader and auxiliary
services until all air is expelled from the loosened
connections and oil flows freely.

7 Stop the engine and retighten connections C or D.

8 Remove the temporary loops from the quick release 341860

couplings and refit the hydraulic filler cap.


D
B

C A

324241 324880A

9803/8520 Issue 1
Section E Hydraulics Section E
12 - 1 Problem Solving 12 - 1
CONTENTS

Levelling Circuit
PROBLEM PROBABLE CAUSE REMEDY

1 Boom delay at start of self-level A Air in system A Cycle boom and bucket slowly
or unstable self-level to rid system of air

2 Loaded bucket dumps or raises A Unloading spool is leaking A Remove and inspect unloading
when control valve is in neutral spool for damage

3 Insufficient self-level A Pin X is out of adjustment A Re-adjust pin to achieve proper

flow split

B Broken unloading spool spring B Replace unloading spool spring

C Flow divider spool stuck C Remove flow divider spool and

towards port B check for damage

4 Bucket dumps faster than boom A Pin X out of adjustment A Re-adjust pin to achieve proper
raises. Too much self-level flow split

B Flow divider spool stuck B Remove flow divider spool and

towards port B check for damage

C Flow divider spool installed C Remove spool and install with

incorrectly internal orifice towards port B

5 With bucket dumped, boom is A Dampening orifice in the A Remove unloading spool and
slow in starting to raise unloading spool is blocked clean dampening orifice

6 Bucket does not move in self-level A Pin X is screwed in all the way A Re-adjust pin to achieve proper
flow split

B Dampening orifice in the B Remove unloading spool and

unloading spool is blocked clean dampening orifice

C Ports A and B cross connected C Reverse hoses to ports A and B

7 Bucket raises in self-level A Ports A and B cross connected A Reverse hoses to ports A and B

8 External leakage A Damaged ‘O’ ring A Replace ‘O’ ring

9803/8520 Issue 1
Section E Hydraulics Section E
21 - 1 Pressure Testing 21 - 1
CONTENTS

Main Relief Valve (M.R.V.)

Remove the seat and seat base.

Connect a 0 - 400 bar (0 - 6000 lb/in 2, 0 - 422 kg/cm 2)

pressure gauge to test connector A located on the right-hand
end of the loader valve block.

With the engine running at maximum speed, check the

M.R.V. setting by raising or lowering the loader arm until the
rams are fully open or closed and noting the maximum gauge
reading. Keep clear of the loader arm. The maximum
pressure should be as stated in Technical Data.

If the pressure is incorrect, remove cap B from the M.R.V.

and turn adjusting screw C clockwise to increase pressure or
anti-clockwise to decrease the pressure. When the pressure
is correct, refit cap B.

Remove the pressure gauge and refit the seat and seat base.




333240

9803/8520 Issue 1
Section E Hydraulics Section E
24 - 1 Pumps 24 - 1
CONTENTS

Pump/Engine Coupling
This is a gear type flexible coupling comprising an outer
coupling B, bolted to the engine drive plate, and an inner
coupling A clamped to the input shaft of the pump unit. Both
are contained within casing C, to which the pump unit is
bolted.

The outer coupling B is bolted to the engine with four

capscrews E. The inner section A is tightened onto the pump
shaft spline with cap screw D.

Coat threads of capscrew D with JCB Threadlocker and

Sealer and torque tighten to 49 Nm (36 lbf ft, 5 kgf m).

Coat threads of capscrews E with JCB Threadlocker and

Sealer and torque tighten to 28 Nm (21 lbf ft, 2.8 kgf m).

324430

D
B

C A

324411

9803/8520 Issue 2
Section E Hydraulics Section E
25 - 2 Pumps 25 - 2
CONTENTS

D
B

C

A



  

 

 324221

332881

9803/8520 Issue 2
Section E Hydraulics Section E
25 - 3 Pumps 25 - 3
CONTENTS

Manual Pump - Return to Idle Controls

Removal and Replacement Screw guide rod F out of the bell housing to compress spring
C to a length of 70 mm (2.75 in). Tighten locknut E making
Slacken locknut E. Slacken all three locknuts D just sufficient sure that the dowelled bracket K is correctly located into the
to release rod F from bracket L. side plate J and into the engine bell housing.

Lift clear the side plate assembly J, complete with blocks A, Tighten locknuts D ensuring that no load is applied to the
B, spring and retainer C and rod F. bracket.

Take care to retain the dowelled bracket K which may remain
in its location in the bell housing or come away with the side
plate.
Replacement is the reverse of Removal, making sure that the
rod F is located through bracket K and into the bell housing.
Also make sure that nuts D are correctly located either side
of bracket L.
Operate both drive control joysticks in forward and reverse.
Check for free movement of the linkage and that no wheel
movement occurs when the joysticks return to neutral.
Repeat adjustment procedure if necessary.
Stop the engine. Refit the left road wheels and the seat and
lower the machine to the ground.

Carry out the following adjustment procedure. Adjusting the Lever Stops for Straight Line Travel

Adjustment
If the machine continues to move when neutral is selected
and also if the installation has been disturbed, the manual
controls should be adjusted as detailed below.
 WARNING
The following procedure requires the machine to be
disabled (wheels raised off the ground, work function
disconnected etc.) while the work is carried out.
HYD 8-1/1
Place the machine safely onto blocks so that all four wheels
are clear of the ground. Ensure that the machine is stable.
Stop the engine and remove both left wheels. Remove the
seat.
If the machine does not travel in a straight line with both
levers pushed fully forward, the control lever stops may be
adjusted.
Caution: Stop the engine and remove the starter key whilst
the adjustment is made.
If the machine is veering to the right, slacken locknut X for
the left hand control lever and screw out (anti-clockwise) stop
bolt Y one flat at a time. Re-tighten the locknut. Start the
engine and check if the machine now travels in a straight
line. If not repeat the adjustment.
If the machine veers to the left, carry out the adjustment
procedure on the right hand control lever stop Z.

Release the bolts securing the adjustment blocks A and B

and slide the blocks away from the control lever rollers.
Check for free movement of the control linkage, lubricate if
necessary.

Release locknuts D and E and screw rod F fully into the

engine bell housing.

Start the engine and allow to idle.

Lower the safety restraint to release the parking brake.

Position the L.H. drive control joystick in neutral so that there

is no movement of the left road wheels. Hold the lever in this
position then slide adjustment block B in its grooves until it
just contacts the rollers on the control lever G. Keep a light
pressure on side plate J against spring C during this process.
Tighten the securing bolts for block B.

Repeat the procedure for the R.H. lever and position and
tighten adjustment block A against the rollers on lever H.

9803/8520 Issue 1
Section E Hydraulics Section E
26 - 3 Pumps 26 - 3
CONTENTS

168030

9803/8520 Issue 1
Section E Hydraulics
26 - 4 Pumps
Manual Pump - End Caps
Dismantling and Assembly
The numerical sequence shown on the illustration is intended
as a guide to dismantling.
For assembly the sequence should be reversed.
Note: The illustration shows a typical pump and is also
shown upside down in this view.
Each end cap 8, 9 is secured to its pump by four capscrews
1. Before dismantling, matchmark each end cap to its pump.
Note that 'O' rings 3, 4 and 5 are only fitted to the rear pump
end cap 8. Locating dowels 6 need only be removed if
damaged.
Note that shims 15 should be retained as a set. On
reassembly, use new 'O' rings and bearings.
Torque tighten bolts 1 to 47 - 61 Nm (4.8 - 6.2 kgf m, 35 - 45
lbf ft).
Torque tighten plug 14 to 54 - 135 Nm (40 - 100 lbf ft, 5.5 -
14 kgf m).
X1
9803/8520
Section E
26 - 4
CONTENTS
Charge Pressure Relief Valve
Checking and adjustment
If the charge pressure relief valve has been dismantled it will
require setting up as follows:
*1 Install a 0 - 40 bar (0 - 600 lb/in2, 0 - 42 kg/cm2) pressure
gauge in the pressure test point X1 at the hydraulic filter.
2 Start the engine and warm the hydraulic oil to its normal
operating temperature.
3 Run the engine at maximum revs. and check the
pressure at the gauge which should be as quoted in
Technical Data.
4 If the pressure is not correct, slacken locknut 13 and
adjust screw 12 quarter of a turn at a time, clockwise to
increase pressure, anti-clockwise to decrease.
* Note: On High-flow machines the charge pressure is
controlled by the Charge Pressure Priority Valve (CPPV). For
these machines the pump mounted charge pressure relief
valve is set by means of shims and is not adjustable.
326680
Issue 2*
Section E Hydraulics Section E
29 - 3 Pumps 29 - 3
CONTENTS

10

11

12
13

14 17
1
2 19
15

16
18
20

3
4

8 6

5
7

337440

9803/8520 Issue 1
Section E
29 - 4
Servo Pump
Charge/Anti-stall Valve
Dismantling and Assembly
1 Mark the plug 17, locknut 16 and the pump body so as
to approximately maintain the original adjustment.
2 Loosen locknut 16 and unscrew plug 17 from pump
body. Remove ‘O’ ring 18 and discard.
3 Remove spring 19 and poppet 20 from pump body.
4 Inspect poppet 20 and mating seat in pump body for
damage. Renew as necessary.
5 Install a new ‘O’ ring 18 on plug 17.
6 Fit poppet 20 and spring 19 into pump body.
7 Screw plug 17 complete with locknut 16 into pump body
to align with the marks made during disassembly.
Tighten the locknut.
8 Check the charge pressure and adjust as necessary.
X1
9803/8520
Hydraulics Section E
Pumps 29 - 4
CONTENTS
Charge Pressure Checking and Adjustment
1 Stop engine. Connect a 0 - 40 bar (0 - 600 lb/in2, 0 - 42
kg/cm 2 ) pressure gauge into test point X1 at the
hydraulic filter.
2 Start engine and check pressure is as specified in
Technical Data.
3 If the pressure is not as specified, stop the engine.
Unscrew locknut 16 and turn adjuster 17 quarter of a
turn at a time (clockwise to increase pressure) then re-
tighten locknut. Start engine and re-check pressure.
Continue procedure until pressure is correct then
remove pressure gauge.
Note: On High-flow machines the charge pressure is
controlled by the Charge Pressure Priority Valve (CPPV). For
these machines the pump mounted charge pressure relief
valve should be disabled by screwing the adjustment screw
in fully.
326680
Issue 1
Section E Hydraulics Section E
36 - 1 Motors 36 - 1
CONTENTS

&
.

) *

+
( -
, F
*

+
, -
- ,
(
. 333710

 /
'
< 31
1 =
> C
? B
@ A
2
2 333720

3 

4
5  9
:0
6 ;
7 8

333740

333700

9803/8520 Issue 1
Section E Hydraulics Section E
36 - 2 Motors 36 - 2
CONTENTS

Drive Motor
Dismantling With the seal grooves in flange 2 facing upwards, install
seals and back-up rings 4 to 8 as shown at F. Make sure that
CAUTION: Do not pick up the motor by the drive shaft 11 as these seals and seal 14 are securely held using petroleum
this can cause damage to the balance plate 9. jelly.

Drain oil from motor. Make sure that the work area and the Position rotor 13 with splined side facing upwards as shown.
exterior of the motor are clean before starting dismantling.
Align all match marks made before dismantling.
Match mark items 2, 9,13, 15 and 17 to assist re-assembly.
Note: The shuttle flow hole A on the underside of flange 2
Dismantle the motor in a vertical position as shown, following
and holes B, C, D and E must all be aligned. Do not confuse
the numerical sequence.
hole A with case drain hole X.
Take care not to lose ball checks 12.
Make sure that check balls 12 are fitted in the seats in rotor
13.
Keep parts of rotor assembly 13 together as they are closely
matched during manufacture. If they are dropped, carefully
When inverting and fitting flange 2, make sure that the seals
remove minor damage using a fine abrasive stone.
are not dislodged.
Renew all parts where the mating surfaces have deep
Lubricate cap screws 1 with hydraulic fluid before fitting.
scratches or burrs which will not easily polish out.
Tighten to stage 1 torque setting in the sequence 1 to 9 as
illustrated. Tighten to stage 2 torque following the same
Wash all metal parts in clean solvent and blow dry using
sequence.
compressed air. Do not use paper towels or cloth as lint in
the hydraulic system will cause damage.
Torque Settings
Inspection
Item Nm kgf m lbf ft
1 (stage 1) 61-75 6.2-7.6 45-55
Item 11:
1 (stage 2) 75-88 7.6-8.9 55-65
Check seal diameter for excessive wear.
19 23-29 2.3-2.9 17-21
Item 13:
23 37-45 3.7-4.5 27-33
a) Check pockets for any signs of excessive wear from
roller contact.
b) Check star profile for any excessive or irregular wear.
c) Check internal splines for any sign of excessive wear.
Spline teeth should not show any signs of spalling or
chipping.
d) Check outer diameter of rollers for any sign of
excessive wear or spalling.
Item 15:
Check mating surface with item 13 for any unusual wear
marks.

Assembly

Reverse the dismantling sequence with the following

exceptions.

Renew all seals, using petroleum jelly as a lubricant and to

hold them in position.
333750
Lubricate machined surfaces with clean hydraulic fluid.

Install poppet 30, spring 29 and dash pot 28 into shuttle valve
bore from valve plate side of end cap 17. Install shuttle piston
31 from opposite side (position Y), followed by the other
poppet 27, spring 26 and dash pot 25. Fit ‘O’ ring 24 and plug
23, tightened to specified torque setting.

Install poppet 22, spring 21, ‘O’ ring 20 and plug 19 at

position Z.. Tighten plug to specified torque setting.

9803/8520 Issue 1
Section E Hydraulics Section E
40 - 2 Valves 40 - 2
CONTENTS

16
17

18
19
20 5
21
3

6 4
25
26
27 29
28

7
23
15 22 8
14
9
10

13
24
12
11
3a
2
1 3b

3c

3e
7a
3d
7b
7c
7d
3f
7

337410

9803/8500 Issue 1
Section E Hydraulics Section E
40 - 3 Valves 40 - 3
CONTENTS

Loader Valve - Servo Machines

Dismantling Assembly

A seal kit may be purchased from JCB Service and this Assembly is a reversal of the dismantling procedure.
should be available before commencing work. Always work
on a clean, dirt free surface. Renew all seals and 'O' rings.

1 Remove cap screws 1 and remove servo cylinder 2.
(These are fitted to both main spools.)
2 Unscrew and remove spool lock solenoids 3 from
mounting blocks 6 (one on each main spool). If required
the solenoid assembly may be dismantled further for
cleaning as shown in the inset. Solenoid 3b may be
renewed separately. It should not normally be necessary
to remove guide 3f as it is an interference fit in body 6
and is also secured with locking fluid.
3 Remove cap screws 4 and remove servo cylinders 5 and
mounting blocks 6 from both main spools.
Lubricate all parts with hydraulic oil before assembly.
If the spools have been dismantled, apply 2 or 3 drops of
JCB Threadlocker & Sealer to threads of shoulder bolt 7a
after degreasing threads.
Ensure that the spools are inserted in their correct bores.
If guide 3f has been removed, assemble using JCB High
Strength Threadlocker and ensure that grooves X are
positioned at right angles to the centre line of the spool as
shown. Press the guide into position. Do not use a hammer
otherwise the body could be damaged.

4 Carefully withdraw each main spool assembly 7.
Remove and discard ‘O’ rings 8, 9 and 12 and wiper
seals 10 and 11.
5 Remove capscrews 13 and seal retainer 14 from
auxiliary spool if fitted.
Check operation of lock-out solenoid 3 after assembly. With
the solenoid de-energised the spool should be locked in the
neutral position. Connect a 12 volt electrical supply to the
solenoid and check for free spool operation. Carry out check
three times to confirm correct operation.

6 Remove capscrews 16 and housing 17. Carefully

withdraw auxiliary spool 18. Remove and discard ‘O’
rings 19, 20 and 23 and wiper seals 21 and 22.

The spools may be dismantled further if required as 3a

shown in the inset. Note that shoulder bolt 7a is secured
with locking fluid.
3c
Note: Work on the spools individually. Return each spool to
its original bore. Do not interchange parts from individual
spools. 3b
7 Remove main relief valve 24.
3d
8 Remove each check valve guide 25, spring 27 and
poppet 28. Discard ‘O’ ring 26.
3f
9 It should not normally be necessary to remove restrictor
29.

10 Clean all parts in kerosene, inspect and check for

damage. 6

3f
X

X 337420

9803/8520 Issue 1
Section E Hydraulics Section E
41 - 2 Valves 41 - 2
CONTENTS

11
12

13
14 4
15
16

20
6
21
22
24
23

8
9
10

19

18
3 17 4a
2
1
4b

4c

4e
7a
4d
7b
7c
7d
4f
7

337400

9803/8500 Issue 1
Section E Hydraulics
41 - 3 Valves
Loader Valve - Manual Machines
Dismantling
A seal kit may be purchased from JCB Service and this
should be available before commencing work. Always work
on a clean, dirt free surface.
1 Remove cap screws 1 and remove seal retainer 2 and
seal 3 from each spool.
2 Unscrew and remove spool lock solenoids 4 from
mounting blocks 6 (one on each main spool). If required
the solenoid assembly may be dismantled further for
cleaning as shown in the inset. Solenoid 4b may be
renewed separately. It should not normally be necessary
to remove guide 4f as it is an interference fit in body 6
and is also secured with locking fluid.
3 Remove cap screws 5 and remove mounting blocks 6
from both main spools.
4 Carefully withdraw each main spool assembly 7.
Remove and discard ‘O’ rings 8, 9 and 18 and wiper
seals 10 and 17.
5 Remove capscrews 11 and housing 12. Carefully
withdraw auxiliary spool 13. Remove and discard ‘O’
rings 14, 15 and 18 and wiper seals 16 and 17.
The spools may be dismantled further if required as
shown in the inset. Note that shoulder bolt 7a is secured
with locking fluid.
Note: Work on the spools individually. Return each spool to
its original bore. Do not interchange parts from individual
spools.
6 Remove main relief valve 19.
7 Remove each check valve guide 20, spring 22 and
poppet 23. Discard ‘O’ ring 21.
8 It should not normally be necessary to remove restrictor
24.
9 Clean all parts in kerosene, inspect and check for
damage.
9803/8520
Section E
41 - 3
CONTENTS
Assembly
Assembly is a reversal of the dismantling procedure.
Renew all seals and 'O' rings.
Lubricate all parts with hydraulic oil before assembly.
If the spools have been dismantled, apply 2 or 3 drops of
JCB Threadlocker & Sealer to threads of shoulder bolt 7a
after degreasing threads.
Ensure that the spools are inserted in their correct bores.
If guide 4f has been removed, assemble using JCB High
Strength Threadlocker and ensure that grooves X are
positioned at right angles to the centre line of the spool as
shown. Press the guide into position. Do not use a hammer
otherwise the body could be damaged.
Check operation of lock-out solenoids 4 after assembly. With
the solenoid de-energised the spool should be locked in the
neutral position. Connect a 12 volt electrical supply to the
solenoid and check for free spool operation. Carry out check
three times to confirm correct operation.
4a
4c
4b
4d
4f
4f
X
X 337420
Issue 1
Section E Hydraulics Section E
50 - 3 Servo Joysticks 50 - 3
CONTENTS

337460

9803/8520 Issue 1
Section E Hydraulics
50 - 4 Servo Joysticks
Dismantling
Lift up the gaiter 1, release locknut 2 and remove the handle
assembly 3. If necessary slacken capscrew 4 and clamp 5 to
release the electrical cable.
Unscrew nut 6 and remove actuator plate 7. Remove
capscrew 4 with clamp 5, remove three capscrews 8 then lift
off plates 7 and 10 from the valve body 17.
Carefully remove gland seal assembly 11 from each bore.
Remove and discard ‘O’ ring 12. Carefully withdraw each
valve unit 13 from its bore.
Note: Ensure that the components of valve units 13 and
gland seals 11 are kept together as sets and returned to their
original locations in the body. Do not mix components from
different valve units.
If necessary, remove adapters 14 and discard ‘O’ rings 15
and 16. Note on the transmission joystick the position of the
extended adapters.
9803/8520
Section E
50 - 4
CONTENTS
Assembly
Lubricate all parts with hydraulic fluid before assembly.
Renew all 'O' rings and seals, lightly coating with vaseline
prior to assembly.
Ensure that valve units 13 and gland seals 11 are located in
the bores from which they were originally removed (see note
opposite).
Assemble plates 10 and 9 and secure with capscrews 8 and
4. Tighten to 12 Nm (9 lbf ft).
Assemble actuator plate and tighten nut 6 so that actuator
plate just touches the plungers in gland seals 11.
Assemble handle 3 and, after positioning correctly, tighten
locknut 2. If necessary, secure electrical cable under clamp
5.
If disturbed, replace adapters 14 using new ‘O’ rings and
noting the position of the extended adapters on the
transmission joystick.
Issue 1
Section E Hydraulics Section E
61 - 1 Hydraulic Tank 61 - 1
CONTENTS

Suction Strainer

 WARNING
2 Remove the suction hose from the stub pipe A.

Make the machine safe before working on it. Park the
machine on level ground and lower the loader arm. Stop
the engine and remove the starter key. Make sure the
parking brake is engaged. Disconnect the battery, to
prevent the engine being started. Chock all four wheels.
3-3-1-2
Note: The hydraulic tank is shown removed from the
machine for clarity.
Removal and Replacement
1 Drain the hydraulic tank. Access to the hydraulic tank
drain plug is through the chassis blanking plate X.
Remove the blanking plate and place a suitable
container beneath the machine to catch the oil.
3 Unscrew bolts B, remove cover plate C together with its
gasket D.
4 Unscrew and remove the suction strainer E. Wash in a
suitable solvent and allow to dry.
Note: A new strainer should be similarly washed before
fitting, to remove the protective coating.
5 Reassemble in reverse order using a new gasket.
Tighten bolts B to 28 Nm (20 lbf ft; 3 kgf m). Refit the
suction hose.
6 Refill the tank with the correct fluid (see page 3/1 - 1).

Note: There are three drain plugs located behind the

blanking plate. The hydraulic oil drain is coloured black.

C B
E

X
338460

9803/8520 Issue 1
Section F Transmission Section F
3-2 Hubs and Driveshafts 3-2
CONTENTS

12

11

10
9
8 13
7
5

4
6

3
1
4
5 5
X 13 Y 13
4
8 7 6 3
2

327500

9803/8520 Issue 1
Section F Transmission Section F
3-3 Hubs and Driveshafts 3-3
CONTENTS

Wheel Hub Assembly (right hand)
Dismantling
Remove bolt 1, plain washer 2 and retainer 3. Remove drive
sprocket 4.
Support the casing assembly on its outer flange with the
wheel hub facing downwards and press out the axle shaft
assembly 5. Bearing 6 will remain in the casing 13 and can
be removed separately if necessary. The outer race of
bearing 7 will also be left in the casing and can be removed if
necessary. Shaft seal 8 should be removed and discarded.
Position a dial gauge against the flat face of the sprocket as
shown at D and zero the gauge. Reposition the dial gauge
onto the end of the axle shaft as shown at E and note the
reading. Remove the gauge and assembly tool.
Retainer 3 is available in three thicknesses to allow for the
correct preload of bearings 6 and 7. The retainers can be
identified as follows:
Colour Preload dimension
Self colour 0.01 - 0.085 mm (0.0004 - 0.0033 in)
Yellow 0.09 - 0.165 mm (0.0035 - 0.0065 in)
Black 0.17 - 0.25 mm (0.0067 - 0.0098 in)

If necessary, remove bolts 9 with washers 10 and remove Select the retainer which gives the closest match to the dial
twine cutter 11. gauge reading and assemble onto the axle shaft. Fit washer
2 and bolt 1. Tighten bolt 1 to the correct torque whilst
Inspection rotating the shaft to seat the bearings.

Thoroughly clean and dry all components. Examine the Fit a torque meter to the head of bolt 1 and check the rolling
bearings, axle shaft and casing for wear or damage. Renew torque is still 80 Nm (59 lbf ft, 8.2 kgf m).
as necessary.
Torque Settings
Assembly
Item Nm lbf ft kgf m
Assemble the twine cutter, if previously removed, and tighten 1 225 166 23
bolts 9 to the correct torque. 9 28 21 3

Lubricate all bearings and seals with JCB Special HP Grease

before assembly.


Press bearing 7 into casing 13 ensuring that the outer race is
pressed fully home.

Assemble outer race of bearing 6 into casing 13. Ensure it is
pressed fully home.

Fit the two halves of the oil seal installer A (825/10003)

around the axle shaft 5 and position a new oil seal 8, with the
seal lip facing inwards, against the installer. Feed axle shaft 5


into the casing.

Assemble the inner race of bearing 6 onto axle shaft 5 and

slide sprocket 4 onto the splines of the axle shaft.
333181
Note: The front sprocket should be assembled with its boss
towards the casing, as at X. The rear sprocket should be
assembled with its boss away from the casing, as at Y.

Screw threaded stud C of assembly tool B (825/10002) fully

into the end of the axle shaft as shown then continue turning

the stud to pull the axle shaft into the casing so that the oil
seal is fully installed. Release the assembly tool and remove

the oil seal installer. Note that it may be necessary to gently
tap the end of the shaft to release the installer.

Reassemble tool B and continue pulling the axle shaft into

position by tightening stud C to preload the bearings. Rotate
the shaft during this process to seat the bearings.

Fit a torque meter to the head of stud C and check the torque
required to rotate the axle shaft. The correct rolling torque
should be 80 Nm (59 lbf ft, 8.2 kgf m). Continue tightening
stud C until the correct rolling torque is acheived.
333191

9803/8520 Issue 1
Section F Transmission Section F
4-1 Hubs and Driveshafts 4-1
CONTENTS

1
2 4
3

5 6

7
9
10
11

8 12 13 14 15

Y
9 8

X
9 8 10 11
1

2
3

327511

9803/8520 Issue 1
Section F Transmission
4-2 Hubs and Driveshafts
Drive Shaft Assembly (left hand)
Dismantling
It is assumed that roadwheels are removed and the machine
is correctly supported.
Drain the oil from the chain case (see Drive Chain
Lubrication, Section 3).
Remove the appropriate right hand hub assembly to gain
access to the shaft retaining bolt (see Wheel Hub
Assembly, this section).
Remove the seat base. Slacken the nuts securing the upper
motor mounting to the chain case. Screw in the adjustment
bolts to lower the mounting and thus slacken the drive chains
(see Drive Chain Adjustment, this section).
Remove bolt 1, plain washer 2 and retainer 3. Remove drive
sprocket 4. Remove spring clip 5 and withdraw oil scraper 6
and spring 7 from inside the chain case.
Drift the axle shaft 8 out of the axle tube. Bearing 9 will
remain in the axle tube and can be removed separately if
necessary. The outer race of bearing 10 will also be left in
the axle tube and can be removed if necessary. Shaft seal 11
should be removed and discarded.
If necessary, remove bolts 12 with washers 13 and remove
twine cutter 14.
Inspection
Thoroughly clean and dry all components. Examine the
bearings and axle shaft for wear or damage. Renew as
necessary. Examine axle tube for wear of the bearing bores.
Check oil scraper for wear, renew as necessary. Check that
oil holes in scraper, and in axle tube, are clear.

9803/8520
Section F
4-2
CONTENTS
Assembly
Assemble the twine cutter, if previously removed, and tighten
bolts 12 to the correct torque.
Lubricate all bearings and seals with JCB Special HP Grease
before assembly.
Press outer bearing 10 into axle tube ensuring that the outer
race is pressed fully home.
Assemble outer race of inner bearing 9 into axle tube. Ensure
it is pressed fully home.
Fit the two halves of the oil seal installer A (825/10003)
around the axle shaft 8 and position a new oil seal 11, with
the seal lip facing inwards, against the installer. Slide axle
shaft 8 into the axle tube.
Fit oil scraper 6 with its spring 7 onto the dowels protruding
from the inner face of the chaincase and secure with spring
clip 5. Check that the scraper slides freely on the dowels.
Note: The short oil scraper fits against the front sprocket.
The long oil scraper fits against the rear sprocket.
Assemble the inner race of bearing 9 onto axle shaft 8 and
slide the sprocket 4 onto the splines of the axle shaft.
Note: The front sprocket should be assembled with its boss
away from the axle tube, as at X. The rear sprocket should
be assembled with its boss towards the axle tube, as at Y.

333201
Issue 1
Section F Transmission Section F
4-3 Hubs and Driveshafts 4-3
CONTENTS

Assembly (continued)

Screw threaded stud C of assembly tool B (825/10002) fully Fit a torque meter to the head of bolt 1 and check the rolling
into the end of the axle shaft as shown then continue turning torque is still 80 Nm (59 lbf ft, 8.2 kgf m).
to pull the axle shaft into the axle tube so that the oil seal is
fully installed. Release the assembly tool and remove the oil Refit and adjust the chains (see Drive Chain Adjustment,
seal installer. Note that it may be necessary to gently tap the this section).
end of the shaft to release the installer.
Refit the right hand wheel hub assembly (see Wheel Hub
Reassemble tool B and continue pulling the axle shaft into Assembly, this section).
position by tightening stud C to preload the bearings. Rotate
the shaft during this process to seat the bearings. Refit the chaincase access cover using a new gasket. Refill
the chain case with the correct oil.
Fit a torque meter to the head of stud C and check the torque
required to rotate the axle shaft. The correct rolling torque Torque Settings
should be 80 Nm (59 lbf ft, 8.2 kgf m). Continue tightening
stud C until the correct rolling torque is acheived. Item Nm lbf ft kgf m
1 225 166 23
Position a dial gauge against the flat face of the sprocket as 12 28 21 3
shown at D and zero the gauge. Reposition the dial gauge
onto the end of the axle shaft as shown at E and note the
reading. Remove the gauge and assembly tool.

Retainer 3 is available in three thicknesses to allow for the

correct preload of bearings 9 and 10. The retainers can be
identified as follows:

Colour Preload dimension

Self colour 0.01 - 0.085 mm (0.0004 - 0.0033 in)
Yellow 0.09 - 0.165 mm (0.0035 - 0.0065 in)
Black 0.17 - 0.25 mm (0.0067 - 0.0098 in)

Select the retainer which gives the closest match to the dial
gauge reading and assemble onto the axle shaft. Fit washer
2 and bolt 1. Tighten bolt 1 to the correct torque whilst
rotating the shaft to seat the bearings.

333211

9803/8520 Issue 1
Section F Transmission Section F
5-2 Drive Chains 5-2
CONTENTS

Adjustment


Note: The drive chains are pre-tensioned during manufacture
and do not require routine adjustment in service. The
following procedure should be carried out whenever the 
chains are disturbed or renewed.

Left Hand Chain Adjustment 

Adjust as follows:

1 Drain the oil from the chaincase.

2 Remove the seat and pump cover. Remove the

chaincase access cover D.

3 Slacken the four bolts A securing the upper motor

mounting to the chaincase.

4 Slacken locknuts B and tighten or loosen bolts C to raise

or lower the mounting. Rotate the sprocket so that one
side of the chain is taut. Position the motor mounting to
give 25 mm (1 in) of slack on the opposite side of the
chain at the midway point.

5 When the correct adjustment is achieved, tighten

locknuts B. Tighten the upper motor mounting bolts A.
333140
6 Refit the chaincase access cover D using a new gasket.
Refill the chaincase with the correct oil.

7 Refit the seat and floorplate.

Right Hand Chain Adjustment


Adjust as follows:


1 Drain the oil from the chaincase.

2 Remove the chaincase access cover D.  

3 The hub mounting bolts E should be loosened and nut F
finger tight only.

4 Slacken locknut G and screw adjustment bolt H out to

push the hub away from the centre of the machine and
so tighten the chain.

5 Rotate the sprocket so that one side of the chain is taut.

Position the hub to give 25 mm (1 in) of slack on the
opposite side of the chain at the midway point.

6 When the correct tension is achieved, tighten bolts E and

nut F. Tighten the second locknut to the adjustment bolt
H. 333150

7 Torque tighten nut F and bolts E to 244 Nm (180 lbf ft,

25 kgf m).

8 Refit the chaincase access cover D using a new gasket.

Refill the chaincase with the correct oil.

9803/8520 Issue 1
Section 3 Routine Maintenance Section 3
8-1 8-1
CONTENTS

Hydraulic System

 WARNING
Fine jets of hydraulic fluid at high pressure can
penetrate the skin. Do not use your fingers to check for
hydraulic fluid leaks. Do not put your face close to
suspected leaks. Hold a piece of cardboard close to
suspected leaks and then inspect the cardboard for
signs of hydraulic fluid. If hydraulic fluid penetrates your X
skin, get medical help immediately.
INT-3-1-10/1

Checking the Fluid Level - for interval see Service

Schedule

1 Lower the lift arm and fully crowd the shovel/ attachment
as shown at X. Stop the engine.

2 Look at the fluid level in the sight glass A. The level

should be at the mark on the sight glass.

If the fluid in the sight glass appears cloudy, then water

or air has entered the system. The hydraulic pump could
be severely damaged if the machine is operated.

3 If more fluid is needed, wait for five minutes, open the

hydraulic tank filler cap B and top up with engine oil. 



323791
Changing the Filter - for interval see Service Schedule

1 Stop the engine and wait until the system has cooled.

2 Open the engine top cover.

3 Loosen the hydraulic tank filler cap B and allow all

pressure to dissipate. Remove the filler cap.

4 Unscrew the old filter canister C, using a chain wrench if

necessary, and discard.

5 Lubricate seal D on the new filter canister with clean

engine oil.

6 Screw on the new filter canister hand tight only.

Note: On machines fitted with the High Flow option a second

filter is fitted behind the main filter. Repeat procedure for 
second filter.

7 Refit cap B, run the engine for a few minutes, then re-
check the fluid level.

Note: Old filters should be disposed of in accordance with

local Health and Safety regulations.
323780

9803/8520 Issue 2
Section 3 Routine Maintenance Section 3
9-2 9-2
CONTENTS

Transmission
Tyres and Wheels Replacing Segments of Optional Non-Inflatable Tyres

Inflating the Tyres Non-inflatable tyres are available as an option for use in
environments where a puncture could have serious

 WARNING
Over-inflated or overheated tyres can explode. Do not
cut or weld the rims. Get a tyre/wheel specialist to do
any repair work.
5-3-2-4
These instructions are for adding air to a tyre which is
already inflated. If the tyre has lost all its air pressure, call in
a qualified tyre mechanic. The tyre mechanic should use a
tyre inflation cage and the correct equipment to do the job.
consequences. These tyres consist of a number of individual
segments bolted to the wheel rim.
Damaged segments can be renewed individually. Loosen
and remove the four nuts and washers A (two each side of
the wheel). Lift the segment clear by extracting its fixing
studs from the holes in the wheel rim.
Fit a new segment in reverse order to removal, then tighten
the retaining nuts to a torque of 28 Nm (21 lbf ft, 3 kgf m).

1 Prepare the Wheel

Before you add air to the tyre, make sure it is correctly

fitted on the machine or installed in a tyre inflation cage.

2 Prepare the Equipment 

Use only an air supply system which includes a pressure
regulator. Set the regulator no higher than 1.38 bar (20
lbf/in 2 , 1.4 kgf/cm 2 ) above the recommended tyre
pressure. See Table below.
Checking the Wheel Bolt Torques
Use an air hose fitted with a self-locking air chuck and
remote shut-off valve. On new machines, and whenever a wheel has been
removed, check the wheel bolt torques every two hours until
3 Add the Air they stay correct.

Make sure that the air hose is correctly connected to the Every day, before starting work, check that the wheel bolts
tyre valve. Clear other people from the area. Stand are tight.
behind the tread of the tyre while adding the air.
The correct torque is shown in the table below.
Inflate the tyre to the recommended pressure. Do not
over-inflate. Front & Rear

Nm lbf ft kgf m
Tyre Pressure Table 244 180 25

 WARNING
Make Size Pressure
bar (lbf/in2)
If, for whatever reason, a wheel bolt is renewed, all the
Solideal 10 x 16.5 x 6Ply 3.1 (45) bolts for that wheel must be changed as a set, since the
remaining bolts may have been damaged.
3-3-2-1
Solideal 10 x 16.5 x 8Ply 4.2 (61)

Galaxy 10 x 16.5 x 8Ply 4.1 (60)

Solideal 700 x 15 x 6Ply 4.1 (60)

Solideal 700 x 15 x 14Ply 4.1 (60)

Galaxy 31.5/1300 x 16.5 x 10Ply 4.1 (60)

9803/8520 Issue 1