JCB 2D, 2DS, 3, 3C, 3CS, 3D & 700 Excavator Loader Workshop Manual (1970–1982)

JCB workshop manual for the 1970–1982 2D, 2DS, 3, 3C, 3CS, 3D and 700 excavator loaders, covering the MK 2 and MK 3 range with manual-gearbox and torque-converter configurations.

PDF Search, Diagram Detail and Page Count

Search and drawing detail: The manual pages do not support PDF text search, and there are no embedded PDF bookmarks. Small wiring identifiers require zooming; some fine circuit lines remain faint at higher magnification.

One printable English PDF with 472 pages, including the cover and section guide (2 pages), 56 blank pages, and one final non-content page.

Drivetrain, Hydraulic and Electrical Workshop Coverage

The following selected coverage highlights are not a complete contents list. Further topics include cab glazing and instrument-cluster service.

• Maintenance and engine removal: Service schedules, lubrication charts, fuel-system bleeding, and separate engine-removal procedures for manual-clutch and torque-converter machines.

• Transmission repair: Manual and synchromesh gearbox procedures, /3 converter clutch service, and /5 shuttle forward-clutch and drive-gear assembly.

• Hydraulics: Plessey and Hamworthy gear-pump inspection, loader and excavator valve overhaul, relief-valve testing, and hydraulic-cylinder seal replacement.

• Steering and front axle: Plessey and Danfoss Orbitrol steering-unit service, internal-leakage tests, steering-cylinder repair, and front-axle bearing work.

• Brakes: Mechanical and hydraulic brake procedures, dry and oil-immersed brake assemblies, master and slave cylinders, and circuit bleeding.

• Electrical diagnosis: Starting, charging and lighting fault finding, Lucas M50 starter service, alternator tests, and market-specific wiring diagrams.

Published mainly for JCB distributor service engineers, this manual is suited to workshop use with lifting equipment, pressure-test instruments and the specified service tools.

Engine Removal and Fuel-System Scope

Step-by-step instructions cover Simms Minimec and CAV D.P.A. fuel-system bleeding, with separate illustrations for the earlier and later rotary-pump arrangements. Fuel-filter, sedimenter, lift-pump and cooling-system maintenance are also included.

Internal engine work: The engine section covers removal and installation. Engine dismantling, internal overhaul and injector testing are referred to a separate Leyland 38TD and 4/98 NT engine service manual, which is not included in this PDF. The CAV D.P.A. material is not a complete injection-pump overhaul section.

Gearboxes, Converter Clutches and Drive Axles

The transmission material explains conventional and synchromesh gearboxes, including shaft removal, selector assemblies, bearing preload and end-float checks. Synchromesh operation diagrams accompany fault-finding charts for noise, difficult selection and gears jumping out.

Powertrain coverage: The /5 material includes shuttle forward-clutch and drive-gear assembly, gearbox fault finding, and drive-axle setup. Axle pages address pinion depth, bearing preload, crownwheel backlash and metallic face seals.

The lubrication pages distinguish /3 and /5 converter oil-level checks. The manual also warns that forcing the converter shaft into the gearbox can damage gearbox bearings.

Hydraulic Testing and Steering Diagnosis

Viewing hydraulic schematics, lubrication charts and component section views alongside the machine supports hose identification and reassembly planning. The “Circuit Diagram JCB 2D, 3 and 3C” and “Circuit Diagram JCB 3D” distinguish Hamworthy shovel circuits from optional Cessna arrangements.

Pump inspection pages give gear, housing and wear-plate limits, with bearing-tool references such as BT2464 and 892/00065. Steering tests distinguish pump and relief-valve faults from internal leakage in the control unit or steering cylinder.

General UNF Grade S and Metric 8.8 torque charts accompany component-specific tightening settings.

Brake Variants and Electrical Fault Finding

Brake-fluid compatibility: Dry-brake and oil-immersed Powertrain systems have different fluid requirements. The manual warns that incorrect fluid can seriously damage the hydraulic brake components.

Electrical material includes charging-circuit checks, Lucas 18ACR and AC Delco DN460 alternator testing, and dynamo/control-box service. Standard and American wiring diagrams are supplemented by Austrian, German and Swedish circuits, with component keys and wire-color codes.

Attachments, Boom and Dipper Service

Hamworthy and Commercial double-pump procedures support the attachment sections. These cover Roadbreaker flow dividers and fault finding, hydraulic power take-off motor and gearbox service, extending-dipper removal, and Powerbreaker servicing and nitrogen charging.

Body and framework pages include slew-actuator overhaul, boom and dipper removal, and kingpost/carriage work. The Roadbreaker handle contains a nitrogen accumulator requiring specialized charging equipment.

Always follow the documented safety precautions and ensure hydraulic pressure is fully relieved before opening hydraulic connections.

Cooling-System and 3D Hydraulic Capacity Preview

The technical data tables list a cooling-system capacity of 13.6 liters.

For the 3D, hydraulic-system capacity is 205 liters. The capacity table separates the other model configurations rather than applying one hydraulic fill quantity across the range.