30 - 2
Removal and Replacement
!!
WARNING
Before working on the brake system make sure the
machine is on level ground and chock all four wheels.
BRAK 1-4
Removal
1 Gain access the the brake pedal box assembly.
Remove the steering wheel, column switches and
console assembly. See Section D, Steering Column -
Removal for procedures.
2 Working inside the cab, remove the actuating rod clevis
pin A at the top of each brake pedal.
3 Working outside the cab, loosen and remove brake
pipe unions B, plug and cap to prevent loss of fluid and
ingress of dirt.
4 Remove the brake pipes from the master cylinders:
Master cylinders bridging pipe C, axle feed pipes E and
reservoir supply pipes F.
6 Loosen and remove the two master cylinder retaining
bolts G (both units).
7 Tag the cylinders (left and right hand). Remove the
master cylinders.
Replacement
Before replacing the cylinders check the adjustment of the
brake pedals as follows:
1 Unlatch the pedals H and check to see if they are
aligned. Both pedals should be at the same height. If
they are not, undo lock nut J and turn the stop bolt K to
correctly align. Tighten the lock nut J.
Do not remove or adjust the actuating rod clevis L. If the
clevis is to be removed (for fitting to a replacement cylinder
for example), measure the position of the pin location hole
relative to the cylinder body as shown at X. Refit the clevis in
the same position.
Replacement is a reversal of the removal sequence, but note
the following;
Refit the cylinders in their original positions.
When reconnecting the cylinder actuating rods at the brake
pedals, ensure that the clevis pins A align without moving
the rods P or brake pedals. If necessary loosen the clevis
lock nut N and turn the rod P until the clevis pin aligns with
the brake pedal. Tighten the lock nut N.
!!
WARNING
Use of incorrect fluid will cause serious damage to the
seals which could in turn cause brake failure.
BRAK 1-1
2 Fill the brake system with JCB Light Hydraulic Fluid and
bleed the system. Refer to Service Brakes - Bleeding.
3 On completion bleed the brake system and check the
brakes operate correctly. Refer to Service Brakes -
Bleeding.
4 Latch pedals and check for straight line braking; if
satisfactory straight line braking cannot be achieved
refer to Fault Finding.
Torque Settings
Item Nm kgf m lbf ft
F 30-34 3.0-3.5 22-25
Section G Brakes
9803/7130
Section G
30 - 2
Issue 1
Compensating Master Cylinder
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