1992-2003 JCB (All Models) OEM Service & Repair Manual
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Introduction
General Information
Backhoe Loaders
Loadalls
RTFL
Excavators
Wheeled Loaders
Fastrac
Skidsteer Range
PUBLISHED BY THE
TECHNICAL PUBLICATIONS DEPARTMENT
OF JCB SERVICE; ©
ROCESTER, STAFFORDSHIRE, ST14 5LS,
ENGLAND
Tel. ROCESTER (01889) 590312
PRINTED IN ENGLAND
Publication No. 9804/1103
Service
Data
Book
1992 on
Robot
1CX
70 - XX - XX/X
Introduction
1992 Data Book
9804/1103 Issue 1
The JCB Service Data Book is compiled in sections as listed on the main title page at the front of the book. The section names
on the title page register with the tabs of the section divider cards to promote rapid reference to the relevant machine ranges.
The General Section is applicable to all machine ranges, covering such subjects as conversion tables, torque settings etc.
The various machine range sections contain information on current or recent machines as detailed in their respective contents
pages. Information on earlier machines is contained in the previous Data Book, publication no. 9804/1102.
The page numbering in each section is not continuous. This is to allow for additional pages to be inserted as they are issued.
A basic explanation of the page number system is given below to enable correct location of pages.
Page number example: 20 - 05 - 02/1
A B C
Machine Range Subject classification Number to suit
e.g. Backhoe Loader, Data, Fault Finding, etc detail variation
Loadall etc. within subject
When locating pages, refer to the page number in the sequence A, followed by B, followed by C.
The service data book is not intended as a substitute for service manuals which should be consulted for all further details.
INDEX
General
9804/1103 Issue 1
CONTENTS
Metric Units 1 - 1
Conversion Factors 1 - 2
Conversion Tables
- Capacity 1 - 3
- Length 1 - 4
- Pressure 1 - 5
- Temperature 1 - 6
Hydraulic Formulae 1 - 7
Torque Settings 2 - 1
Antifreeze Protection 3 - 1
Hydraulic Circuit Symbols 4 - 1
Contents
General Section Contents
INDEX
General
9804/1103
Issue 1
CONTENTS
Metrication - S.I.Units
The following list gives the units and symbols to be found in technical publications.
Quantity Name of Unit Unit Symbol
Angle second "
minute '
degree 0
Area square millimetre mm
2
Capacity litre l
Electric — Current Ampere A
— Resistance ohm
— Tension Volt V
Flow litre per minute l/m
Force Newton N
Length millimetre mm
metre m
kilometre km
Mass kilogram kg
Moment of force Newton metre Nm
Pressure bar bar
Speed kilometre per hour km/h
Temperature degree Celsius °C
Time second s
minute min
hour h
day d
Volume cubic millimetre mm
3
cubic centimetre cm
3
cubic metre m
3
1 - 1
1 - 1
General
9804/1103 Issue 1
CONTENTS
Conversion Factors
Imperial to S.l. Units
To convert imperial units to Sl multiply by the conversion factor.
To convert Sl units to imperial divide by the conversion factor.
Quantity Imperial Metric Conversion Factor
Area in
2
mm
2
645.2
ft
2
m
2
0.0929
yd
2
m
2
0.8361
Capacity pints—UK I 0.5683
pints—US I 0.4731
gallon—UK I 4.5461
gallon—US l 3.785
Flow gal/min—UK l/min 4.5461
gal/min—US I/min 3.785
Force Ibf N 4.45
Length in mm 25.4
mile km 1.6093
Mass Ib kg 0.4536
Moment of force Ibf in Nm 0.112 985
Ibf ft Nm 1.3558
Ibf ft kgf m 0.1383
Pressure Ibf/in
2
bar 0.068 95
Ibf/in
2
kgf/cm
2
0.070 31
Speed ft/s m/s 0.3048
mile/h km/h 1.6093
Volume in
3
cm
3
16.387
yd
3
m
3
0.7646
1 - 2
1 - 2
General
9804/1103
Issue 1
CONTENTS
Conversion Tables - Capacity
UK gallons to US gallons and litres
Select the known capacity from the centre column and read off the required conversion.
US gallon UK gallon Litres UK gallon
1.201 1 0.833 4.546 1 0.219
2.402 2 1.665 9.092 2 0.440
3.603 3 2.498 13.638 3 0.659
4.804 4 3.331 18.184 4 0.879
6.005 5 4.163 22.730 5 1.099
7.206 6 4.996 27.276 6 1.319
8.407 7 5.829 31.822 7 1.539
9.608 8 6.661 36.368 8 1.759
10.809 9 7.494 40.914 9 1.979
12.010 10 8.327 45.461 10 2.199
18.014 15 12.490 68.191 15 3.299
24.019 20 16.653 90.922 20 4.399
30.024 25 20.815 113.652 25 5.499
36.029 30 24.980 136.383 30 6.599
42.033 35 29.143 159.113 35 7.699
48.038 40 33.307 181.844 40 8.799
54.043 45 37.470 204.574 45 9.898
60.047 50 41.634 227.305 50 10.998
66.052 55 45.797 250.035 55 12.098
72.057 60 49.960 272.766 60 13.198
78.062 65 54.124 295.496 65 14.298
84.067 70 58.287 318.227 70 15.398
90.071 75 62.450 340.957 75 16.498
96.076 80 66.614 363.688 80 17.598
102.081 85 70.777 386.418 85 18.697
108.086 90 74.940 409.149 90 19.797
114.090 95 79.104 431.879 95 20.897
120.095 100 83.267 454.610 100 21.997
1 - 3
1 - 3
General
9804/1103 Issue 1
CONTENTS
Conversion Tables - Length
Fractions of an inch to decimals of an inch and millimetres.
Inch Millimetre
1/64 0.015 625 0.396 875
1/32 0.031 250 0.793 750
1/16 0.062 500 1.587 500
1/8 0.125 000 3.175 000
3/16 0.187 500 4.762 500
1/4 0.250 000 6.350 000
5/16 0.312 500 7.937 500
3/8 0.375 000 9.525 000
7/16 0.437 500 11.112 500
1/2 0.500 000 12.700 000
9/16 0.562 500 14.287 500
5/8 0.625 000 15.875 000
11/16 0.687 500 17.462 500
3/4 0.750 000 19.050 000
13/16 0.812 500 20.637 500
7/8 0.875 000 22.225 000
15/16 0.937 500 23.812 500
1 1.000 000 25.400 000
Inches to millimetres and feet to metres
Select the known length from the centre column and read off the required conversion.
Inch Millimetres Feet Metres
0.039 1 25.4 3.281 1 0.3048
0.078 2 50.8 6.562 2 0.6096
0.118 3 76.2 9.843 3 0.9144
0.157 4 101.6 13.124 4 1.2192
0.197 5 127.0 16.405 5 1.5240
0.236 6 152.4 19.686 6 1.8288
0.275 7 177.8 22.967 7 2.1336
0.315 8 203.2 26.248 8 2.4384
0.354 9 228.6 29.529 9 2.7432
0.394 10 254.0 32.810 10 3.0480
0.590 15 381.0 49.215 15 4.5720
0.787 20 508.0 65.620 20 6.0960
0.984 25 635.0 82.025 25 7.6200
1.181 30 762.0 98.430 30 9.1440
1.378 35 889.0 114.835 35 10.668
1.574 40 1016.0 131.240 40 12.192
1.772 45 1143.0 147.645 45 13.716
1.968 50 1270.0 164.050 50 15.240
2.165 55 1397.0 180.455 55 16.764
2.362 60 1524.0 196.860 60 18.288
2.559 65 1651.0 213.265 65 19.812
2.756 70 1778.0 229.670 70 21.336
2.953 75 1905.0 246.075 75 22.860
3.149 80 2032.0 262.480 80 24.384
3.346 85 2159.0 278.885 85 25.908
3.543 90 2286.0 295.290 90 27.432
3.740 95 2413.0 311.695 95 28.956
3.937 100 2540.0 328.100 100 30.480
1 - 4
1 - 4
General
9804/1103
Issue 1
CONTENTS
Conversion Tables - Pressure
Ibf/in
2
to kgf/cm
2
and Bar
Select the known pressure from the centre column and read off the required conversion.
Ibf/in
2
kgf/cm
2
Ibf/in
2
Bar
142.233 10 0.703 145.038 10 0.690
284.466 20 1.406 290.076 20 1.379
426.699 30 2.109 435.114 30 2.069
568.932 40 2.812 580.152 40 2.758
711.165 50 3.516 725.190 50 3.448
853.398 60 4.219 870.228 60 4.137
995.631 70 4.922 1015.266 70 4.827
1137.864 80 5.625 1160.304 80 5.516
1280.097 90 6.328 1305.342 90 6.206
1422.330 100 7.031 1450.380 100 6.895
2844.660 200 14.062 2900.760 200 13.790
4266.990 300 21.093 4351.140 300 20.685
5689.320 400 28.124 5801.520 400 27.580
7111.650 500 35.155 7251.900 500 34.475
8533.980 600 42.186 8702.280 600 41.370
9956.310 700 49.217 10152.660 700 48.265
11378.640 800 56.248 11603.040 800 55.160
12800.970 900 63.279 13053.420 900 62.055
14223.300 1000 70.310 14503.800 1000 68.950
28446.600 2000 140.620 29007.600 2000 137.900
42669.900 3000 210.930 43511.400 3000 206.850
1 - 5
1 - 5
General
9804/1103 Issue 1
CONTENTS
Conversion Tables - Temperature
Select the known temperature from the centre column and read off:
To the right for equivalent in deg F
To the left for equivalent in deg C.
Deg C Deg F Deg C Deg F
- 31.7 - 25 - 13.0 87.8 190 374
- 28.9 - 20 - 4.0 90.6 195 383
- 26.1 - 15 5.0 93.3 200 392
- 23.3 - 10 14.0 96.1 205 401
- 20.6 - 5 23.0 98.9 210 410
- 17.8 0 32.0 101.7 215 419
- 15.0 5 41.0 104.4 220 428
- 12.2 10 50.0 107.2 225 437
- 9.4 15 59.0 110.0 230 446
- 6.7 20 68.0 112.8 235 455
- 3.9 25 77.0 115.6 240 464
- 1.1 30 85.0 118.3 245 473
1.7 35 95.0 121.1 250 482
4.4 40 104.0 123.9 255 491
7.2 45 113.0 126.7 260 500
10.0 50 122.0 129.4 265 509
12.8 55 131.0 132.2 270 518
15.6 60 140.0 135.0 275 527
18.3 65 149.0 137.8 280 536
21.1 70 158.0 140.6 285 545
23.9 75 167.0 143.3 290 554
26.7 80 176.0 146.1 295 563
29.4 85 185.0 148.9 300 572
32.2 90 194.0
35.0 95 203.0
37.8 100 212.0
40.6 105 221.0
43.3 110 230.0
46.1 115 239.0
48.9 120 248.0
51.7 125 257.0
54.4 130 266.0
57.2 135 275.0
60.0 140 284.0
62.8 145 293.0
65.6 150 302.0
68.3 155 311.0
71.1 160 320.0
73.9 165 329.0
76.7 170 338.0
79.4 175 347.0
82.2 180 356.0
85.0 185 365.0
1 - 6
1 - 6
General
9804/1103
Issue 1
CONTENTS
Hydraulic Formulae
Pump flow (litres/min) = Displacement (cm
3
/rev) x Speed (rev/min)
1000
Pump flow (UK gal/min) = Displacement (in
3
/rev) x Speed (rev/min)
277.4
Power output of Hydraulic Pump (kw) = Flow (litres/min) x Pressure (bar)
600
Power output of Hydraulic Pump (hp) = Flow (UK gal/min) x Pressure (Ibf/in
2
)
1430
Power output of Hydraulic Motor (kw) = Torque (Nm) x Speed (rev/min)
9550
Power output of Hydraulic Motor (hp) = Torque (Ibf ft) x Speed (rev/min)
5250
Cylinder Thrust (kgf) = pressure (bar) x piston area (mm
2
)
98
Cylinder Thrust (Ibf) = pressure (Ibf/in
2
) x piston area (in
2
)
1 - 7
1 - 7
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1992-2003 JCB (All Models) Service & Repair Manual
Models covered:
- Backhoe Loaders
- Loadalls
- RTFL
- Excavators
- Wheeled Loaders
- Fastrac
- Skidsteer Range
- Teletruck
- Articulated Dump Trucks
- 2CX
- All Models
- 926
- JS 70, 110, 130, 130W, 145W, 150, 150W, 160, 160W, 175W, 180, 200, 200W, 210, 220, 240, 260, 300
- ROBOT 185
- 714
- 2DX
- 930
- JS 110
- 210S
- 940
- JS 130
- 212S
- JS 130W
- & Variants
- JS 145W
- ROBOT 170
- 3CX (200 Series)
- JS 150
- ROBOT 150
- 4CX (200 Series)
- JS 150W
- ROBOT 165
- JS 160
- 1CX (208S)
- JS 160W
- JS 175W
- JS 180
- JS 200
- JS 200W
- JS 210
- JS 220
- JS 240
- JS 260
- JS 300,
- 330
- 450LC
- 460
Unlock the power to maintain, repair, and optimize your JCB machinery with our comprehensive service and repair manual. Designed specifically for JCB models spanning the years 1992 to 2003, this manual is the ultimate companion for both professional technicians and passionate JCB owners.
Key Features:
- Unparalleled Coverage: Our manual covers all JCB models produced between 1992 and 2003, ensuring that you have access to the information you need for any JCB machine from this era.
- OEM Precision: This manual is an original equipment manufacturer (OEM) publication, meaning it is produced directly by JCB, guaranteeing accuracy and reliability.
- Comprehensive Specifications: Every JCB model comes with its unique specifications, and our manual provides detailed information on engine specifications, electrical systems, hydraulics, transmission, chassis, and much more.
- Step-by-Step Procedures: Our manual offers step-by-step procedures, accompanied by detailed diagrams and illustrations, to guide you through every task.
- Troubleshooting and Diagnostics: When issues arise, our manual becomes your troubleshooting companion.
- Time and Money Saver: By having this comprehensive manual at your disposal, you can reduce downtime and avoid expensive visits to service centers.
- Easy to Use: We've designed our manual with user-friendliness in mind. Its organized structure and clear instructions make it accessible to professionals and enthusiasts alike.
Invest in the Ultimate 1992-2003 JCB (All Models) Service & Repair Manual today, and elevate your JCB machinery maintenance to a whole new level. Empower yourself with the knowledge and guidance necessary to keep your JCB equipment running smoothly, efficiently, and reliably for years to come.
Printable: Yes
Language: English
Compatibility: Pretty much any electronic device, incl. PC & Mac computers, Android and Apple smartphones & tablet, etc.
Requirements: Adobe Reader (free)
