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JCB Beaver II Hydraulic power pack.

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Allthough unintentional, Ive now acquired a number of old power packs, so rather than the thread get mixed up I felt it is more appropriate to do a separate topic for each one. This is my Beaver II power pack that I collected yesterday morning. Basically the problem with the Beaver 1 was that the frame was just not up to the job, so after only 2 years in production in 1988 a much more substantial version was introduced.  Having said that this one has suffered quite a bit in the frame department, with a few kinks and the axle is missing altogether. Also someone has dismantled the hydraulic side and lost some of the parts. I plan on getting at least 3 of my packs frames sorted so I can spray them all together.

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Today is the first day in a few weeks that ive felt well enough to carry on with this project. Ive stripped the engine down and got as far as the head,now ive got to find out my special spanner that I adapted years ago to enable the head to be removed without taking the exhaust off because the nuts are blocked in by the oil tank/fan housing on most power packs.

Somebody has already moved the fan along the crank and because it has been exposed to the elements for so long its again fused itself together. For some reason this fan doesn't have any threaded holes(as every other one ive seen does) to attach the puller to so may be intresting to get it to move again!

Now the engine is out of its frame I can see just how much work there is going to be returning this machine to factory. The axle support hole has gone on the one side, theres also some bad bends in the chasis  that will take quite a bit of straightening. Plus the engine support bar has been crudely beefed up with some angle iron, even on the latest models this part is very prone to distorting.

Ive sourced a piece of 20mm bar and a new set of 5" wheels to sort the axle out, and ive also turned up a couple more manuals for my collection.

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Look's like you have a few challenges with that Frame Gareth. A good project. I know nothing about Hydro Units, so I'll follow this and try to learn some.  

 

Always good to be able to obtain Manuals to go with these projects. It makes the restored subject more complete.

 

I know it's a bit of a nuisance when you want to get on with something and your health won't let you, but just chip away at it, a little at a time.   

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Today I got the head off, the engine looks in pretty good condition internally, just quite a bit of carbon. The valves have been reground and ive now decoked it. Also the exhaust studs have been soaked in freeing oil in the hope I can remove them intact.

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Look's like you have a few challenges with that Frame Gareth. A good project. I know nothing about Hydro Units, so I'll follow this and try to learn some.

Always good to be able to obtain Manuals to go with these projects. It makes the restored subject more complete.

I know it's a bit of a nuisance when you want to get on with something and your health won't let you, but just chip away at it, a little at a time.

Thanks Richard, there's nothing particuarly complicated about hydraulics, but they can just get very expensive. The hammers will be a learning curve for me too as allthougth I repair breakers mounted on excavators daily, I've never done a hand held one yet.

The health issues are getting me down, however things can only get better. For the frame I've got a couple of thoughts using the press and some tube along with a blow lamp.

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Wow, those manifold bolts are fused like Pompeii resident

I've moved worse, I'm hoping after some soaking a blast with the impact gun will shift them.

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As I'm still searching for a engine for the solite I thought id make some progress with the beaver II. This morning Ive got the engine almost ready to trial run, the only major component that ive changed so far is the fuel tank (on ebay they are only 20 quid brand new so not even worth straightening and repainting), the rest of the engine is just cleaned up and repainted. The fan came off with a bit of persuasion by heat and is now refitted in the correct position. Just got to sort a key out for it and I can give the unit a run up. Ive also received in the post today some genuine Honda decals for the choke and throttle lever.

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Well, for once all the rust was a blessing, it meant all the paint stripped off the chasis fairly easily. I just hope the top frame is as quick to do.

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Due to the frame being so battered on this machine, I had put it on the back burner whilst I looked out for a

replacement chasis, however non have turned up within my budget so today Ive started on getting it back into

shape. (Sod's law says one probably turns up for a fiver the day I paint this one). I used a press, vice and

blow lamp to get it some where near, and have now started filling in the dents in the tube. I also today

sprayed up a couple of wheels in yellow as I couldn't find any new ones the right size anywhere except in black.

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Today I made up a replacement axle. I put a piece of solid 20mm bar (the originals were hollow tube that nearly

allways bends) in the lathe and drill and tapped 2x 8mm holes. Then I welded 2 washers in place. Now just needs

another coat of paint to finish.

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Finally have got the frame some where near straight. Just got to wait for the next dryish day to paint it.

(May be waiting quite sometime) Also today Ive overhauled the rear foot for this machine and the compact.

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Managed to get a quick break in the rain and got the chasis sprayed up, literaly 5 mins

after I put it inside it started to pee down. Will it ever stop? Had a bit of luck on ebay, managed

to obtain 4 obsolete filters for six quid each. Ideal for this, the compact and the beaver 1, so all

My machines will have new oil filters.

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Yesterday I masked up the engine so I could spray up the hydraulic tank. The load lever

has a little ball on the end that nearly allways get knocked off, when I checked with JCB

they wanted a stupid amount for a new one, however I spotted one on ebay for a fiver

that was identical apart being tapped to M8, so I simply drilled it out to 1/2" and bonded

it in place.

All I need to do now is to sort out the engine support bar then build up the hydraulics

which Ive got most of the missing parts on a scrap machine to help keep the costs down.

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Today Ive pressed on with the laborious task of the top frame. Due to the chasis badly bending, this

allowed the hydraulic tank assembly to drop down (common problem even on the latest beavers)

and the couplings rest on the rear panel. This has led to bad distortion. This was beat somewhere

near back into shape, rebuilt up with weld and ground, then given a skim of filler along with a couple

of dents in the frame. After the bank holiday I will finish rubbing it down (may take a while to get all

the nylon coating off), then paint it.

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Been sorting out the oil cooler and guard today. Also dug out my doner machine for the pump which was

cleaned up, just got to get the drive cog off along with the key.

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