jcb 1CX, Service Manual

Page: 192 / 242

Section E Hydraulics
9803/8550
Section E
Rams
Fit new wear rings J (2) and K (4). Rotate the wear rings so
that the piston retention dowel is covered by the wear ring,
NOT as shown at L.
DRILLING DETAILS FOR PISTON HEAD RETENTION
(all dimensions in mm)
Ram Dowel Guide Guide Dowel Dowel
Size Size Drill Ø Drill Drill Ø X Drill
Depth Depth Y
50 x 25 20 x 6Ø 4 19 6.1/6.02 23/22
60 x 30 20 x 6Ø 4 19 6.1/6.02 23/22
70 x 40 20 x 6Ø 4 19 6.1/6.02 23/22
80 x 50 20 x 6Ø 4 19 6.1/6.02 23/22
22 - 3
Assembling (cont'd)
Sleeve E must be used to protect the rod seals from damage
when fitting end cap 1 onto the piston rod 7. There are
various sizes of sleeve (see Service Tools, Section 1). Make
sure the hexagon on the end cap is towards the eye end of
the rod.
Apply JCB Activator to the threads of the piston head 6.
Allow to dry for 15 minutes before bringing into contact with
JCB Threadlocker.
Note: Neither Threadlocker nor Activator must be allowed to
contact seals, bearing rings or 'O' rings.
Apply JCB Threadlocker & Sealer (High Strength) to all
threads of the piston rod. Fit and torque-tighten the piston
head.
Fit the locking dowel 5 to the piston head/rod as follows:
1 New rod and piston head.
If both are required, the following procedure should be
followed:
a Drill through the piston head into the piston rod,
shown at Z. Use an undersized diameter drill first as
a guide and then drill using the correct size diameter
drill to suit: refer to the table for drill diameters and
depths.
b Remove all swarf and contamination. Insert dowel 5
into the drilled hole, making sure that the tapped
extractor hole is to the outside.
2 New piston head fitted to a pre-drilled piston rod.
a Redrill and dowel BOTH the piston head and piston
rod at 90° from the existing drilled dowel hole in the
piston rod. Follow the procedure described in step 1.
3 New piston rod fitted to a pre-drilled piston head.
Use the pre-drilled hole in the piston head. Care must be
taken not to elongate the existing hole in the piston head.
a Use a drill of 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),
making sure that the drill has centred correctly on the
'centre mark' made in step 3a.
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
5 into the drilled hole, making sure that the tapped
extractor hole is to the outside.
22 - 3
Issue 3
A187361
E
338490
L
K
J
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