JCB 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader. Service Manual

Section E

Hydraulics

Section E

70 - 3

Hose Burst Protection Valves

70 - 3

Dismantling and Assembly (Cont’d)

- Boom and Dipper Rams

This procedure applies to Hose Burst Protection Valves

fitted to the boom/dipper rams ONLY.

There is no servicing permitted on this valve apart from the

removing and fitting a new check valve assembly A when

the seal B has been broken.

DO NOT use the machine with a broken seal.

If the assembly is fitted to the machine, before removing the

check valve A, operate the main service control levers back

and forth to vent residual pressure.

After fitting a new check valve ensure that the valve

assembly operates correctly, refer to Service Procedures,

Hose Burst Protection Valves - Checking.

S327320

9803/3280

Issue 1

www.WorkshopManuals.co.uk_{Section E}

Section E

Hydraulics

75 - 2

Hydraulic Rams

75 - 2

Removal and Replacement

- Loader Lift Ram

Removal

Replacement

! WARNING

Replacement is a reversal of the removal sequence.

The loader arm interlevers are potentially dangerous,

when pivoting about their centre they form a 'scissor'

point with the loader arm. Make sure the interlevers are

! WARNING

securely blocked when working in the loader arm area.

Fine jets of hydraulic fluid at high pressure can

BF 2-1

penetrate the skin. Do not use your fingers to check for

hydraulic fluid leaks. Do not put your face close to

Park the machine on firm level ground. Engage the

suspected leaks. Hold a piece of cardboard close to

parking brake and set the transmission to neutral.

suspected leaks and then inspect the cardboard for

signs of hydraulic fluid. If hydraulic fluid penetrates your

Raise the loader arms to give access to the lift ram pivot

skin, get medical help immediately.

pins C. The loader arms must be supported, use a tool

INT-3-1-10/1

as shown.

Coat pivot pins with anti-rust lubricant.

! DANGER

Hydraulic Pressure

Make sure that the head of item D is on the engine side.

Hydraulic fluid at system pressure can injure you. Before

disconnecting or connecting hydraulic hoses, stop the

Coat mainframe bores with grease.

engine and operate the controls to release pressure

trapped in the hoses. Make sure the engine cannot be

Assembly sequence for shim F and klipring:

started while the hoses are open.

INT-3-1-11/1

1st shim

2nd ram

Switch off the engine and vent residual hydraulic

3rd shim (as required)

pressure from the loader end by operating the loader

4th klipring

controls back and forth several times.

Pivot pins with M24 pin extractor hole

Note: If a hose burst protection valve is fitted on the ram, the

1st spacer

system will not vent. Extreme caution must be used when

2nd ram

releasing hydraulic connections - release the connections

3rd shim (as required)

one turn and allow the pressure to dissipate.

4th klipring

Label and then remove the lift ram hoses A. Plug and

All klipring installations to have a maximum end float of

cap all open orifices to prevent loss of fluid and ingress

2mm (0.080in.)

of dirt.

! CAUTION

This component is heavy. Do not attempt to remove it

unless its weight is held by a sling. Make sure that the

sling is attached to a suitable lifting appliance.

HYD 2-3/1

Fasten lifting straps to the lift ram, make sure that the

weight of the ram is supported by the sling.

Remove pivot pin retaining bolt B and then remove the

pivot pin C.

Remove pivot pin retaining bolt D.

Remove klipring E and shim F from both sides of ram,

use slide hammer kit (service tool 993/68100) to remove

pivot pin G.

Remove the lift ram.

9803/3280

Issue 1

www.WorkshopManuals.co.uk_{Section E}

Section E

Hydraulics

76 - 2

Hydraulic Rams

76 - 2

Removal and Replacement

- Loader Shovel Ram

Removal

Replacement

! WARNING

Replacement is a reversal of the removal sequence.

The loader arm interlevers are potentially dangerous,

when pivoting about their centre they form a 'scissor'

point with the loader arm. Make sure the interlevers are

! WARNING

securely blocked when working in the loader arm area.

Fine jets of hydraulic fluid at high pressure can

BF 2-1

penetrate the skin. Do not use your fingers to check for

hydraulic fluid leaks. Do not put your face close to

Park the machine on firm level ground. Engage the

suspected leaks. Hold a piece of cardboard close to

parking brake and set the transmission to neutral.

suspected leaks and then inspect the cardboard for

signs of hydraulic fluid. If hydraulic fluid penetrates your

Rest the shovel flat on the ground.

skin, get medical help immediately.

INT-3-1-10/1

DANGER

Coat pivot pins with anti-rust lubricant.

Hydraulic Pressure

Hydraulic fluid at system pressure can injure you. Before

All klipring intallations to have a maximum end float of 2mm

disconnecting or connecting hydraulic hoses, stop the

(0.080in.)

engine and operate the controls to release pressure

trapped in the hoses. Make sure the engine cannot be

Make sure that each klipring is installed with a shim.

started while the hoses are open.

INT-3-1-11/1

Switch off the engine and vent residual hydraulic

pressure from the loader end by operating the loader

controls back and forth several times.

Label and then remove the shovel ram hoses A. Plug

and cap all open orifices to prevent loss of fluid and

ingress of dirt.

! CAUTION

This component is heavy. Do not attempt to remove it

unless its weight is held by a sling. Make sure that the

sling is attached to a suitable lifting appliance.

HYD 2-3/1

Fasten lifting straps to the shovel ram, make sure that

the weight of the ram is supported by the sling.

Remove kliprings B, shims C and spacers D.

Remove pivot pins E.

9803/3280

Issue 1

Section E

Hydraulics

77 - 2

Hydraulic Rams

77 - 2

Removal and Replacement

- Slew Ram

Removal

Inspection

Slew the backhoe to the left to remove the right hand

Inspect the liner bearings 7 (located in the trunnion retaining

slew ram and visa versa.

bracket 3) and liner bearing 8 for signs of damage, wear,

scores or nicks etc. Replace as required.

Lower the bucket to the ground and switch off the

engine.

To remove the liner bearing 8 use a jack located against

blanking plate 9. Shown in the inset at Y.

! WARNING

Hydraulic fluid at system pressure can injure you. Before

To remove the bearing liner 7 from the trunnion bracket use

disconnecting or connecting hydraulic hoses, stop the

flat faced bearing pullers.

engine and operate the controls to release pressure

trapped in the hoses. Make sure the engine cannot be

started while the hoses are open.

Replacement

INT-3-1-11/1

! WARNING

Vent any residual hydraulic pressure by operating the

Fine jets of hydraulic fluid at high pressure can

backhoe and slew control levers.

penetrate the skin. Do not use your fingers to check for

hydraulic fluid leaks. Do not put your face close to

Disconnect the hydraulic hoses 1 to the slew rams -

suspected leaks. Hold a piece of cardboard close to

before disconnecting the hoses make sure that they are

suspected leaks and then inspect the cardboard for

labelled (to assist with reassembly).

signs of hydraulic fluid. If hydraulic fluid penetrates your

skin, get medical help immediately.

Plug and cap all open hydraulic connections to prevent

INT-3-1-10/1

ingress of dirt and loss of hydraulic fluid.

Replacement is generally a reversal of the removal

Loosen and remove trunnion bracket retaining nuts 2

procedures, however note the following:

and hardened washers 2A (see note).

The liner bearings 7 and 8 have a ‘lead-in’ diameter

Note: On assembly, the correct grade of nut (grade 12) and

(noticeable with a slight step), always install the smaller

bolt (grade 10.9) must be used. Also, use hardened washers

diameter first into the pivot bore. The bearings must be

2A - NOT ordinary washers. Using incorrect specification

installed so that they sit flush.

items could result in a reduction of clamping efficiency.

The eye end pivot pins 6 should be secured first - i.e.

Remove the trunnion bracket 3.

BEFORE the trunnion bracket retaining nuts 2, this will help

to maximise ram assembly alignment.

! CAUTION

This component is heavy. Do not attempt to remove it

Make sure that the hydraulic hoses are correctly installed.

unless its weight is held by a sling. Make sure that the

sling is attached to a suitable lifting appliance.

Make sure that any new or reused bearings are clean and

HYD 2-3/1

smeared with grease prior to reassembly of pins and

trunnion journals.

Attach suitable lifting straps to the slew ram assembly.

Note that the weight of the slew ram assembly is

When fully assembled, apply grease at each grease nipple

approximately 44 kg (97 lbs).

BEFORE operating the machine.

Remove thin nuts 4 ( 2 off per pivot pin) and remove the

Torque Setting

pivot pin retaining bolt 5. Use a 25 - 30 mm diameter

Item

lb ft

kgf m

bar to knock the pin out vertically.

650

480

66.3

Remove the slew ram (eye end) pivot pin 6 and swing

the ram to clear the kingpost casting.

Lift the slew ram assembly clear of the machine.

9803/3280

Issue 1

www.WorkshopManuals.co.uk_{Section E}

Section E

Hydraulics

78 - 2

Hydraulic Rams

78 - 2

Removal and Replacement

- Stabiliser Ram (Sideshift)

Removal

Replacement

Park the machine on firm level ground, engage the

Replacement is a reversal of the removal sequence.

parking brake and set the transmission to neutral.

Lower the backhoe and loader end to the ground.

! WARNING

Fine jets of hydraulic fluid at high pressure can

Lower the stabiliser legs until the pads are

penetrate the skin. Do not use your fingers to check for

approximately 4 in. (100mm) off the ground and stop

hydraulic fluid leaks. Do not put your face close to

the engine.

suspected leaks. Hold a piece of cardboard close to

suspected leaks and then inspect the cardboard for

Remove the bottom locking nut A and bolt B. Drive out

signs of hydraulic fluid. If hydraulic fluid penetrates your

the bottom pivot pin C and allow the stabiliser foot D to

skin, get medical help immediately.

fall clear. Lift the inner leg and temporarily refit the pivot

INT-3-1-10/1

pin C through inner leg and ram.

Place a block of wood underneath the stabiliser leg.

Use suitable lifting appliances to locate the stabiliser ram.

Remove circlips E and drive out top pivot pin F with

After replacing or fitting the ram, connect the hydraulic

spacing collars G.

pipes, make sure that the ram and leg operate freely and do

not foul.

Start the engine and slowly extend the stabiliser ram so

that the dump end of the ram protrudes from the top of

the outer leg section.

Attach suitable lifting gear to the ram as shown at H.

Make sure that the weight of the ram is supported by

the sling and remove the bottom pivot pin C.

DANGER

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

Make sure the engine is switched off, vent residual

hydraulic pressure by moving the backhoe and

stabiliser control levers back and forth.

Note: If a check valve is fitted on the ram, the system will not

vent. Extreme caution must be used when releasing

hydraulic connections - release the connections one turn and

allow the pressure to dissipate.

Loosen and remove the stabiliser hoses L, label the

hoses before removing (as an aid to assembly). Plug all

open orifices to prevent loss of fluid and ingress of dirt.

! CAUTION

This component is heavy. Do not attempt to remove it

unless its weight is held by a sling. Make sure that the

sling is attached to a suitable lifting appliance.

HYD 2-3/1

Using suitable lifting equipment, lift the ram clear.

9803/3280

Issue 1

www.WorkshopManuals.co.uk_{Section E}

Section E

Hydraulics

78 - 3

Hydraulic Rams

78 - 3

Removal and Replacement

- Stabiliser Ram (Centremount)

Removal

Replacement

Park the machine on firm level ground, engage the

Replacement is a reversal of the removal sequence.

parking brake and set the transmission to neutral.

Lower the stabiliser legs to the ground.

! WARNING

Fine jets of hydraulic fluid at high pressure can

Lower the backhoe and loader end to the ground and

penetrate the skin. Do not use your fingers to check for

stop the engine.

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

DANGER

signs of hydraulic fluid. If hydraulic fluid penetrates your

Hydraulic Pressure

skin, get medical help immediately.

Hydraulic fluid at system pressure can injure you. Before

INT-3-1-10/1

disconnecting or connecting hydraulic hoses, stop the

engine and operate the controls to release pressure

Use suitable lifting appliances to locate the stabiliser ram.

trapped in the hoses. Make sure the engine cannot be

started while the hoses are open.

INT-3-1-11/1

After replacing or fitting the ram, connect the hydraulic

pipes, make sure that the ram and leg operate freely and do

not foul.

Make sure the engine is switched off, vent residual

hydraulic pressure by moving the backhoe and

stabiliser control levers back and forth.

Note: If a check valve is fitted on the ram, the system will not

vent. Extreme caution must be used when releasing

hydraulic connections - release the connections one turn and

allow the pressure to dissipate.

Carefully disconnect hydraulic hoses A and B from the

stabiliser hydraulic ram, label the hoses before

removing (as an aid to assembly). Release the

connections slowly.

! CAUTION

This component is heavy. Do not attempt to remove it

unless its weight is held by a sling. Make sure that the

sling is attached to a suitable lifting appliance.

HYD 2-3/1

Wrap a suitable sling around the stabiliser ram, make

sure that the weight of the ram is supported by the

sling.

Remove the ram pivot pin retaining nut and

bolt, drive out the ram pivot pin as shown at

Remove the stabiliser ram.

S263080

S261790

9803/3280

Issue 1

www.WorkshopManuals.co.uk_{Section E}

Section E

Hydraulics

79 - 2

Hydraulic Rams

79 - 2

Removal and Replacement

- Dipper Ram

Removal

Replacement

Park the machine on firm level ground, engage the

Replacement is a reversal of the removal sequence.

parking brake and set the transmission to neutral.

Lower the backhoe and loader end to the ground and

! WARNING

stop the engine.

Fine jets of hydraulic fluid at high pressure can

penetrate the skin. Do not use your fingers to check for

DANGER

hydraulic fluid leaks. Do not put your face close to

Hydraulic Pressure

suspected leaks. Hold a piece of cardboard close to

Hydraulic fluid at system pressure can injure you. Before

suspected leaks and then inspect the cardboard for

disconnecting or connecting hydraulic hoses, stop the

signs of hydraulic fluid. If hydraulic fluid penetrates your

engine and operate the controls to release pressure

skin, get medical help immediately.

INT-3-1-10/1

trapped in the hoses. Make sure the engine cannot be

started while the hoses are open.

INT-3-1-11/1

Vent residual hydraulic pressure from the backhoe

hoses by operating the backhoe controls back and forth

several times.

Note: If a hose burst protection valve is fitted on the ram, the

system will not vent. Extreme caution must be used when

releasing hydraulic connections - release the connections

one turn and allow the pressure to dissipate.

Label and then remove the dipper ram hoses A. Plug

and cap all open orifices to prevent loss of fluid and

ingress of dirt.

! CAUTION

This component is heavy. Do not attempt to remove it

unless its weight is held by a sling. Make sure that the

sling is attached to a suitable lifting appliance.

HYD 2-3/1

Fasten lifting straps to the dipper ram, make sure that

the weight of the ram is supported by the sling.

Remove the pivot pin retaining nut B and bolt C,

remove the pivot pin D.

Remove dipper ram.

9803/3280

Issue 1

www.WorkshopManuals.co.uk_{Section E}

Section E

Hydraulics

80 - 2

Hydraulic Rams

80 - 2

Removal and Replacement

- Bucket Crowd Ram

Removal

Replacement

Park the machine on firm level ground, engage the

Replacement is a reversal of the removal sequence.

parking brake and set the transmission to neutral.

Lower the backhoe and loader end to the ground and

! WARNING

stop the engine.

Fine jets of hydraulic fluid at high pressure can

penetrate the skin. Do not use your fingers to check for

DANGER

hydraulic fluid leaks. Do not put your face close to

Hydraulic Pressure

suspected leaks. Hold a piece of cardboard close to

Hydraulic fluid at system pressure can injure you. Before

suspected leaks and then inspect the cardboard for

disconnecting or connecting hydraulic hoses, stop the

signs of hydraulic fluid. If hydraulic fluid penetrates your

engine and operate the controls to release pressure

skin, get medical help immediately.

INT-3-1-10/1

trapped in the hoses. Make sure the engine cannot be

started while the hoses are open.

INT-3-1-11/1

Vent residual hydraulic pressure from the backhoe

hoses by operating the backhoe controls back and forth

several times.

Note: If a hose burst protection valve is fitted on the ram, the

system will not vent. Extreme caution must be used when

releasing hydraulic connections - release the connections

one turn and allow the pressure to dissipate.

Label and then remove the bucket crowd ram hoses A.

Plug and cap all open orifices to prevent loss of fluid

and ingress of dirt.

! CAUTION

This component is heavy. Do not attempt to remove it

unless its weight is held by a sling. Make sure that the

sling is attached to a suitable lifting appliance.

HYD 2-3/1

Fasten lifting straps to the bucket crowd ram, make

sure that the weight of the ram is supported by the

sling.

Remove the pivot pin retaining nut B and bolt C,

remove the pivot pin D.

Remove the bucket crowd ram.

9803/3280

Issue 1

www.WorkshopManuals.co.uk_{Section E}

Section E

Hydraulics

81 - 2

Hydraulic Rams

81 - 2

Removal and Replacement

- Boom Ram

Removal

Replacement

Park the machine on firm level ground, engage the

Replacement is a reversal of the removal sequence.

parking brake and set the transmission to neutral.

Lower the backhoe and loader end to the ground and

! WARNING

stop the engine.

Fine jets of hydraulic fluid at high pressure can

Remove pivot pin retaining nut A and bolt B. Remove

penetrate the skin. Do not use your fingers to check for

hydraulic fluid leaks. Do not put your face close to

the pivot pin C.

suspected leaks. Hold a piece of cardboard close to

suspected leaks and then inspect the cardboard for

Remove the grease nipple from the eye end of the ram

signs of hydraulic fluid. If hydraulic fluid penetrates your

(through access hole D).

skin, get medical help immediately.

INT-3-1-10/1

Use the machine hydraulics to SLOWLY retract the ram.

Remove the hose clamp.

It will be necessary to extend the ram to align and engage

the boom pivot pin C. As the ram extends, the ram will tend

to turn.

DANGER

Hydraulic Pressure

For this reason it is recommended that a smaller diameter

Hydraulic fluid at system pressure can injure you. Before

steel bar is used to locate the boom ram at the kingpost

disconnecting or connecting hydraulic hoses, stop the

casting. The steel bar can be more readily removed to allow

engine and operate the controls to release pressure

for re-alignment of the boom pivot pin C.

trapped in the hoses. Make sure the engine cannot be

started while the hoses are open.

When the boom pivot pin has been correctly aligned and

INT-3-1-11/1

fitted, then fit the correct pivot pin H at the kingpost.

Vent residual hydraulic pressure from the backhoe

hoses by operating the backhoe controls back and forth

several times.

Note: If a hose burst protection valve is fitted on the ram, the

system will not vent. Extreme caution must be used when

releasing hydraulic connections - release the connections

one turn and allow the pressure to dissipate.

Label and then remove the boom ram hoses E. Plug

and cap all open orifices to prevent loss of fluid and

ingress of dirt.

! CAUTION

This component is heavy. Do not attempt to remove it

unless its weight is held by a sling. Make sure that the

sling is attached to a suitable lifting appliance.

HYD 2-3/1

Fasten lifting straps to the boom ram, make sure that

the weight of the ram is supported by the sling.

Remove the pivot pin retaining nut F and bolt G remove

the kingpost pivot pin H.

Remove the boom ram.

9803/3280

Issue 1

www.WorkshopManuals.co.uk_{Section E}

Section E

Hydraulics

85 - 2

Hydraulic Rams

85 - 2

Dismantling and Assembly

Assembly

- Loader Lift Ram

Clean threads of piston rod, piston head, end cap and

- Loader Shovel Ram

cylinder using a wire brush. Use JCB Cleaner/Degreaser to

- Boom Ram

ensure that all threads are free from grease, hydraulic oil and

sealant. Allow 15 minutes for solvent to dry before applying

- Bucket Ram

JCB Threadlocker and Sealer (High Strength).

- Stabiliser Ram

Ensure that lubricants used during assembly do not come

Dismantling

into contact with the JCB Threadlocker and Sealer (High

The numerical sequence shown on the illustration is intended

Strength).

as a guide to dismantling.

Refer to JCB Ram Sealing Procedure for the correct

For assembly the sequence should be reversed.

method of fitting seals to the end cap and piston head.

Place ram assembly on a locally manufactured strip/rebuild

Apply JCB Activator to threads of end cap and cylinder.

bench as shown.

Allow Activator to dry for 15 minutes before bringing into

contact with the JCB Threadlocker and Sealer (High

Strength).

Note: Neither the JCB Threadlocker and Sealer (High

Strength) nor Activator must be allowed to contact seals,

bearing rings, or 'O' rings.

Fit locking dowel 6 to piston head/rod as follows:

Fit 'O' ring 8 into piston head 7.

S263670

Fit piston head to piston rod and torque tighten to 405

Nm (300 lbf ft).

Slacken end cap 1 using special spanner (see Service

Tools), and remove the piston rod assembly 2 from the

New ram Shaft and piston head fitted.

cylinder.

If both are required, the following procedure should

! WARNING

be followed:

If air or hydraulic pressure is used to force out the piston

a Drill through piston head into piston rod. Use an

assembly, ensure that the end cap is securely fitted.

undersized diameter drill first as a guide and then

Severe injury can be caused by a suddenly released

drill with the correct size diameter drill to suit; refer

piston rod.

HYD 1-2

to the table for drill diameters and depths.

Position piston rod assembly on bench in place of ram

b Remove all swarf and contamination. Insert dowel 6

cylinder. Remove seal 4 and wear rings 3 and 5 from piston

into drilled hole, make sure tapped extractor hole is

head.

to outside.

Extract dowel 6 from the piston head using a metric screw

New piston head fitted on a pre-drilled piston rod.

(M3, M4, or M6 depending on ram size) threaded into the

Re-drill and dowel BOTH the piston head and

extractor hole.

piston rod at 90° from the existing drilled dowel

hole in the piston rod. Follow the procedures

Remove piston head from rod using special spanner (see

described in step 3.

Service Tools).

New piston rod fitted to a pre-drilled piston head.

Remove gland bearing and end cap 1 from piston rod and

Use the pre-drilled hole in the piston head. Care

remove the ‘O’ ring 9, wiper seal 10 and rod seal 11. Check

must be taken not to elongate the existing hole in

the end cap bearing for damage, scores or nicks. If

the piston head.

damaged, the bearing must be replaced as part of the end

cap assembly.

a Use a drill the same diameter as the pre-drilled hole

in the piston head to make a 'centre mark' in the

Ensure that metal components are free from scoring, nicks

piston rod. DO NOT drill the piston rod at this

and burrs. A damaged rod will impair the life of the seals.

stage.

Check the bore of the ram cylinder for damage.

...........continued

9803/3280

Issue 1

www.WorkshopManuals.co.uk_{Section E}

Section E

Hydraulics

85 - 3

Hydraulic Rams

85 - 3

Dismantling and Assembly:

- Loader Lift Ram

- Loader Shovel Ram

- Boom Ram

- Bucket Ram

- Stabiliser Ram

DRILLING DETAILS FOR PISTON HEAD RETENTION

Assembly (continued)

b Use an undersized diameter drill as a guide and drill

into the piston rod to the required depth (see table),

make sure the drill has centred correctly on the

'centre mark' made at step 5a.

c Use the correct size diameter drill to suit the dowel

and drill to the required depth (see table).

d Remove all swarf and contamination, insert the

dowel.

Position cylinder on bench and install rod assembly into

cylinder.

A263750

Apply JCB Threadlocker and Sealer (High Strength) to first

three threads of cylinder, torque tighten the end cap to 678

(all dimensions in mm)

Nm (500 lbf ft).

Ram

Dowel

Guide Guide Dowel

Dowel

Size

Drill Ø Drill

Drill Ø X

Drill

Note: If hydraulic oil contacts the uncured JCB Threadlocker

and Sealer (High Strength) a weakening of the bond will

Depth

Depth Y

result. Cure times vary according to the ambient

80 x 50

6Ø x 20

6.02/6.10

22/23

temperature. Allow a minimum of 2 hours between assembly

70 x 40

and filling the ram with oil.

Note: Cold weather operation. When operating in conditions

90 x 50

8Ø x 25

8.02/8.10

27/28

which are consistently below freezing, it is recommended

100 x 60

that the rams are operated slowly to their full extent before

110 x 60

12Ø x 30

12.02/12.10

32/33

commencing normal working.

110 x 65

Torque Settings

120 x 65

12Ø x 35

12.02/12.10

37/38

130 x 75

Item

kgf m

lbf ft

405

41.3

300

678

69.2

500

9803/3280

Issue 1

www.WorkshopManuals.co.uk_{Section E}

Section E

Hydraulics

86 - 2

Hydraulic Rams

86 - 2

Dismantling and Assembly

Assembly

- Dipper Ram

Clean threads of piston rod, piston head, end cap and

cylinder using a wire brush. Use JCB Cleaner/Degreaser to

Dismantling

ensure that all threads are free from grease, hydraulic oil and

The numerical sequence shown on the illustration is intended

sealant. Allow 15 minutes for solvent to dry before applying

as a guide to dismantling.

JCB Threadlocker and Sealer (High Strength).

For assembly the sequence should be reversed.

Ensure that lubricants used during assembly do not come

into contact with the JCB Threadlocker and Sealer (High

Place ram assembly on a locally manufactured strip/rebuild

Strength).

bench as shown.

Refer to JCB Ram Sealing Procedure for the correct

method of fitting seals to the end cap and piston head.

Apply JCB Activator to threads of end cap and cylinder.

Allow Activator to dry for 15 minutes before bringing into

contact with the JCB Threadlocker and Sealer (High

Strength).

Note: Neither the JCB Threadlocker and Sealer (High

Strength) nor Activator must be allowed to contact seals,

S263670

bearing rings, or 'O' rings.

Ensure that end damping spring 9 is engaged with collar 10

Slacken end cap 1 using special spanner (see Service

and piston head 7.

Tools), and remove the piston rod assembly 2 from the

cylinder.

Fit locking dowel 6 to piston head/rod as follows:

! WARNING

If air or hydraulic pressure is used to force out the piston

Fit 'O' ring 8 into piston head 7.

assembly, ensure that the end cap is securely fitted.

Severe injury can be caused by a suddenly released

Fit piston head to piston rod and torque tighten to 405

piston rod.

Nm (300 lbf ft).

HYD 1-2

New ram Shaft and piston head fitted.

Position piston rod assembly on bench in place of ram

If both are required, the following procedure should

cylinder. Remove seal 4 and wear rings 3 and 5 from piston

be followed:

head.

a Drill through piston head into piston rod. Use an

Extract dowel 6 from the piston head using a metric screw

undersized diameter drill first as a guide and then

(M3, M4, or M6 depending on ram size) threaded into the

drill with the correct size diameter drill to suit; refer

extractor hole.

to the table for drill diameters and depths.

Remove piston head from rod using special spanner (see

b Remove all swarf and contamination. Insert dowel 6

Service Tools).

into drilled hole, make sure tapped extractor hole is

to outside.

Remove gland bearing and end cap 1 from piston rod and

remove the ‘O’ rings 11 and 12, wiper seal 13 and rod seal

New piston head fitted on a pre-drilled piston rod.

14. Check the end cap bearing for damage, scores or nicks.

Re-drill and dowel BOTH the piston head and

If damaged, the bearing must be replaced as part of the end

piston rod at 90° from the existing drilled dowel

cap assembly.

hole in the piston rod. Follow the procedures

described in step 3.

Ensure that metal components are free from scoring, nicks

and burrs. A damaged rod will impair the life of the seals.

New piston rod fitted to a pre-drilled piston head.

Use the pre-drilled hole in the piston head. Care

Check the bore of the ram cylinder for damage.

must be taken not to elongate the existing hole in

the piston head.

...........continued

9803/3280

Issue 1

www.WorkshopManuals.co.uk_{Section E}

Section E

Hydraulics

86 - 3

Hydraulic Rams

86 - 3

Dismantling and Assembly:

- Dipper Ram

Assembly (continued)

DRILLING DETAILS FOR PISTON HEAD RETENTION

a Use a drill the same diameter as the pre-drilled hole

in the piston head to make a 'centre mark' in the

piston rod. DO NOT drill the piston rod at this

stage.

b Use an undersized diameter drill as a guide and drill

into the piston rod to the required depth (see table),

make sure the drill has centred correctly on the

'centre mark' made at step 5a.

c Use the correct size diameter drill to suit the dowel

and drill to the required depth (see table).

d Remove all swarf and contamination, insert the

dowel.

A263750

Position cylinder on bench and install rod assembly into

(all dimensions in mm)

cylinder.

Ram

Dowel

Guide

Dowel

Apply JCB Threadlocker and Sealer (High Strength) to first

Size

Drill Ø

Drill

Drill Ø X

Drill

three threads of cylinder, torque tighten the end cap to 678

Depth

Depth Y

Nm (500 lbf ft).

80 x 50

6Ø x 20

6.02/6.10

22/23

Note: If hydraulic oil contacts the uncured JCB Threadlocker

70 x 40

and Sealer (High Strength) a weakening of the bond will

result. Cure times vary according to the ambient

90 x 50

8Ø x 25

8.02/8.10

27/28

temperature. Allow a minimum of 2 hours between assembly

100 x 60

and filling the ram with oil.

110 x 60

12Ø x 30

12.02/12.10

32/33

Note: Cold weather operation. When operating in conditions

110 x 65

which are consistently below freezing, it is recommended

that the rams are operated slowly to their full extent before

120 x 65

12Ø x 35

12.02/12.10

37/38

commencing normal working.

130 x 75

Torque Settings

Item

kgf m

lbf ft

405

41.3

300

678

69.2

500

9803/3280

Issue 1

www.WorkshopManuals.co.uk_{Section E}

Section E

Hydraulics

87 - 2

Hydraulic Rams

87 - 2

Dismantling and Assembly

Assembly

- Slew Ram

Clean threads of piston rod, piston head, end cap and

cylinder using a wire brush. Use JCB Cleaner/Degreaser to

Dismantling

ensure that all threads are free from grease, hydraulic oil and

The numerical sequence shown on the illustration is intended

sealant. Allow 15 minutes for solvent to dry before applying

as a guide to dismantling.

JCB Threadlocker and Sealer (High Strength).

For assembly the sequence should be reversed.

Ensure that lubricants used during assembly do not come

into contact with the JCB Threadlocker and Sealer (High

Place ram assembly on a locally manufactured strip/rebuild

Strength).

bench as shown, or alternatively, hold the ram in a suitable

vice taking care not to damage machined faces.

Refer to JCB Ram Sealing Procedure for the correct

method of fitting seals to the end cap and piston head.

Remove cylinder 6 using special spanner (see Service

Tools). Tap the cylinder off the piston head assembly using a

Apply JCB Activator to threads of end cap and cylinder.

suitable drift (e.g. nylon).

Allow Activator to dry for 15 minutes before bringing into

contact with the JCB Threadlocker and Sealer (High

Position the piston rod assembly in a vice, use soft jaws and

Strength).

stand the assembly vertical whilst clamping on the eye end.

Note: Neither the JCB Threadlocker and Sealer (High

Strength) nor Activator must be allowed to contact seals,

bearing rings, or 'O' rings.

Fit locking dowel 10 to piston head/rod as follows:

Fit 'O' ring 12 into piston head 11.

Fit piston head to piston rod and torque tighten to 405

Nm (300 lbf ft).

New ram Shaft and piston head fitted.

If both are required, the following procedure should

be followed:

a Drill through piston head into piston rod. Use an

undersized diameter drill first as a guide and then

drill with the correct size diameter drill to suit; refer

to the table for drill diameters and depths.

S266380

b Remove all swarf and contamination. Insert dowel

10 into drilled hole, make sure tapped extractor

hole is to outside.

Remove seal 8 and wear rings 7 and 9 from piston head.

Extract dowel 10 from the piston head using a metric screw

New piston head fitted on a pre-drilled piston rod.

threaded into the extractor hole.

Re-drill and dowel BOTH the piston head and

piston rod at 90° from the existing drilled dowel

Remove piston head from rod using special spanner (see

hole in the piston rod. Follow the procedures

Service Tools).

described in step 3.

Remove ‘O’ ring 12.

New piston rod fitted to a pre-drilled piston head.

Use the pre-drilled hole in the piston head. Care

Lift the end cap assembly 13 off the piston rod. Remove ‘O’

must be taken not to elongate the existing hole in

ring 14, rod wiper seal 15 and rod seal 16 from the end cap

the piston head.

assembly. Check the end cap bearing 13A for damage,

scores or nicks.

a Use a drill the same diameter as the pre-drilled hole

in the piston head to make a 'centre mark' in the

Item 18 is the metering orifice plate and item 17 its retaining

piston rod. DO NOT drill the piston rod at this

wire, do not remove these items unless problems with the

stage.

metering are suspected.

Ensure that metal components are free from scoring, nicks

...........continued

and burrs. A damaged rod will impair the life of the seals.

Check the bore of the ram cylinder for damage.

9803/3280

Issue 1

www.WorkshopManuals.co.uk_{Section E}

Section E

Hydraulics

87 - 3

Hydraulic Rams

87 - 3

Dismantling and Assembly

- Slew Ram

Assembling (continued)

DRILLING DETAILS FOR PISTON HEAD RETENTION

b Use an undersized diameter drill as a guide and drill

into the piston rod to the required depth (see table),

make sure the drill has centred correctly on the

'centre mark' made at step 5a.

c Use the correct size diameter drill to suit the dowel

and drill to the required depth (see table).

d Remove all swarf and contamination, insert the

dowel.

Install cylinder onto the rod assembly, make sure that the

cylinder is fitted square to the rod assembly. Firmly push the

cylinder over the piston head seals.

A263750

Apply JCB Threadlocker and Sealer (High Strength) to first

three threads of cylinder, torque tighten the cylinder to 678

(all dimensions in mm)

Nm (500 lbf ft).

Ram

Dowel

Guide

Dowel

Note: If hydraulic oil contacts the uncured JCB Threadlocker

Size

Drill Ø

Drill

Drill Ø X

Drill

and Sealer (High Strength) a weakening of the bond will

Depth

Depth Y

result. Cure times vary according to the ambient

temperature. Allow a minimum of 2 hours between assembly

80 x 50

6Ø x 20

6.02/6.10

22/23

and filling the ram with oil.

70 x 40

Note: Cold weather operation. When operating in conditions

90 x 50

8Ø x 25

8.02/8.10

27/28

which are consistently below freezing, it is recommended

100 x 60

that the rams are operated slowly to their full extent before

commencing normal working.

110 x 60

12Ø x 30

12.02/12.10

32/33

110 x 65

Position pipe assembly in correct position and torque tighten

probe assembly 2 to 75Nm (55 lbf ft; 7.6 kgf m). DO NOT

120 x 65

12Ø x 35

12.02/12.10

37/38

over-tighten the probe.

130 x 75

Make sure seals 19 and 21 are fitted the correct way as

shown.

Torque Settings

Item

kgf m

lbf ft

405

41.3

300

678

69.2

500

9803/3280

Issue 1

JCB 3CX, 4CX, 214e, 214, 215, 217 & VARIANTS Backhoe Loader. Service Manual - page 20