Copyright 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
World Class
Customer Support
9803/3760-07
Publication No.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Service Manual
Side Engine Loadalls
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
Section M - Electronic Data Systems
Section 0 - Service Manual
0-0
0-0
9803/3760-07
Notes:
Copyright 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
World Class
Customer Support
9803/3760-06
Publication No.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section 1
General Information
Service Manual - Side Engine Loadalls
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
Section M - Electronic Data Systems
Section 1 - General Information
1-0
1-0
9803/3760-06
Notes:
Page No.
Contents
Section 1 - General Information
1-i
1-i
Applications
Introduction ............................................................................................. 1-1-1
Tables ..................................................................................................... 1-1-2
Use
Introduction ............................................................................................. 1-2-1
Scope ..................................................................................................... 1-2-2
Format .................................................................................................... 1-2-3
Left and Right Sides ............................................................................... 1-2-4
Hydraulic Schematic Codes ................................................................... 1-2-5
Electrical Device Codes .......................................................................... 1-2-6
Machine Identification
Introduction ............................................................................................. 1-3-1
Related Topics ........................................................................................ 1-3-2
Machine Identification Plate .................................................................... 1-3-3
Component Identification Plates ............................................................. 1-3-6
Torque Settings
Introduction ............................................................................................. 1-4-1
Zinc Plated Fasteners and Dacromet Fasteners .................................... 1-4-2
Hydraulic Connections ............................................................................ 1-4-6
`Positional Type' Hydraulic Adaptors .................................................... 1-4-10
Service Tools
Introduction ............................................................................................. 1-5-1
Numerical List ......................................................................................... 1-5-2
Tool Detail Reference ............................................................................. 1-5-5
Rivet Nuts ............................................................................................. 1-5-24
Slide Hammer Kit .................................................................................. 1-5-26
Service Consumables
Introduction ............................................................................................. 1-6-1
Sealing and Retaining Compounds ........................................................ 1-6-2
Fuel
Introduction ............................................................................................. 1-7-1
Related Topics ........................................................................................ 1-7-2
Acceptable and Unacceptable Fuels ...................................................... 1-7-3
Stall Speed Combinations
Introduction ............................................................................................. 1-8-1
Related Topics ........................................................................................ 1-8-2
Specifications ......................................................................................... 1-8-3
Page No.
Contents
Section 1 - General Information
1-ii
1-ii
Section 1-1 - General Information
Applications
Introduction
1-1-1
1-1-1
9803/3760-06 (1-14-02)
Applications
Introduction
This manual contains topics that relate to JCB Loadall
machines in the 5A and 5T groups. There are several machine
model codes in the family.
Machine Group
Model Code
Model Name
5A
A
531-70
5A
B
535-95
5A
C
536-60
5A
D
541-70
5A
H
533-105
5A
R
536-70
5A
S
526-56
5T
A
531-T70
5T
B
541-T70
5T
C
536-T60
5T
D
535-T95
5T
E
536-T70
Machine variants: There are different machine variants within the same model name. This happens because of market
requirements, or when the machine specification changes after a period of time. Where applicable information is given to
help identify which machine variant is applicable for the given specifications and procedures.
For machines with LLMC built after October 2010 refer to the service manual 9813/0900.
Use the applications tables to see which topics relate to which machine models and variants. Where no variant information
is given the topic is applicable to all machine models indicated on the table.
Important: The machine model names are NOT referred to in the topics. You must refer to the applications tables for the
applicable machine model. Table entries shaded grey indicate a topic not included in this issue of the manual.
K Tables ( T 1-1-2)
K Section 1 - General Information ( T 1-1-2)
K Section 2 - Care and Safety ( T 1-1-2)
K Section 3 - Routine Maintenance ( T 1-1-3)
K Section B - Body and Framework ( T 1-1-4)
K Section C - Electrics ( T 1-1-5)
K Section E - Hydraulics ( T 1-1-6)
K Section F - Transmission ( T 1-1-9)
K Section G - Brakes ( T 1-1-11)
K Section H - Steering ( T 1-1-12)
K Section K - Engine ( T 1-1-13)
K Section M - Electronic Data Systems ( T 1-1-14)
Section 1-1 - General Information
Applications
Tables
1-1-2
1-1-2
9803/3760-06 (1-14-02)
TablesSection 1 - General InformationSection 2 - Care and SafetyMachine modelsTopic RefTitleVariant531-70, 531-T70535-95, 535-T95536-60, 536-T60541-70, 541-T70533-105536-70, 536-T70526-561-2UseAll Machines1-3Machine IdentificationAll Machines1-4Torque SettingsAll Machines1-5Service ToolsAll Machines1-6Service ConsumablesAll Machines1-7FuelAll Machines1-8Stall Speed CombinationsAll MachinesMachine modelsTopic RefTitleVariant531-70, 531-T70535-95, 535-T95536-60, 536-T60541-70, 541-T70533-105536-70, 536-T70526-562-1Safety NoticesAll Machines2-2General ProceduresAll Machines
Section 1-1 - General Information
Applications
Tables
1-1-3
1-1-3
9803/3760-06 (1-14-02)
Section 3 - Routine MaintenanceMachine modelsTopic RefTitleVariant531-70, 531-T70535-95, 535-T95536-60, 536-T60541-70, 541-T70533-105536-70, 536-T70526-563-1IntroductionAll Machines3-2Service Schedules - Machines with SD and SF EnginesMechanical F.I. engineszzzzzzz3-3Service Schedules - Machines with SE EnginesElectronic F.I. engineszzzzz3-4Fluids, Lubricants and CapacitiesAll Machines3-5Cleaning the MachinesAll Machines3-6InspectionAll Machines3-7Seat BeltsAll Machines3-8ROPS/FOPS (and OECD) StructureAll Machines3-9GreasingAll Machines3-10Heater and Air ConditioningAll Machines3-11BrakesAll Machines3-12Electrical SystemAll Machines3-13EngineAll Machines3-14Engine Air FIlterAll Machines3-15Fuel SystemAll Machines3-16Hydraulic SystemAll Machines3-17TransmissionAll Machines3-18Tyres and WheelsAll Machines3-19Wear PadsAll Machines3-20Windscreen WasherAll Machines3-21Access PanelsAll Machines3-22Fire Extinguisher All Machines
Section 1-1 - General Information
Applications
Tables
1-1-4
1-1-4
9803/3760-06 (1-14-02)
Section B - Body and Framework Machine modelsTopic RefTitleVariant531-70, 531-T70535-95, 535-T95536-60, 536-T60541-70, 541-T70533-105536-70, 536-T70526-56B1Fork CarriagezzzzzzzB2Cab Heating and Ventilation SYSTEMzzzzzzzB3Cab Air Conditioning SYSTEMzzzzzzzB4Load Moment Indicator (LMI) SYSTEMzzzzzzzB5Longitidinal Load Moment SYSTEMAgri, Agri Plus, Agri Super November 2009 to October 2010zzzzzB6CabzzzzzzzB7Air Conditioning Condenser - Cooling Pack Mounted Machines with non intercooled enginesB8Air Conditioning Condenser - Cab Roof Mounted Machines with intercooled enginesB9Cab HV and HVAC UnitzzzzzzzB10Air Conditioning Binary SwitchzzzzzzzB11Heater ValvezzzzzzzB12Fuel TankzzzzzzzB13Chassis PanelszzzzzzzB14BoomzzzzzzzB15Hydraulic TankzB16Load Moment Indicator Axle TransducerzzzzzzzElectric InclinometersAgri, Agri Plus, Agri Super November 2009 to October 2010zzzzzB17StabiliserszB18Longitudinal Load Moment Indicator UnitAgri, Agri Plus, Agri Super November 2009 to October 2010zzzzz
Section 1-1 - General Information
Applications
Tables
1-1-5
1-1-5
9803/3760-06 (1-14-02)
Section C - ElectricsMachine modelsTopic RefTitleVariant531-70, 531-T70535-95, 535-T95536-60, 536-T60541-70, 541-T70533-105536-70, 536-T70526-56C1Fuses and RelayszzzzzzzC2SchematicszzzzzzzC3Electrical Harness SYSTEMzzzzzzzC4Battery Charging SYSTEMzzzzzzzC5AlternatorzzzzzzzC6BatteryzzzzzzzC7Machine Control ECU (S1)SLC machines without LLMC, LLMC machines up to October 2010(1)zC8Machine Control ECU (S2)Agri, Agri Plus, Agri Super Nov 2009 to October 2010(1)(1)For details of LLMC machines from October 2010 refer to the Service Manual 9813/0900zzzzz
Section 1-1 - General Information
Applications
Tables
1-1-6
1-1-6
9803/3760-06 (1-14-02)
Section E - HydraulicsMachine modelsTopic RefTitleVariant531-70, 531-T70535-95, 535-T95536-60, 536-T60541-70, 541-T70533-105536-70, 536-T70526-56E1Systems and SchematicszzzzzzzE2Parallel Hydraulic SYSTEMNon LLMC machines, LLMC machines up to October 2010(1)zzzzzzE3LSP Gearpump Hydraulic SYSTEMUp to November 2009zzzzzE4LSP Variflow Hydraulic SYSTEM Up to November 2009zzzzzE5LSP Electro Servo SYSTEM (S1)Agri XtrazzzE6LSP Electro Servo SYSTEM (S2)Agri, Agri Plus, Agri Super November 2009 to October 2010(1)zzzzzE7Servo Parallel Hydraulic SYSTEMSLC machines up to October 2010(1)zE8Smooth Ride SYSTEM (SRS) - ParallelzzzzzzE9Smooth Ride SYSTEM (SRS) LSPUp to November 2009zzzzzE10Smooth Ride SYSTEM (SRS) Electro Servo (S1)Agri XtrazzzzE11Smooth Ride SYSTEM (SRS) Electro Servo (S2)Agri, Agri Plus, Agri Super November 2009 to October 2010(1)zzzzzE12Smooth Ride SYSTEM (SRS)Servo ParallelSLC machines up to October 2010(1)zE13Parallel Control Valve 4 SectionNon LLMC machines, LLMC machines up to October 2010(1)zzzzzE14Parallel Control Valve 6 SectionNon LLMC machines, LLMC machines up to October 2010(1)zE15Flowshare (LSP) Control ValvezzzzzE16LSP Electro Servo Control Valve (S1)Agri Xtrazzzz
Section 1-1 - General Information
Applications
Tables
1-1-7
1-1-7
9803/3760-06 (1-14-02)
LSP Electro Servo Control Valve (S2)Agri, Agri Plus, Agri Super November 2009 to October 2010(1)zzzzzE17Servo Parallel Control ValveSLC machines up to October 2010(1)zE18Inloader ValveGearpump SystemszzzzzE19Servo Pilot ValveLSP Hydraulic Systems - Up to November 2009zzzzzE20Servo Pilot Pressure Supply Valve (S1)Agri Xtra up to October 2010(1)zzzzE21Servo Pilot Pressure Supply Valve (S2)Agri, Agri Plus, Agri Super November 2009 to October 2010(1)zzzzzE22Pilot Manifold BlockSLC machines up to October 2010(1)zE23Main Pump - Variflow zzzzzE24Main Pump - Gearpump 80 l/min Double Pumpzzzzzz80 l/min Triple Pumpzzzzz110 l/minzzzz125 l/minzE25Cooling Fan MotorzzzzzzzE26Control Lever - Electro Servo (S1)Agri XtrazzzzE27Control Lever - Electro Servo (S2)Agri, Agri Plus, Agri Super November 2009 to October 2010(1)zzzzzE28Control Lever - Servo ParallelSLCzE29Extension RamzzzzzzzE30Lift RamszzzzzzzE31Tilt RamzzzzzzzMachine modelsTopic RefTitleVariant531-70, 531-T70535-95, 535-T95536-60, 536-T60541-70, 541-T70533-105536-70, 536-T70526-56
Section 1-1 - General Information
Applications
Tables
1-1-8
1-1-8
9803/3760-06 (1-14-02)
E32Displacement RamzzzzzzzE33Sway RamzzzzE34Stabiliser RamszE35Ram MaintenancezzzzzzzE36Sway/Fan Changeover Valvezzzz(1)For details of LLMC machines from October 2010 refer to the Service Manual 9813/0900Machine modelsTopic RefTitleVariant531-70, 531-T70535-95, 535-T95536-60, 536-T60541-70, 541-T70533-105536-70, 536-T70526-56
Section 1-1 - General Information
Applications
Tables
1-1-9
1-1-9
9803/3760-06 (1-14-02)
Section F - TransmissionMachine modelsTopic RefTitleVariant531-70, 531-T70535-95, 535-T95536-60, 536-T60541-70, 541-T70533-105536-70, 536-T70526-56F1ConfigurationzzzzzzzF2Wheels and TyreszzzzzzzF3Front AxleszzzzzzzF4Rear AxleszzzzzzzF5PS750 Gearbox SYSTEMzzzzzzzF6PS750 Mk IV Gearbox SYSTEMzzzzzzzF7PS764 Gearbox SYSTEMzzzzzF8PS766 Gearbox SYSTEM (ECU 2.3)zzzzzF9SS700 Gearbox SYSTEMzF10Lock Up Torque Converter SYSTEMPS766 SystemzzzzzF11Dual Control SYSTEM (S1)LSP Hydraulic System - Up to November 2009zzzzzF12Dual Control SYSTEM (S2)Agri, Agri Plus, Agri Super November 2009 to October 2010(1)zzzzzF13Dual Control SYSTEM (S3)SLCzF14Shiftmaster ECUzzzzzF15PS750 GearboxzzzzzzzF16PS750 Mk IV GearboxzzzzzzzF17PS760 GearboxzzzzzF18SS700 GearboxzF19Bevel GearboxzzzzzzzF20Torque ConverterzzzzzzzF21Transmission Oil Cooler - Liquid to LiquidMachine with non intercooled engines
Section 1-1 - General Information
Applications
Tables
1-1-10
1-1-10
9803/3760-06 (1-14-02)
F22Transmission Oil Cooler - Air BlastMachines with intercooled enginesF23PropshaftszzzzzzzF24Transmission Speed SensorzzzzzF25Engine Speed SensorzzzzzF26SpeedometerzzzzzzzF27SS700 Cable Shiftz(1)For details of LLMC machines from October 2010 refer to the Service Manual 9813/0900Machine modelsTopic RefTitleVariant531-70, 531-T70535-95, 535-T95536-60, 536-T60541-70, 541-T70533-105536-70, 536-T70526-56
Section 1-1 - General Information
Applications
Tables
1-1-11
1-1-11
9803/3760-06 (1-14-02)
Section G - BrakesMachine modelsTopic RefTitleVariant531-70, 531-T70535-95, 535-T95536-60, 536-T60541-70, 541-T70533-105536-70, 536-T70526-56G1Single Axle Service Brakes SYSTEMzzzzzzzG2External Park Brake SYSTEMPS750 and SS700 Gearbox SystemzzzzzzzG3Internal Park Brake SYSTEMPS760 Gearbox SystemszzzzzG4Park Brake CalliperPS750 and SS700 Gearbox SystemzzzzzzzG5Park Brake DiscPS750 and SS700 Gearbox SystemzzzzzzzG6Park Brake SwitchzzzzzzzG7Servo Exhauster UnitzzzzzzzG8Servo Unit - Single Axle BrakeszzzzzzzG9Master CylinderzzzzzzzG10Fluid Reservoirzzzzzzz
Section 1-1 - General Information
Applications
Tables
1-1-12
1-1-12
9803/3760-06 (1-14-02)
Section H - SteeringMachine modelsTopic RefTitleVariant531-70, 531-T70535-95, 535-T95536-60, 536-T60541-70, 541-T70533-105536-70, 536-T70526-56H1Steering SYSTEMzzzzzzzH2Manual Steer Mode SYSTEMzzzzzzzH3Auto Steer Mode SYSTEMzzzzzzzH4Hydraulic Steering UnitzzzzzzzH5Priority ValvezzzzzzzH6Power Track RodzzzzzzzH7Steering ColumnzzzzzzzH8Manual Steer Mode ValvezzzzzzzH9Auto Steer Mode Valvezzzzzzz
Section 1-1 - General Information
Applications
Tables
1-1-13
1-1-13
9803/3760-06 (1-14-02)
Section K - EngineMachine modelsTopic RefTitleVariant531-70, 531-T70535-95, 535-T95536-60, 536-T60541-70, 541-T70533-105536-70, 536-T70526-56K1Stop and Start SYSTEM (Mechanical F.I. Engines)zzzzzzzK2Stop and Start SYSTEM (Electronic F.I. Engines)zzzzzK3Cold Start Heater SYSTEMMechanical F.I. engineszzzzzzzK4Starter MotorzzzzzzzK5Cooling Pack - Non IntercooledzzzzzzK6Cooling Pack - Intercooled (Mechanical F.I. Engines)zzzzzzzK7Cooling Pack - Intercooled (Electronic F.I. Engines)zzzzzK8Coolant Expansion TankzzzzzzzK9Air Filter Vacuum SwitchzzzzzzzK10Throttle Pedal and CableMechanical F.I. engineszzzzzzzK11Throttle Position Sensor (TPS)Electronic F.I. engineszzzzzK12Exhaust SilencerzzzzzzzK13JCB Dieselmax Engine (Mechanical F.I.)zzzzzzzK14JCB Dieselmax Engine (Electronic F.I.)zzzzz
Section 1-1 - General Information
Applications
Tables
1-1-14
1-1-14
9803/3760-06 (1-14-02)
Section M - Electronic Data SystemsMachine modelsTopic RefTitleVariant531-70, 531-T70535-95, 535-T95536-60, 536-T60541-70, 541-T70533-105536-70, 536-T70526-56M1CANbus SYSTEMzzzzzzzM2Loadall Monitoring SYSTEMzzzzzzzM3Fault Code SYSTEMzzzzzzzM4Servicemaster SYSTEMzzzzzzzM5Servicemaster ToolszzzzzzzM6Electronic Control Unit TheoryzzzzzM7Pulse Width Modulation Theoryzzzzz
Section 1-2 - General Information
1-2-1
1-2-1
9803/3760-06 (1-01-00)
Use
Introduction
This topic contains information about the structure of the manual and how to use the manual.
K Scope ( T 1-2-2)
K Personnel ( T 1-2-2)
K Applications ( T 1-2-2)
K Newest Data ( T 1-2-2)
K Format ( T 1-2-3)
K Left and Right Sides ( T 1-2-4)
K Hydraulic Schematic Codes ( T 1-2-5)
K Colour Codes ( T 1-2-5)
K Electrical Device Codes ( T 1-2-6)
Section 1-2 - General Information
Use
Scope
1-2-2
1-2-2
9803/3760-06 (1-01-00)
Scope
Personnel
This publication is designed for the benefit of JCB
Distributor Service Engineers who are receiving, or have
received, training by JCB Technical Training Department.
These personnel should have a sound knowledge of
workshop practice, safety procedures, and general
techniques associated with the maintenance and repair of
hydraulic earthmoving equipment. Finally, please
remember above all else SAFETY MUST COME FIRST!
Applications
This manual contains data relevant to a range of
machines. Make sure you reference the data for the
correct machine. K Applications ( T 1-1-1)
Newest Data
From time to time new machines, systems or devices
require the manual to be re-issued. Make sure you have
the newest issue.
Always check the on-line JCB data system for relevant
technical information.
Section 1-2 - General Information
Use
Format
1-2-3
1-2-3
9803/3760-06 (1-01-00)
Format
The manual is compiled in sections, the first three are
numbered and contain information as follows:
1
General Information - Use the Applications Tables
at the front of the section to see which topic in the
manual is applicable to which machine model. The
section also includes general information such as
torque settings and service tools.
2
Care & Safety - includes warnings, cautions and
general procedures related to aspects of workshop
procedures contained in the manual.
3
Routine Maintenance - includes service schedules
and recommended lubricants for all the machine.
The remaining sections are alphabetically coded and deal
with dismantling, overhaul etc. of specific components, for
example:
The sections contain topics. Each topic is a self contained
set of data about a machine SYSTEM or Device.
Some topics are only applicable to some machine models.
Use the Applications Tables in this section to see which
topic is applicable to which machine model.
Each topic contains data such as specifications,
descriptions, fault finding and test procedures. Device
topics also contain removal, replacement, dismantle and
assemble procedures.
Some topics contain procedures and specifications for
different variants. This happens because of market
requirements, or when the machine specification changes
after a period of time. Where applicable, a table in the
introduction of each topic contains information to help you
identify the correct specifications or procedures.
Each topic also contains a Related Topics table. This
table lists all the topics that contain related data. For
example a hydraulic SYSTEM contains devices such as
valves and pumps. These devices have their own topics
and they are listed in the SYSTEM related topics table.
A
Attachments
B
Body and Framework...etc.
Section 1-2 - General Information
Use
Left and Right Sides
1-2-4
1-2-4
9803/3760-06 (1-01-00)
Left and Right Sides
'Left Hand' and 'Right Hand' are as viewed from the rear of
the machine facing forwards.
Section 1-2 - General Information
Use
Hydraulic Schematic Codes
1-2-5
1-2-5
9803/3760-06 (1-01-00)
Hydraulic Schematic Codes
Colour Codes
The following colour coding, used on illustrations to denote
various conditions of oil pressure and flow, is standardised
throughout JCB Service Publications.
Red
Full Pressure: Pressure generated from operation of a service. Depending on application this
may be anything between neutral circuit pressure and LSRV operating pressure.
Pink
Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red.
Orange
Pilot: Oil pressure used in controlling a device (Pilot).
Blue
Neural: Neutral circuit pressure.
Green
Exhaust:
Light Green
Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).
Yellow
Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).
Section 1-2 - General Information
Use
Electrical Device Codes
1-2-6
1-2-6
9803/3760-06 (1-01-00)
Electrical Device Codes
This manual uses a code system to help you identify the
electrical devices on the machine.
When the electrical system is designed at the factory
codes are given to the electrical connectors on the
electrical harnesses. The system allows the same code to
be used for different connectors.
For this reason a different system is used in this manual.
Each main category of devices is given a code type:
Each device is given one code and the code is used
throughout the manual. The same code is given to both the
device and its electrical connector.
Important: The electrical schematics and the harness
drawings in Section C are reproduced from the factory
drawings. For this reason they retain the factory connector
codes.
Code Type Category
-000
Earth points
+000
Power (from battery or alternator)
1000
Switches
2000
Relays
3000
Valves/Coils
4000
ECU's
5000
Sensors
6000
Indicators/Lamps
7000
Other devices
8000
Harness Interconnections
9000
Fuses
Section 1-3 - General Information
1-3-1
1-3-1
9803/3760-06 (1-02-02)
Machine Identification
Introduction
This topic contains information about a machine identification. On the machine and on the machine devices there are
identification data plates.
K Related Topics ( T 1-3-2)
K Machine Identification Plate ( T 1-3-3)
K Typical Product Identification Number (PIN) ( T 1-3-3)
K European Tractor Type Approved Builds ( T 1-3-5)
K Component Identification Plates ( T 1-3-6)
K Typical Engine Identification Number ( T 1-3-6)
K Transmission Identification Numbers ( T 1-3-7)
K ROPS/FOPS and OECD Certification Plates ( T 1-3-9)
Section 1-3 - General Information
Machine Identification
Related Topics
1-3-2
1-3-2
9803/3760-06 (1-02-02)
Related Topics
Table 1. Related Topics in This Publication
The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to
complete your procedures. Where applicable the text in this section contains cross references to this page to help you find
the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer
to Section 1 - Applications.
Sections Topic Titles
Sub Titles
1
K Applications ( T 1-1-1)
ALL
Section 1-3 - General Information
Machine Identification
Machine Identification Plate
1-3-3
1-3-3
9803/3760-06 (1-02-02)
Machine Identification Plate
The machine has an identification plate mounted as
shown. K Fig 1. ( T 1-3-3). The serial numbers of the
machine and its major units are stamped on the plate.
Note: The machine model and build specification is
indicated by the PIN.
The serial number of each major unit is also stamped on
the unit itself. If a major unit is replaced by a new one, the
serial number on the identification plate will be wrong.
Either stamp the new number of the unit on the
identification plate, or simply stamp out the old number.
This will prevent the wrong unit number being quoted when
replacement parts are ordered.
The machine and engine serial numbers can help identify
exactly the type of equipment you have.
420811
Fig 1.
Typical Product Identification Number
(PIN)
Machines Built Before January 2010
T011100
1 World Manufacturer Identification (3 Digits)
2 Machine Model (3 Digits)
3
Engine Type (1 Digit)
4 Gearbox Model (1 Digit)
5
Randomly generated check letter (1 Digit)
6
Year of Manufacture (1 Digit)
Standard Builds:
5AA = 531-70
5AB = 535-95
5AC = 536-60
5AD = 541-70
5AH = 533-105
5AR = 536-70
5AS = 526-56
European Tractor Type Approved Builds:
5TA = 531-70
5TD = 535-95
5TB = 541-70
5TE = 536-70
5TC = 536-60
JCB Dieselmax (Tier 3):
P = Turbocharged and after-cooled, 85kW (114Hp)
R = Turbocharged and after-cooled, 97kW (130Hp)
S = Turbocharged, 74.2kW (100Hp)
T = Turbocharged, 63kW (85Hp)
E = 3 Speed (PS750)
H = 4 Speed (PS760)
F = 3 Speed (PS760)
J = 6 Speed (PS760)
G = 4 Speed (PS750)
M = 4 Speed (SS700)
N = 4 Speed (PS750 - 40 KPH)
7 = 2007
A = 2010
Section 1-3 - General Information
Machine Identification
Machine Identification Plate
1-3-4
1-3-4
9803/3760-06 (1-02-02)
7 Machine Serial Number (7 Digits)
Each machine has a unique serial number.
Machines Built After January 2010
T011100-C1
1 World Manufacturer Identification (3 Digits)
2 Machine Model (3 Digits)
3
Engine Type (1 Digit)
4 Gearbox Model (1 Digit)
5
Randomly generated check letter (1 Digit)
6 Machine Serial Number (8 Digits)
Each machine has a unique serial number.
8 = 2008
B = 2011
9 = 2009
C = 2012
Standard Builds:
5AA = 531-70
5AB = 535-95
5AC = 536-60
5AD = 541-70
5AH = 533-105
5AR = 536-70
5AS = 526-56
European Tractor Type Approved Builds:
5TA = 531-70
5TD = 535-95
5TB = 541-70
5TE = 536-70
5TC = 536-60
JCB Dieselmax (Tier 3):
P = Turbocharged and after-cooled, 85kW (114Hp)
R = Turbocharged and after-cooled, 97kW (130Hp)
S = Turbocharged, 74.2kW (100Hp)
T = Turbocharged, 63kW (85Hp)
E = 3 Speed (PS750)
H = 4 Speed (PS760)
F = 3 Speed (PS760)
J = 6 Speed (PS760)
G = 4 Speed (PS750)
M = 4 Speed (SS700)
N = 4 Speed (PS750 - 40 KPH)
Section 1-3 - General Information
Machine Identification
Machine Identification Plate
1-3-5
1-3-5
9803/3760-06 (1-02-02)
European Tractor Type Approved Builds
P5-1003_2
332-d6975-4
Fig 2.
Table 2.
Item
531-70
535-95
536-60
536-70
541-70
kg (lb)
kg (lb)
kg (lb)
kg (lb)
kg (lb)
A
Total Permissible Mass
8200 (18073) 8500 (18734) 8200 (18073) 8350 (18403) 8400 (18513)
B
Permissible Front Axle Load(1)
(1) Dependent on tyres option.
From 2400 (5291)
2400 (5291)
2400 (5291)
2400 (5291)
2400 (5291)
To 6600 (14550) 7300 (16093) 6200 (13668) 7000 (15432) 7000 (15432)
C
Permissible Rear Axle Load(1)
From 2400 (5291)
2400 (5291)
2400 (5291)
2400 (5291)
2400 (5291)
To 6600 (14550) 7300 (16093) 6200 (13668) 7000 (15432) 7000 (15432)
D Unbraked Towable Mass
750 (1653)
750 (1653)
750 (1653)
750 (1653)
750 (1653)
E
Independently Braked Towable Mass
6000 (13227) 6000 (13227) 6000 (13227) 6000 (13227) 6000 (13227)
F
Inertia Braked Towable Mass
3500 (7716)
3500 (7716)
3500 (7716)
3500 (7716)
3500 (7716)
G
Towable Mass Fitted with a Proportional
Assisted Braking System
10 Tonne Hydraulic Hitch
10000
(22040)
10000
(22040)
10000
(22040)
10000
(22040)
10000
(22040)
Rockinger/Tractor Hitch
17800
(39231)
17100
(37699)
17800
(39231)
17250
(38019)
17200
(37909)
Section 1-3 - General Information
Machine Identification
Component Identification Plates
1-3-6
1-3-6
9803/3760-06 (1-02-02)
Component Identification Plates
Typical Engine Identification Number
Engine data labels 3A are located on the cylinder block at
position 3C and rocker cover 3D (if fitted). The data label
contains important engine information and includes the
engine identification number 3E.
A typical engine identification number is explained as
follows:
1
Engine Type
SD = turbocharged
SE = electronic common rail
fuel
injection,
turbocharged and intercooled.
SF = turbocharged and intercooled.
2
Engine part number
3
Country of manufacture
U = United Kingdom
4
Engine Serial Number
5
Year of Manufacture
The last three parts of the engine identification number are
stamped on the cylinder block at position 3B.
C007280-C2
Fig 3. Engine
SD
320/40001
U
00001
04
1
2
3
4
5
U
00001
04
B
C
D
B
E
Section 1-3 - General Information
Machine Identification
Component Identification Plates
1-3-7
1-3-7
9803/3760-06 (1-02-02)
Transmission Identification Numbers
The transmission components have a serial number
stamped on a data plate A as shown.
A710840-C1
Fig 4. Front Axle
A710830-C1
Fig 5. Rear Axle
263370-C1
Fig 6. PS750 Powershift Transmission
A401030-C2
Fig 7. PS760 Powershift Transmission
Section 1-3 - General Information
Machine Identification
Component Identification Plates
1-3-8
1-3-8
9803/3760-06 (1-02-02)
C007640
Fig 8. SS700 Transmission
Section 1-3 - General Information
Machine Identification
Component Identification Plates
1-3-9
1-3-9
9803/3760-06 (1-02-02)
ROPS/FOPS and OECD Certification
Plates
Machines built to ROPS/FOPS standards have an
identification label A fitted to the inside of the cab.
Machines built to ROPS/FOPS and OECD standards have
identification label B fitted to the inside of the cab.
T016800-3-C1
Fig 9. 526-56 machines
Definition of terms:
ROPS Roll Over Protection Structure
FOPS Falling Objects Protection Structure
OECD Organisation for Economic Co-operation and
Development.
Section 1-3 - General Information
Machine Identification
Component Identification Plates
1-3-10
1-3-10
9803/3760-06 (1-02-02)
445911-5
Fig 10. Other Machines
Section 1-4 - General Information
1-4-1
1-4-1
9803/3760-06 (1-05-00)
Torque Settings
Introduction
This topic contains information about torques. Torque values are given for types and sizes of bolts and hydraulic
connectors and adapters.
Where a torque is given as a single figure it may be varied by plus or minus 3%. Torque figures are given for fasteners
with different surface treatments. Make sure you use the correct torque figures.
Where torques are given in topics within the other sections always use these values.
K Zinc Plated Fasteners and Dacromet Fasteners ( T 1-4-2)
K Introduction ( T 1-4-2)
K Bolts and Screws ( T 1-4-2)
K Hydraulic Connections ( T 1-4-6)
K 'O' Ring Face Seal System ( T 1-4-6)
K 'Torque Stop' Hose System ( T 1-4-9)
K `Positional Type' Hydraulic Adaptors ( T 1-4-10)
K Fitting Procedure ( T 1-4-10)
Section 1-4 - General Information
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
1-4-2
1-4-2
9803/3760-06 (1-05-00)
Zinc Plated Fasteners and Dacromet Fasteners
T11-002
Introduction
Some external
fasteners on JCB machines are
manufactured using an improved type of corrosion
resistant finish. This type of finish is called Dacromet and
replaces the original Zinc and Yellow Plating used on
earlier machines.
The two types of fasteners can be readily identified by
colour and part number suffix. K Table 1. Fastener Types
( T 1-4-2).
Table 1. Fastener Types
Note: As the Dacromet fasteners have a lower torque
setting than the Zinc and Yellow fasteners, the torque
figures used must be relevant to the type of fastener.
Note: A Dacromet bolt should not be used in conjunction
with a Zinc or Yellow plated nut, as this could change the
torque characteristics of the torque setting further. For the
same reason, a Dacromet nut should not be used with a
Zinc or Yellow plated bolt.
Note: All bolts used on JCB machines are high tensile and
must not be replaced by bolts of a lesser tensile
specification.
Note: Dacromet bolts, due to their high corrosion
resistance are used in areas where rust could occur.
Dacromet bolts are only used for external applications.
They are not used in applications such as gearbox or
engine joint seams or internal applications.
Bolts and Screws
Use the following torque setting tables only where no
torque setting is specified in the text.
Note: Dacromet fasteners are lubricated as part of the
plating process, do not lubricate.
Torque settings are given for the following conditions:
Condition 1
Un-lubricated fasteners
Zinc fasteners
Yellow plated fasteners
Condition 2
Zinc flake (Dacromet) fasteners
Lubricated zinc and yellow plated fasteners
Where there is a natural lubrication. For example,
cast iron components
Verbus Ripp Bolts
Fig 1.
Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.
Fastener
Type
Colour
Part No. Suffix
Zinc and
Yellow
Golden finish
'Z' (e.g. 1315/3712Z)
Dacromet Mottled silver finish
'D' (e.g. 1315/3712D)
Section 1-4 - General Information
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
1-4-3
1-4-3
9803/3760-06 (1-05-00)
Table 2. Torque Settings - UNF Grade 'S' Fasteners
Table 3. Torque Settings - Metric Grade 8.8 Fasteners
Bolt Size
Hexagon (A/F)
Condition 1
Condition 2
in.
mm
in.
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
1/4
6.3
7/16
11.2
1.1
8.3
10.0
1.0
7.4
5/16
7.9
1/2
22.3
2.3
16.4
20.0
2.0
14.7
3/8
9.5
9/16
40.0
4.1
29.5
36.0
3.7
26.5
7/16
11.1
5/8
64.0
6.5
47.2
57.0
5.8
42.0
1/2
12.7
3/4
98.00
10.0
72.3
88.0
9.0
64.9
9/16
14.3
13/16
140.0
14.3
103.2
126.0
12.8
92.9
5/8
15.9
15/16
196.0
20.0
144.6
177.0
18.0
130.5
3/4
19.0
1 1/8
343.0
35.0
253.0
309.0
31.5
227.9
7/8
22.2
1 15/16
547.0
55.8
403.4
492.0
50.2
362.9
1
25.4
1 1/2
814.0
83.0
600.4
732.0
74.6
539.9
1 1/8
31.7
1 7/8
1181.0
120.4
871.1
1063.0
108.4
784.0
1 1/4
38.1
2 1/4
1646.0
167.8
1214.0
1481.0
151.0
1092.3
Bolt Size
Hexagon (A/F)
Condition 1
Condition 2
ISO Metric
Thread
mm
mm
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
M5
5
8
5.8
0.6
4.3
5.2
0.5
3.8
M6
6
10
9.9
1.0
7.3
9.0
0.9
6.6
M8
8
13
24.0
2.4
17.7
22.0
2.2
16.2
M10
10
17
47.0
4.8
34.7
43.0
4.4
31.7
M12
12
19
83.0
8.5
61.2
74.0
7.5
54.6
M16
16
24
205.0
20.9
151.2
184.0
18.8
135.7
M20
20
30
400.0
40.8
295.0
360.0
36.7
265.5
M24
24
36
690.0
70.4
508.9
621.0
63.3
458.0
M30
30
46
1372.0
139.9
1011.9
1235.0
125.9
910.9
M36
36
55
2399.0
244.6
1769.4
2159.0
220.0
1592.4
Section 1-4 - General Information
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
1-4-4
1-4-4
9803/3760-06 (1-05-00)
Table 4. Metric Grade 10.9 Fasteners
Table 5. Metric Grade 12.9 Fasteners
Bolt Size
Hexagon (A/F)
Condition 1
Condition 2
ISO Metric
Thread
mm
mm
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
M5
5
8
8.1
0.8
6.0
7.3
0.7
5.4
M6
6
10
13.9
1.4
10.2
12.5
1.3
9.2
M8
8
13
34.0
3.5
25.0
30.0
3.0
22.1
M10
10
17
67.0
6.8
49.4
60.0
6.1
44.2
M12
12
19
116.0
11.8
85.5
104.0
10.6
76.7
M16
16
24
288.0
29.4
212.4
259.0
26.4
191.0
M20
20
30
562.0
57.3
414.5
506.0
51.6
373.2
M24
24
36
971.0
99.0
716.9
874.0
89.1
644.6
M30
30
46
1930.0
196.8
1423.5
1737.0
177.1
1281.1
M36
36
55
3374.0
344.0
2488.5
3036.0
309.6
2239.2
Bolt Size
Hexagon (A/F)
Condition 1
Condition 2
ISO Metric
Thread
mm
mm
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
M5
5
8
9.8
1.0
7.2
8.8
0.9
6.5
M6
6
10
16.6
1.7
12.2
15.0
1.5
11.1
M8
8
13
40.0
4.1
29.5
36.0
3.7
26.5
M10
10
17
80.0
8.1
59.0
72.0
7.3
53.1
M12
12
19
139.0
14.2
102.5
125.0
12.7
92.2
M16
16
24
345.0
35.2
254.4
311.0
31.7
229.4
M20
20
30
674.0
68.7
497.1
607.0
61.9
447.7
M24
24
36
1165.0
118.8
859.2
1048.0
106.9
773.0
M30
30
46
2316.0
236.2
1708.2
2084.0
212.5
1537.1
M36
36
55
4049.0
412.9
2986.4
3644.0
371.6
2687.7
Section 1-4 - General Information
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
1-4-5
1-4-5
9803/3760-06 (1-05-00)
Table 6. Torque Settings - Rivet Nut Bolts/Screws
Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc)
Bolt Size
Nm
kgf m
lbf ft
ISO Metric
Thread
mm
M3
3
1.2
0.1
0.9
M4
4
3.0
0.3
2.0
M5
5
6.0
0.6
4.5
M6
6
10.0
1.0
7.5
M8
8
24.0
2.5
18.0
M10
10
48.0
4.9
35.5
M12
12
82.0
8.4
60.5
Bolt Size
Nm
kgf m
lbf ft
ISO Metric
Thread
M3
2.0
0.2
1.5
M4
6.0
0.6
4.5
M5
11.0
1.1
8.0
M6
19.0
1.9
14.0
M8
46.0
4.7
34.0
M10
91.0
9.3
67.0
M12
159.0
16.2
117.0
M16
395.0
40.0
292.0
M18
550.0
56.0
406.0
M20
770.0
79.0
568.0
M24
1332.0
136.0
983.0
Section 1-4 - General Information
Torque Settings
Hydraulic Connections
1-4-6
1-4-6
9803/3760-06 (1-05-00)
Hydraulic Connections
T11-003
'O' Ring Face Seal System
Adaptors Screwed into Valve Blocks
Adaptor screwed into valve blocks, seal onto an 'O' ring
which is compressed into a 45 seat machined into the
face of the tapped port.
Table 8. Torque Settings - BSP Adaptors
Table 9. Torque Settings - SAE Connections
BSP Adaptor
Size
Hexagon (A/F)
Nm
kgf m
lbf ft
in.
mm
1/4
19.0
18.0
1.8
13.0
3/8
22.0
31.0
3.2
23.0
1/2
27.0
49.0
5.0
36.0
5/8
30.0
60.0
6.1
44.0
3/4
32.0
81.0
8.2
60.0
1
38.0
129.0
13.1
95.0
1 1/4
50.0
206.0
21.0
152.0
SAE Tube
Size
SAE Port
Thread Size
Hexagon (A/F)
Nm
kgf m
lbf ft
mm
4
7/16 - 20
15.9
20.0 - 28.0
2.0 - 2.8
16.5 - 18.5
6
9/16 - 18
19.1
46.0 - 54.0
4.7 - 5.5
34.0 - 40.0
8
3/4 - 16
22.2
95.0 - 105.0
9.7 - 10.7
69.0 - 77.0
10
7/8 - 14
27.0
130.0 - 140.0
13.2 - 14.3
96.0 - 104.0
12
1 1/16 - 12
31.8
190.0 - 210.0
19.4 - 21.4
141.0 - 155.0
16
1 5/16 - 12
38.1
290.0 - 310.0
29.6 - 31.6
216.0 - 230.0
20
1 5/8
47.6
280.0 - 380.0
28.5 - 38.7
210.0 - 280.0
Section 1-4 - General Information
Torque Settings
Hydraulic Connections
1-4-7
1-4-7
9803/3760-06 (1-05-00)
Hoses Screwed into Adaptors
Fig 2.
Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring
2-C which is compressed into a 45 seat machined into the
face of the adaptor port.
Note: Dimension 2-D will vary depending upon the torque
applied.
Table 10. BSP Hose - Torque Settings
BSP Hose Size
Hexagon (A/F)
Nm
kgf m
lbf ft
in.
mm
1/8
14.0
14.0 - 16.00
1.4 - 1.6
10.3 - 11.8
1/4
19.0
24.0 - 27.0
2.4 - 2.7
17.7 - 19.9
3/8
22.0
33.0 - 40.0
3.4 - 4.1
24.3 - 29.5
1/2
27.0
44.0 - 50.0
4.5 - 5.1
32.4 - 36.9
5/8
30.0
58.0 - 65.0
5.9 - 6.6
42.8 - 47.9
3/4
32.0
84.0 - 92.0
8.6 - 9.4
61.9 - 67.8
1
38.0
115.0 - 126.0
11.7 - 12.8
84.8 - 92.9
1 1/4
50.0
189.0 - 200.0
19.3 - 20.4
139.4 - 147.5
1 1/2
55.0
244.0 - 260.0
24.9 - 26.5
180.0 - 191.8
Section 1-4 - General Information
Torque Settings
Hydraulic Connections
1-4-8
1-4-8
9803/3760-06 (1-05-00)
Adaptors into Component Connections with Bonded Washers
Table 11. BSP Adaptors with Bonded Washers - Torque Settings
BSP Size
Nm
kgf m
lbf ft
in.
1/8
20.0
2.1
15.0
1/4
34.0
3.4
25.0
3/8
75.0
7.6
55.0
1/2
102.0
10.3
75.0
5/8
122.0
12.4
90.0
3/4
183.0
18.7
135.0
1
203.0
20.7
150.0
1 1/4
305.0
31.0
225.0
1 1/2
305.0
31.0
225.0
Section 1-4 - General Information
Torque Settings
Hydraulic Connections
1-4-9
1-4-9
9803/3760-06 (1-05-00)
'Torque Stop' Hose System
Fig 3.
`Torque Stop' Hoses 3-B screwed into adaptors 3-A seal
onto an 'O' ring 3-C which is compressed into a 45 seat
machined in the face of the adaptor port. To prevent the 'O'
ring being damages as a result of over tightening, 'Torque
Stop' Hoses have an additional shoulder 3-D, which acts
as a physical stop.
Note: Minimum dimension 3-E fixed by shoulder 3-D.
Table 12. BSP `Torque Stop' Hose - Torque Settings
BSP Hose Size
Hexagon (A/F)
Nm
kgf m
lbf ft
in.
mm
1/8
14.0
14.0
1.4
10.0
1/4
19.0
27.0
2.7
20.0
3/8
22.0
40.0
4.1
30.0
1/2
27.0
55.0
5.6
40.0
5/8
30.0
65.0
6.6
48.0
3/4
32.0
95.0
9.7
70.0
1
38.0
120.0
12.2
89.0
1 1/4
50.0
189.0
19.3
140.0
1 1/2
55.0
244.0
24.9
180.0
Section 1-4 - General Information
Torque Settings
`Positional Type' Hydraulic Adaptors
1-4-10
1-4-10
9803/3760-06 (1-05-00)
`Positional Type' Hydraulic Adaptors
Fitting Procedure
On a typical machine, some hydraulic components may
utilise `Positional Type' SAE Hydraulic Adaptors. When
fitting Positional Type' Hydraulic Adaptors it is important to
adopt the following procedure. If this procedure is not
followed correctly, damage to the `O' ring seal 4-A can
occur resulting in oil leaks.
1
Ensure the locknut 4-B is screwed back onto the body
of the adaptor as far as possible as shown.
2
Check the `O' ring backing washer 4-C is a tight fit on
the adaptor. Note that the washer should not move
freely, if the washer is slack do not use the adaptor.
3
Check the `O' ring 4-A is fitted and that it is free from
damage or nicks. Before fitting the adaptor, smear the
`O' ring with clean hydraulic fluid.
Note: The dimensions and shore hardness of the `O' ring
is critical. Should it become necessary to replace the `O'
ring, ensure that only JCB Genuine Parts are used.
4
Screw the adaptor into the port of the hydraulic
component as far as possible, so that ALL the threads
engage and the `O' ring is correctly seated against
the sealing face.
5
Set the angular position of the adaptor as required,
then secure by tightening the locknut 4-B.
Note: When fitted correctly no more than one thread
should be visible at 5-Z as shown.
6
Torque tighten the locknut to 81 Nm (60 lbf ft).
Fig 4.
Fig 5.
Section 1-5 - General Information
1-5-1
1-5-1
9803/3760-06 (1-06-00)
Service Tools
Introduction
The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools
are available from JCB Service or, in some instances, can be manufactured locally from the specifications given in this
section.
Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well
equipped workshop or be available locally from any good tool supplier.
K Numerical List ( T 1-5-2)
K Tool Detail Reference ( T 1-5-5)
K Rivet Nuts ( T 1-5-24)
K Slide Hammer Kit ( T 1-5-26)
Section 1-5 - General Information
Service Tools
Numerical List
1-5-2
1-5-2
9803/3760-06 (1-06-00)
Numerical List
Some tools are supplied as kits or sets. Cross references
are given to tables showing the kit contents.
Part
Number:
Description:
Tool Detail Reference:
-
Bonded Washers - see tool detail reference for content
K Fig 40. ( T 1-5-16)
-
Electrical Repair Kit - see tool detail reference for content
K Fig 23. ( T 1-5-10)
-
Female Cone Blanking Plugs - see tool detail reference for content
K Fig 37. ( T 1-5-16)
-
Female Connectors - see tool detail reference for content
K Fig 39. ( T 1-5-16)
-
Hydraulic Hand Pump Equipment - see tool detail reference for content
K Fig 43. ( T 1-5-17)
-
Male Adaptors BSP x BSP - see tool detail reference for content
K Fig 33. ( T 1-5-14)
-
Male Cone Blanking Caps - see tool detail reference for content
K Fig 38. ( T 1-5-16)
-
Pressure Test Point `T' Adaptors - see tool detail reference for content
K Fig 35. ( T 1-5-15)
-
Pressure Test Point Adaptors - see tool detail reference for content
K Fig 34. ( T 1-5-14)
-
Rivet Nut Tool - see tool detail reference for content
K Fig 1. ( T 1-5-5)
320/20050 Engine Lifting Bracket Kit
K Fig 66. ( T 1-5-23)
332/E0800 Variflow pump test lead
K Fig 32. ( T 1-5-14)
332/E7911 Exhaust fitting clamp
K Fig 64. ( T 1-5-23)
332/F1311 SS700 Cableshift Neutral Locking Tool
4104/1310 Hand Cleaner
K Fig 15. ( T 1-5-8)
460/15708 Flow Test Adaptor (Powershift) - Other components required, see tool detail
K Fig 47. ( T 1-5-18)
718/20235 USB PC Cable
K Fig 67. ( T 1-5-23)
718/20236 Serial PC Cable
K Fig 67. ( T 1-5-23)
718/20237 Machine Cable
K Fig 67. ( T 1-5-23)
728/26500 USB DLA
K Fig 67. ( T 1-5-23)
892/00011 Spool Clamp
K Fig 50. ( T 1-5-19)
892/00167 Ram Protection Sleeve for 90 mm Rod Diameter
K Fig 54. ( T 1-5-21)
892/00180 Seal Fitting Tool - Hydraulic Steer Unit
K Fig 51. ( T 1-5-19)
892/00229 Flow Meter
K Fig 45. ( T 1-5-17)
892/00253 Hydraulic Pressure Test Kit - see tool detail reference for content
K Fig 29. ( T 1-5-13)
892/00268 Flow Monitoring Unit - Other components required, see tool detail
K Fig 27. ( T 1-5-12)
892/00301 Flow test adaptor - Synchro Shuttle - Other components required
K Fig 60. ( T 1-5-22)
892/00334 Ram Seal Fitting Tool
K Fig 55. ( T 1-5-21)
892/00349 Crimp Tool
K Fig 25. ( T 1-5-11)
892/00350 Butane Heater Assembly
K Fig 24. ( T 1-5-10)
892/00351 Splice 0.5-1.5 mm (Red)
K Fig 26. ( T 1-5-11)
Section 1-5 - General Information
Service Tools
Numerical List
1-5-3
1-5-3
9803/3760-06 (1-06-00)
892/00352 Splice 1.5-2.5 mm (Blue)
K Fig 26. ( T 1-5-11)
892/00353 Splice 3.0-6.0 mm (Yellow)
K Fig 26. ( T 1-5-11)
892/00812 Drive Coupling Spanner
K Fig 61. ( T 1-5-22)
892/00822 Splined Bolt Socket
K Fig 59. ( T 1-5-22)
892/00842 Glass Lifter
K Fig 3. ( T 1-5-6)
892/00843 Folding Stand for Holding Glass
K Fig 4. ( T 1-5-6)
892/00844 Long Knife
K Fig 17. ( T 1-5-8)
892/00845 Cartridge Gun
K Fig 5. ( T 1-5-6)
892/00846 Glass Extractor (Handles)
K Fig 6. ( T 1-5-6)
892/00847 Nylon Spatula
K Fig 7. ( T 1-5-6)
892/00848 Wire Starter
K Fig 8. ( T 1-5-6)
892/00849 Braided Cutting Wire
K Fig 9. ( T 1-5-7)
892/00881 Valve Spool Seal Fitting Tool
K Fig 44. ( T 1-5-17)
892/00893 Torque Converter Alignment Tool
K Fig 62. ( T 1-5-22)
892/00905 LMI Test Box
K Fig 21. ( T 1-5-9)
892/00948 Nitrogen Charging Kit (without gauge)
K Fig 49. ( T 1-5-18)
892/00949 Gauge
K Fig 49. ( T 1-5-18)
892/00964 Test Point 1/8 BSP (Powershift)
K Fig 41. ( T 1-5-17)
892/00965 Test Point 3/8 BSP (Powershift)
K Fig 42. ( T 1-5-17)
892/01016 Ram Protection Sleeve for 25 mm Rod Diameter
K Fig 54. ( T 1-5-21)
892/01017 Ram Protection Sleeve for 30 mm Rod Diameter
K Fig 54. ( T 1-5-21)
892/01018 Ram Protection Sleeve for 40 mm Rod Diameter
K Fig 54. ( T 1-5-21)
892/01019 Ram Protection Sleeve for 50 mm Rod Diameter
K Fig 54. ( T 1-5-21)
892/01020 Ram Protection Sleeve for 50 mm Rod Diameter
K Fig 54. ( T 1-5-21)
892/01021 Ram Protection Sleeve for 60 mm Rod Diameter
K Fig 54. ( T 1-5-21)
892/01022 Ram Protection Sleeve for 60 mm Rod Diameter
K Fig 54. ( T 1-5-21)
892/01023 Ram Protection Sleeve for 65 mm Rod Diameter
K Fig 54. ( T 1-5-21)
892/01024 Ram Protection Sleeve for 70 mm Rod Diameter
K Fig 54. ( T 1-5-21)
892/01025 Ram Protection Sleeve for 75 mm Rod Diameter
K Fig 54. ( T 1-5-21)
892/01026 Ram Protection Sleeve for 80 mm Rod Diameter
K Fig 54. ( T 1-5-21)
892/01027 Piston Seal Assembly Tool
K Fig 57. ( T 1-5-21)
892/01174 Data Link Adaptor Kit
K Fig 67. ( T 1-5-23)
892/01268 Digital Pressure Gauge 0-400 bar
K Fig 46. ( T 1-5-17)
892/01271 Hose for Digital Pressure Gauge 892/01268
K Fig 46. ( T 1-5-17)
926/15500 Rubber Spacer Blocks
K Fig 10. ( T 1-5-7)
992/01100 Glazing Tool
K Fig 16. ( T 1-5-8)
992/04000 Torque Multiplier
K Fig 58. ( T 1-5-22)
Part
Number:
Description:
Tool Detail Reference:
Section 1-5 - General Information
Service Tools
Numerical List
1-5-4
1-5-4
9803/3760-06 (1-06-00)
992/04800 Flange spanner
K Fig 65. ( T 1-5-23)
992/09100 Spool Clamp
K Fig 50. ( T 1-5-19)
992/09300 Hexagon Spanner 55 mm A/F
K Fig 56. ( T 1-5-21)
992/09400 Hexagon Spanner 65 mm A/F
K Fig 56. ( T 1-5-21)
992/09500 Hexagon Spanner 75 mm A/F
K Fig 56. ( T 1-5-21)
992/09600 Hexagon Spanner 85 mm A/F
K Fig 56. ( T 1-5-21)
992/09700 Hexagon Spanner 95 mm A/F
K Fig 56. ( T 1-5-21)
992/09900 Hexagon Spanner 115 mm A/F
K Fig 56. ( T 1-5-21)
992/10000 Hexagon Spanner 125 mm A/F
K Fig 56. ( T 1-5-21)
992/12300 12V Mobile Oven
K Fig 11. ( T 1-5-7)
992/12400 24V Static Oven (2 Cartridge)
K Fig 12. ( T 1-5-7)
992/12800 Cut-Out Knife
K Fig 13. ( T 1-5-7)
992/12801
`L' Blades
K Fig 14. ( T 1-5-7)
993/68100 Slide Hammer Kit - see tool detail reference for content
K Fig 2. ( T 1-5-5)
993/85700 Battery Tester
K Fig 22. ( T 1-5-9)
Part
Number:
Description:
Tool Detail Reference:
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-5
1-5-5
9803/3760-06 (1-06-00)
Tool Detail Reference
Fig 1. Rivet Nut Tool
1
826/01099
M6 x 16 mm Rivet Nut
826/01101
M6 x 19 mm Rivet Nut
826/01102
M8 x 18 mm Rivet Nut
826/01103
M8 x 21 mm Rivet Nut
826/01104
M10 x 23 mm Rivet Nut
826/01105A M10 x 26 mm Rivet Nut
2
-
Installation Tool available from: Bollhoff
Fastenings Ltd (www.bollhof.com)
Fig 2. 993/68100 Slide Hammer Kit
1
993/68101
Slide Hammer
7
993/68107
Bar - M20 x M20 X 800 mm
2
993/68102
End Stops
8
993/68108
Adaptor - M20 x 7/8" UNF
3
993/68103
Adaptor - M20 x 5/8" UNF
9
993/68109
Adaptor - M20 x M12
4
993/68104
Adaptor - M20 x 1" UNF
10 993/68110
Adaptor - M20 x 5/8" UNF (Shoulder)
5
993/68105
Adaptor - M20 x M20
11 993/68111
Adaptor - M20 x 1/2" UNF
6
993/68106
Adaptor - M20 x M24
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-6
1-5-6
9803/3760-06 (1-06-00)
Fig 3. 892/00842 Glass Lifter
Minimum 2 off - Essential for glass installation, 2 required
to handle large panes of glass. Ensure suction cups are
protected from damage during storage.
Fig 4. 892/00843 Folding Stand
Essential for preparing new glass prior to installation.
Fig 5. 892/00845 Cartridge Gun
Hand operated. Essential for the application of sealants,
polyurethane materials etc.
Fig 6. 892/00846 Glass Extractor (Handles)
Used with braided cutting wire to cut out broken glass.
K Fig 9. ( T 1-5-7).
Fig 7. 892/00847 Nylon Spatula
General tool used for smoothing sealants - also used to
re-install glass in rubber glazing because metal tools will
chip the glass edge.
Fig 8. 892/00848 Wire Starter
Used to access braided cutting wire through original
polyurethane seal. K Fig 9. ( T 1-5-7).
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-7
1-5-7
9803/3760-06 (1-06-00)
Fig 9. 892/00849 Braided Cutting Wire
Consumable heavy duty cut-out wire used with the glass
extraction tool. K Fig 6. ( T 1-5-6). Approx 25 m length.
Fig 10. 926/15500 Rubber Spacer Blocks
Used to provide the correct set clearance between glass
edge and cab frame. Unit quantity = 500 off.
Fig 11. 992/12300 Mobile Oven 12V
1 cartridge capacity. Required to pre-heat adhesive prior
to use. It is fitted with a male plug (703/23201) which fits
into a female socket (715/04300).
Fig 12. 992/12400 Static Oven 240V
Required to pre-heat adhesive prior to use. No plug
supplied.
Note: 110V models available upon request - contact JCB
Technical Service.
Fig 13. 992/12800 Cut-Out Knife
Used to remove broken glass.
Fig 14. 992/12801 'L' Blades
25 mm (1 in.) cut. Replacement blades for cut-out knife.
K Fig 13. ( T 1-5-7). Unit quantity = 5 off.
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-8
1-5-8
9803/3760-06 (1-06-00)
Fig 15. 4104/1310 Hand Cleaner
Special blend for the removal of polyurethane adhesives
(454g; 1 lb tub).
Fig 16. 992/01100
Glazing Tool, used to insert aperture seal expansion strip.
Fig 17. 892/00844 Long Knife
Used to give extended reach for normally inaccessible
areas.
Fig 18. 892/00298 Fluke Meter
Fig 19. 892/00285 Hydraulic Temperature Probe
Fig 20. 892/00284 Venture Microtach Digital
Tachometer
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-9
1-5-9
9803/3760-06 (1-06-00)
Fig 21. 892/00905 LMI Test Box
For testing load moment indicator system
Fig 22. 993/85700 Battery Tester
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-10
1-5-10
9803/3760-06 (1-06-00)
Fig 23. Electrical Repair Kit
K Electrical Repair Kit ( T 1-5-10)
1
Electrical Repair Kit
2A 7212/0002
2 Way Pin Housing
2B 7212/0004
2 Way Pin Retainer
2C 7212/0003
2 Way Socket Retainer
2D 7212/0001
2 Way Socket Connector
3A 7213/0002
3 Way Pin Housing
3B 7213/0004
3 Way Pin Retainer
3C 7213/0003
3 Way Socket Retainer
3D 7213/0001
3 Way Socket Connector
4A 7213/0006
3 Way Pin Housing (DT)
4B 7213/0008
3 Way Pin Retainer (DT)
4C 7213/0007
3 Way Socket Retainer (DT)
4D 7213/0005
3 Way Socket Connector (DT)
5A 7214/0002
4 Way Pin Housing
5B 7214/0004
4 Way Pin Retainer
5C 7214/0003
4 Way Socket Retainer
5D 7214/0001
4 Way Socket Connector
6A 7216/0002
6 Way Pin Housing
6B 7216/0004
6 Way Pin Retainer
6C 7216/0003
6 Way Socket Retainer
6D 7216/0001
6 Way Socket Connector
7A 7218/0002
8 Way Pin Housing
7B 7218/0004
8 Way Pin Retainer
7C 7218/0003
8 Way Socket Retainer
7D 7218/0001
8 Way Socket Connector
8A 7219/0002
10 Way Pin Housing
8B 7219/0004
10 Way Pin Retainer
8C 7219/0003
10 Way Socket Retainer
8D 7219/0001
10 Way Socket Connector
9A 7219/0006
14 Way Pin Housing
9B 7219/0008
14 Way Pin Retainer
9C 7219/0007
14 Way Socket Retainer
9D 7219/0005
14 Way Socket Connector
10
7210/0001
Dummy Plug
11
7210/0002
Wire Seal (1.4 - 2.2 mm dia.)
12
7210/0003
Wire Seal (2.2 - 2.9 mm dia.)
Fig 24. 892/00350 Butane Heater Assembly
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-11
1-5-11
9803/3760-06 (1-06-00)
Fig 25. 892/00349 Crimp Tool
Fig 26. Splice
892/00351
Splice 0.5-1.5 mm (Red)
892/00352
Splice 1.5-2.5 mm (Blue)
892/00353
Splice 3.0-6.0 mm (Yellow)
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-12
1-5-12
9803/3760-06 (1-06-00)
Note: No longer available, refer to 998/11046 JCB
ServiceMaster Flow Test Kit. K Fig 28. ( T 1-5-12).
892/00268
Flow Monitoring Unit
Fig 27. Flow Test Equipment
892/00269
Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)
892/00273
Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min)
892/00293
Connector Pipe
892/00270
Load Valve
1406/0021
Bonded Washer
1604/0006A Adapter 3/4 in M x 3/4 in M BSP
1612/2054
Adapter 3/4 in F x 3/4 in M BSP
892/00271
Adapter 3/4 in F x 5/8 in M BSP
892/00272
Adapter 5/8 in F x 3/4 in M BSP
816/20008
Adapter 3/4 in F x 1/2 in M BSP
892/00275
Adapter 1/2 in F x 3/4 in M BSP
892/00276
Adapter 3/4 in F x 3/8 in M BSP
892/00277
Adapter 3/8 in F x 3/4 in M BSP
1606/0015
Adapter 1.1/4 in M BSP x 1 in M BSP
892/00078
Connector 1 in F x 1 in F BSP
1604/0008
Adapter 1 in M x 1 in M BSP
1606/0012
Adapter 1 in M x 3/4 in M BSP
816/20013
Adapter 3/4 in F x 1 in M BSP
Fig 28. 998/11046 JCB ServiceMaster Flow Test Kit
998/11047
600 LPM Flow Turbine with Loading Valve
998/11048
1-7/8" UNF x1 - 1/4" BSP Flow Block Adaptors
x2
998/11049
Carrying Case for Flow Test Kit
998/11050
Temperature Sensor (125C Max)
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-13
1-5-13
9803/3760-06 (1-06-00)
Note: No longer available, refer to 998/11051 JCB
ServiceMaster Digital Hydraulic Datalogger Pressure
Test Kit. K Fig 30. ( T 1-5-13).
892/00201
Replacement Gauge 0-20 bar (0-300 lbf/in2)
Fig 29. 892/ 00253 Hydraulic Circuit Pressure Test Kit
892/00202
Replacement Gauge 0-40 bar (0-600 lbf/in2)
892/00203
Replacement Gauge 0-400 bar (0-6000 lbf/in2)
892/00254
Replacement Hose
993/69800
Seal Kit for 892/00254 (can also be used with
probe 892/00706)
892/00706
Test Probe
892/00347
Connector - Hose to gauge
Fig 30. 998/11051 JCB ServiceMaster Digital
Hydraulic Datalogger Pressure Test Kit
998/11052
Hand Held 4-Channel ServiceMaster Unit
998/11053
SensoWin Software Kit and PC Cable
998/11054
Equiment Case SCC-750
998/11055
0-600 Bar Pressure Transduce x2
998/11056
0-100 Bar pressureTransducer x2
998/11057
RPM Tachometer (includes fixed cable, 2
meters)
998/11058
5 Meter Connecting Cable
998/11059
M16 Metric Adaptors for Test Points x4
998/11060
400mm Test Hose 90 HSP to M16 x2
998/11061
400mm Test Hose Straight HSP to M16 x2
Fig 31. Hydraulic Circuit Test Gauges and
Connections
892/00280
Pressure Gauge 0-600 bar (0-9000 lbf/in2)
892/00279
Pressure Gauge 0-400 bar (0-6000 lbf/in2)
892/00346
Pressure Gauge 0-70 bar (0-1000 lbf/in2)
892/00347
Connector
892/00254
Hose
3
2
1
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-14
1-5-14
9803/3760-06 (1-06-00)
Fig 32. 332/E0800 Variflow Pump Test Lead
Fig 33. Male Adaptors
Male Adapters - BSP x BSP
1606/2052
3/8 in. x 1/4 in.
1604/0003A 3/8 in. x 3/8 in.
892/00071
3/8 in. x 3/8 in. taper
1606/0004
1/2 in. x 1/4 in.
1606/0007A 1/2 in. x 3/8 in.
1604/0004A 1/2 in. x 1/2 in.
1606/0017
5/8 in. x 1/2 in.
1606/0008
3/4 in. x 3/8 in.
Male Adapters - BSP x NPT (USA only)
1606/0009
3/4 in. x 1/2 in.
816/00439
3/8 in. x 1/4 in.
1604/2055
3/4 in. x 3/4 in.
816/00440
1/2 in. x 1/4 in.
1606/0012
3/4 in. x 1 in.
816/15007A 3/8 in. x 3/8 in.
1606/0014
3/4 in. x 1.1/4 in.
816/15008
1/2 in. x 3/8 in.
1606/0015
1 in. x 1.1/4 in.
Fig 34. Pressure Test Adapters
892/00255
1/4 in. BSP x Test Point
892/00256
3/8 in. BSP x Test Point
892/00257
1/2 in. BSP x Test Point
892/00258
5/8 in. BSP x Test Point
816/15118
3/4 in. BSP x Test Point
892/00259
1 in BSP x Test Point
892/00260
1.1/4 in. BSP x Test Point
892/00261
5/8 in. UNF x Test Point
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-15
1-5-15
9803/3760-06 (1-06-00)
Fig 35. Pressure Test 'T' Adapters
816/55045
1/4 in. M BSP x 1/4 in. F BSP x Test Point
816/55038
3/8 in. M BSP x 3/8 in. F BSP x Test Point
816/55040
1/2 in. M BSP x 1/2 in. F BSP x Test Point
892/00263
5/8 in. M BSP x 5/8 in. F BSP x Test Point
892/00264
3/4 in. M BSP x 3/4 in. F BSP x Test Point
892/00265
1 in. M BSP x 1 in. F BSP x Test Point
892/00266
1.1/4 in. M BSP x 1.1/4 in. F BSP x Test Point
892/00267
1.1/4 in. M BSP x 1.1/2 in. F BSP x Test Point
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-16
1-5-16
9803/3760-06 (1-06-00)
Fig 36. 'T' Adapters
892/00047
3/8 in. BSP (A) x 1/4 in. BSP (B)
892/00048
1/2 in. BSP (A) x 1/4 in. BSP (B)
892/00049
5/8 in. BSP (A) x 1/4 in. BSP (B)
816/50043
3/4 in. BSP (A) x 1/4 in. BSP (B)
892/00051
1 in. BSP (A) x 1/4 in. BSP (B)
816/50005
1/2 in. BSP (A) x 1/2 in. BSP (B)
816/60096
3/4 in. BSP (A) x 3/4 in. BSP (B)
816/00017
1 in. BSP (A) x 1 in. BSP (B)
Fig 37. Female Blanking Caps
892/00055A 1/4 in. BSP
892/00056A 3/8 in. BSP
892/00057
1/2 in. BSP
892/00058A 5/8 in. BSP
892/00059A 3/4 in. BSP
892/00060
1 in. BSP
Fig 38. Male Cone Blanking Caps
816/90045
1/4 in. BSP
816/00189A 3/8 in. BSP
816/00190A 1/2 in. BSP
816/90022
5/8 in. BSP
816/90274
3/4 in. BSP
816/90205
1 in. BSP
Fig 39. Female Connectors
892/00074
3/8 in. BSP x 3/8 in. BSP
892/00075
1/2 in. BSP x 1/2 in. BSP
892/00076
5/8 in. BSP x 5/8 in. BSP
892/00077
3/4 in. BSP x 3/4 in. BSP
Fig 40. Bonded Washers
1406/0011
1/4 in. BSP
1406/0018
1/2 in. BSP
1406/0014
5/8 in. BSP
1406/0021
3/4 in. BSP
1406/0029
1.1/4 in. BSP
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-17
1-5-17
9803/3760-06 (1-06-00)
Fig 41. 892/00964 Test Point 1/8 BSP
Fig 42. 892/00965 Test Point 3/8 BSP
Fig 43. Hand Pump Equipment
892/00223
Hand Pump
892/00137
Micro-bore Hose 1/4 in BSP x 3 metres
892/00274
Adapter 1/4 in M BSP x 3/8 in M BSP Taper
892/00262
1/4 in M BSP x 1/4 in F BSP x Test Point
892/00706
Test Probe
892/00278
Gauge 0 - 40 bar (0 - 600 lbf/in2)
892/00279
Gauge 0 - 400 bar (0 - 6000 lbf/in2)
Fig 44. 892/00881 Valve Spool Seal Fitting Tool
Fig 45. 892/00229 Flow Meter
TBA
Fig 46. 892/01268 Digital Pressure Gauge 0-400 bar
892/01271
Hose for pressure gauge
C068360
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-18
1-5-18
9803/3760-06 (1-06-00)
Fig 47. 460/15708 Flow Test Adaptor
Note: Components listed below also required:
Item Description
1
460/15707 Banjo bolt
2
2401/0222 O-ring
3
2403/0110 O-ring
4
2403/0108 O-ring
5
1604/0004 Adaptor - 2 off
6
1406/0018 Sealing washer - 2 off
A313250-C1
1
3
4
2
6
5
Fig 48. 892/00301 Flow Test Adaptor
Note: Components listed as follows also required:
Item Description
1
892/00920 Adaptor
2
892/00302 Adaptor
Fig 49. Nitrogen Charging Kit
892/00948 Charging Kit (without gauge)
892/00949 Gauge
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-19
1-5-19
9803/3760-06 (1-06-00)
Fig 50. Spool Clamps
992/09100 Spool Clamp
892/00011
Spool Clamp
Fig 51. 892/00180 - Seal Fitting Tool
Seal Fitting Tool for fitting 'O' ring and back-up ring to
Danfoss Orbitrol Unit.
892/00181 - Replacement Plastic Boss
Fig 52. Ram Piston Nut Removal/Fitting Spanner
993/99512
Spanner 55 mm A/F
993/99513
Spanner 60 mm A/F
993/99514
Spanner 65 mm A/F
993/99515
Spanner 70 mm A/F
993/99516
Spanner 75 mm A/F
993/99517
Spanner 85 mm A/F
993/99518
Spanner 90 mm A/F
993/99519
Spanner 100 mm A/F
993/99520
Spanner 110 mm A/F
993/99521
Spanner 115 mm A/F
SSP0046
Spanner 80 mm A/F
SSP0047
Spanner 95 mm A/F
JS07050
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-20
1-5-20
9803/3760-06 (1-06-00)
Fig 53. Ram Piston Nut Removal/Fitting Rig
993/99525
Rig Assembly (not including spanners and ram)
993/99522
Anchor Side Plate (supplied loose unwelded)
993/99523
Anchor Cross Member
(supplied
loose
unwelded)
993/99524
Ram Eye End Modification Plate Assembly
556/43400
Lift Ram
545/18000
Lynch Pin
811/50232
1.1/4in Pivot Pin
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-21
1-5-21
9803/3760-06 (1-06-00)
Fig 54. Ram Protection Sleeves
892/01016
For 25 mm Rod Diameter
892/01017
For 30 mm Rod Diameter
892/01018
For 40 mm Rod Diameter
892/01019
For 50 mm Rod Diameter
892/01020
For 50 mm Rod Diameter (slew ram)
892/01021
For 60 mm Rod Diameter
892/01022
For 60 mm Rod Diameter (slew ram)
892/01023
For 65 mm Rod Diameter
892/01024
For 70 mm Rod Diameter
892/01025
For 75 mm Rod Diameter
892/01026
For 80 mm Rod Diameter
892/00167
For 90 mm Rod Diameter
Fig 55. 892/00334 Ram Seal Fitting Tool
Fig 56. Hexagon Spanners for Ram Pistons and End
Caps
992/09300
55mm A/F
992/09400
65mm A/F
992/09500
75mm A/F
992/09600
85mm A/F
992/09700
95mm A/F
992/09900
115mm A/F
992/10000
125mm A/F
Fig 57. 892/01027 Piston Seal Assembly Tool
110mm
175mm
R 1.4mm
3o
R
3m
m
7mm
11o
10mm
20mm
5mm
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-22
1-5-22
9803/3760-06 (1-06-00)
Fig 58. 992/04000 Torque Multiplier
Fig 59. 892/00822 Splined Bolt Socket
Fig 60. 892/00301 Flow Test Adaptor
Note: Components listed as follows also required
Item Description
1
892/00920 Adaptor
2
892/00302 Adaptor
Fig 61. 892/00812 Drive Coupling Spanner
Fig 62. 892/00893 Torque Converter Alignment Tool
For use with 11" torque converters
Fig 63. 332/F1311 Neutral Locking Tool
For use with SS700 Cableshift Transmission
Section 1-5 - General Information
Service Tools
Tool Detail Reference
1-5-23
1-5-23
9803/3760-06 (1-06-00)
Fig 64. 332/E7911 Exhaust Fitting Clamp
Fig 65. 992/04800 Flange Spanner
Fig 66. 320/20050 Lifting Bracket Kit
Fig 67. 892/01174 Data Link Adaptor Kit
A
USB PC Cable
718/20235
B
Serial PC Cable
718/20236
C
USB DLA
728/26500
D
Machine Cable
718/20237
Kit 892/01174 (includes items A,B,C and D)
A
B
D
C
Section 1-5 - General Information
Service Tools
Rivet Nuts
1-5-24
1-5-24
9803/3760-06 (1-06-00)
Rivet Nuts
TB-001_2
A 'Rivet Nut' is a one piece fastener installed 'blind' from
one side of the machine body/framework. The rivet nut 68-
A is compressed so that a section of its shank forms an
'upset' against the machine body/framework, leaving a
durable thread 68-B.
Fig 68.
Rivet nuts are fitted to various parts of the machine body
and framework. They are used in a number of applications,
for instance, hose clamp and hydraulic valve retention etc.
Various sized rivet nuts are available. K Table 1.
Specifications ( T 1-5-24) to determine the size of rivet
nut to be used for particular applications.
If for any reason a new rivet nut requires fitting, then the
correct installation procedure must be followed. K Fitting
Procedure ( T 1-5-25).
Note: In an emergency, and if no installation tool is
available, it is possible to fit a rivet nut by using a nut and
bolt the same thread diameter as the rivet nut being
installed. However, this is not the recommended method.
Table 1. Specifications
Note: All dimensions in mm
Rivet Nut
Thread
Diameter
Rivet Nut
Outside
Diameter
Material
Thickness
Rivet
Length
(Total)
Drill
Hole
Dia.
M5
7
0.25 - 3.00
14.00
7.10
3.00 - 5.50
17.00
M6
9
0.50 - 3.00
16.00
9.10
3.00 - 5.50
19.00
M8
11
0.50 - 3.00
18.00
11.10
3.00 - 5.50
21.00
M10
13
1.00 - 3.50
23.00
13.10
3.50 - 6.00
26.00
Section 1-5 - General Information
Service Tools
Rivet Nuts
1-5-25
1-5-25
9803/3760-06 (1-06-00)
Fitting Procedure
1
Drill a hole in the machine body/framework where the
rivet nut is to be fitted. De-burr hole edges.
2
Screw the rivet nut onto the mandrel of the installation
tool. The bottom of the mandrel should be in line with
the bottom of the rivet nut 69-A.
Fig 69.
3 Wind the body of the installation tool down the
threaded mandrel until it touches the head of the rivet
nut 70-B.
Fig 70.
4
Insert the rivet nut (assembled to the tool) into the
hole drilled in step 1.
5
Hold handle 71-C and at the same time draw the
mandrel into the installation tool by turning nut 71-D.
The rivet nut will contract in length and form an 'upset'
(smooth bulge) seating itself against the body/
framework 71-E.
Note: The thread of the rivet nut must not be stripped, take
care when 'upsetting' the rivet nut.
Fig 71.
6
Remove the installation tool.
Section 1-5 - General Information
Service Tools
Slide Hammer Kit
1-5-26
1-5-26
9803/3760-06 (1-06-00)
Slide Hammer Kit
TB-003
Fig 72. Typical M/c. Installation
The slide hammer kit is used to remove pivot pins that
must be extracted, i.e. cannot be 'knocked through'. The
purpose of this description is to explain how the kit and the
various components are used to remove the pivot pins.
The adaptors 72-A that form part of the kit have a screwed
thread at each end. One of the threads will always be M20
size, this is to accommodate the end stops, items 72-B and
72-C. The other end of the adaptor will have varying thread
sizes to suit the different size of threads in the pivot pins.
Fitting Procedure
1
Prepare the pivot pin, for instance, if fitted, remove
the pivot pin retaining bolt.
2
Determine the thread size of the pivot pin and then fit
the appropriate adaptor 72-A as shown. Use the
spanner flats 72-D to securely fit the adaptor.
3
Fit an end stop 72-B onto the other end of the adaptor
(M20 thread size), make sure that the adaptor
threads are fully engaged.
4
Fit the 'slide bar' 72-E into the end stop. Again make
sure that the threads are fully engaged.
5
Fit the 'slide hammer', item 72-F, onto the slide bar as
shown.
6
Finally, fit another end stop, item 72-C, at the end of
the slide bar, as shown. The slide hammer kit is now
ready to use.
7
To extract the pivot pin, slide the hammer along the
bar until it contacts end stop 72-C. Repeat this step
until the pivot pin is released.
8
To remove the slide hammer kit, reverse steps 2 to 7.
Section 1-6 - General Information
1-6-1
1-6-1
9803/3760-6 (1-07-00)
Service Consumables
Introduction
Consumables such as sealing and retaining compounds are necessary to complete some procedures. Before you start
work make sure that the consumables show in the tables are available.
K Sealing and Retaining Compounds ( T 1-6-2)
Section 1-6 - General Information
Service Consumables
Sealing and Retaining Compounds
1-6-2
1-6-2
9803/3760-6 (1-07-00)
Sealing and Retaining Compounds
T11-001_4
Table 1.
Type
Description
Part No.
Quantity
JCB Multi-Gasket
A medium strength sealant suitable for all sizes of
gasket flanges, and for hydraulic fittings of 25-65 mm
diameter.
4102/1212
50 ml
JCB High Strength Threadlocker
A high strength locking fluid for use with threaded
components. Gasketing for all sizes of flange where
the strength of the joint is important.
4102/0551
50 ml
JCB Retainer (High Strength)
For all retaining parts which are unlikely to be
dismantled.
4101/0601
10 ml
4101/0651
50 ml
JCB Threadlocker and Sealer
A medium strength locking fluid for sealing and
retaining nuts, bolts, and screws up to 50 mm
diameter, and for hydraulic fittings up to 25 mm
diameter.
4101/0250
10 ml
4101/0251
50 ml
JCB Threadlocker and Sealer
(High Strength)
A high strength locking fluid for sealing and retaining
nuts, bolts, and screws up to 50 mm diameter, and
for hydraulic fittings up to 25 mm diameter.
4101/0550
10 ml
4101/0552
200 ml
JCB Threadseal
A medium strength thread sealing compound.
4102/1951
50 ml
JCB Activator
A cleaning primer which speeds the curing rate of
anaerobic products.
4104/0251
200 ml (Aerosol)
4104/0253
1 ltr (Bottle)
JCB Cleaner/Degreaser
For degreasing components prior to use of
anaerobic adhesives and sealants.
4104/1557
400 ml (Aerosol)
Direct Glazing Kit
For one pane of glass; comprises of:
1 x Ultra Fast Adhesive (310 ml)
1 x Active Wipe 205 (30 ml)
1 x Black Primer 206J (30 ml)
plus applicator nozzle etc.
993/55700
Ultra Fast Adhesive
For direct glazing.
4103/2109
310 ml
Active Wipe 205
For direct glazing.
4104/1203
250 ml
Black Primer 206J
For direct glazing.
4201/4906
30 ml
Clear Silicone Sealant
To seal butt jointed glass.
4102/0901
Plastic to Metal Bonder
To seal plastic to metal joints.
4103/0956
50 g
Black Polyurethane Sealant
To finish exposed edges of laminated glass.
4102/2309
310 ml
Section 1-7 - General Information
1-7-1
1-7-1
9803/3760-06 (1-08-00)
Fuel
Introduction
This topic contains information fuel types and use with JCB Dieselmax engines.
When investigating engine related faults find out what types and sources of fuel are used by the operator.
K Related Topics ( T 1-7-2)
K Acceptable and Unacceptable Fuels ( T 1-7-3)
K Additives ( T 1-7-4)
K Service Requirements for use of B20 Biodiesel ( T 1-7-4)
K Fuel Types ( T 1-7-5)
K Usage and Effects of Fuels ( T 1-7-6)
K Sulphur Content ( T 1-7-7)
K Effects of Fuel Contaminates ( T 1-7-8)
Section 1-7 - General Information
Fuel
Related Topics
1-7-2
1-7-2
9803/3760-06 (1-08-00)
Related Topics
Table 1. Related Topics in This Publication
The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to
complete your procedures. Where applicable the text in this section contains cross references to this page to help you find
the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer
to Section 1 - Applications.
Sections Topic Titles
Sub Titles
1
K Machine Identification ( T 1-3-1)
2
ALL (Care and Safety)(1)
(1) You must obey all of the relevant care and safety procedures.
ALL
3
Service Schedules
ALL
Section 1-7 - General Information
Fuel
Acceptable and Unacceptable Fuels
1-7-3
1-7-3
9803/3760-06 (1-08-00)
Acceptable and Unacceptable Fuels
Important: No warranty liability whatsoever will be
accepted for failure of fuel injection equipment where the
failure is attributed to the quality and grade of the fuel used.
!MCAUTION
Consult your fuel supplier or JCB distributor about the
suitability of any fuel you are unsure of.
GEN-9-2
Table 2.
Fuel Specification
Applicable Engines
Service Requirements
EN590 Diesel fuel types - Auto/C0/C1/C2/
C3/C4
All Dieselmax engines.
Obey
the
usual
routine
maintenance
schedules
and
procedures.
BS2869 Class A2
ASTM D975-91 Class 2, US DF1, US DF2,
US DFA
JIS K2204 (1992) Grades 1, 2, 3 and Special
Grade 3
ASTM D975-91 Class 1DA
All Dieselmax engines.
Important: Engines operated with
these fuels may have a reduced
service life.
Obey
the
usual
routine
maintenance
schedules
and
procedures. Fuel additives are
recommended for use with low
sulphur fuels. K Additives ( T 1-
7-4).
MIL T38219 XF63
NATO F63
French EN590 (RME5) with 5% maximum
AVTURFSII, NATO F34, JP8, MIL T83133,
DERD 2463, DEF STAN 91-87
All Dieselmax engines.
Important: Engines operated with
these fuels may have a reduced
service life.
Obey
the
usual
routine
maintenance
schedules
and
procedures. Fuel additives must be
used. K Additives ( T 1-7-4).
AVCAT FSII, NATO F44, JP5, MIL T5624,
DERD 2452, AVTOR
NATO F35, JET A1, DEF STAN 91-91,
DERD 2494, JP7
AVCAT, NATO F43 (obsolete), JP5 without
additives
JET A (ASTM D1655)
ASTM D3699 Kerosene
B20 Biodiesel - RME content blended with
mineral derived diesel (20% maximum) -
ASTM D6751, DIN 51606, ISO 14214
Dieselmax engines manufactured
from 2007 on only(1).
(1) The year of manufacture is part of the engine serial number. Refer to Typical Engine Identification Number.
You must obey special routine
maintenance
schedules
and
procedures. K Warranty ( T 1-
7-4).
AVTAG (obsolete)
These fuels are not acceptable with or
without additives. Engines must not
be operated with these fuels.
AVTAG FSII (obsolete), NATO F40, JP4,
DERD 2454
JET B (ASTM D1655)
BS MA100
JIS K2203 No.2
Unmodified vegetable oils
Section 1-7 - General Information
Fuel
Acceptable and Unacceptable Fuels
1-7-4
1-7-4
9803/3760-06 (1-08-00)
Additives
The additives listed below are advertised as being suitable
for bringing the lubricity levels of kerosene/low sulphur
fuels up to those of diesel fuels. They must be used as
specified by your fuel supplier who will understand the
concentration level necessary.
Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%),
specifically for Indian Superior Kerosene (SKO) but
may be applicable to other fuels.
Lubrizol 539N. Dosage (on Swedish low sulphur fuel)
250 ppm.
Paradyne 7505 (from Infineum). Dosage 500 ppm
(0.05%).
Note: These products are given as examples only. The
information is derived from the manufacturers data. The
products are not recommended or endorsed by JCB.
Service Requirements for use of B20
Biodiesel
The engine oil must be a grade CH4 as minimum
specification.
Do not leave unused B20 biodiesel in the fuel tank for
extended periods (top up each day).
Make sure that 1 in 5 fuel tank fills use standard diesel
to EN590 specification, this will help to prevent
'gumming'.
Make sure regular oil sampling is completed (look for
excessive unburnt fuel content, water or wear
particles.
Change the engine oil and filter more frequently (as a
minimum half the recommended intervals), or as
indicated by oil sampling.
Change the fuel filters more frequently (as a minimum
half the recommended intervals), or if there are
engine performance related issues.
Make sure the fuel is stored correctly, care must be
taken to make sure no water enters the machine fuel
tank (or the storage tank). Water will encourage mico-
bacterial growth.
Make sure that the fuel pre-filter is drained daily (not
every week as currently advised).
Only JCB engines built after Jan. 2007 are applicable
(i.e. engines with 07 on the end of their serial number
and factory filled with CH4 oil) - this is not approved
with other manufacturers.
Use heater kits in low ambient temperature territories.
The biodiesel must meet the following standards:
ASTM D6751, DIN 51606, ISO 14214
Note: If necessary use a test kit to confirm the fuel
specification. Testing kits are available (not from JCB
currently), use the internet as a source for the kits.
Note: If performance related issues are to be reported to
JCB Service, and the engine has been run on biodiesel,
then the fuel system must be filled with standard diesel (at
least 2 x tank fills) to EN590 specification and relevant stall
speeds recorded prior to making the report.
Warranty
JCB have shown a commitment to support
the
environment by approving the use of biodiesel blended
fuels.
Using a B20 blend of biodiesel requires caution and
additional servicing of the engine is required. K Service
Requirements for use of B20 Biodiesel ( T 1-7-4).
Failure to follow the additional recommended service
requirements may lead to a warranty claim being declined.
Failures resulting by the incorrect use of biodiesels or
other fuel additives are not defects of the JCB Dieselmax
engine workmanship and therefore will not be supported
by JCB Warranty.
Section 1-7 - General Information
Fuel
Acceptable and Unacceptable Fuels
1-7-5
1-7-5
9803/3760-06 (1-08-00)
Fuel Types
Note: The information that follows does not indicate types
of fuel that are acceptable or unacceptable. K Acceptable
and Unacceptable Fuels ( T 1-7-3).
Any fuel purchased for operation of the JCB Dieselmax
engine must be purchased from reputable oil producers/
outlets and stored in accordance with the manufacturers
recommendations.
K Effects
of
Fuel
Contaminates ( T 1-7-8)
1
Diesel - mineral derived, hydrocarbon fuels to
European standard EN590 or equivalent.
2
Low Sulphur Diesel - mineral derived, hydrocarbon
fuels to EN590 or equivalent. This fuel has totally
replaced automotive (road use) diesel
in the
European Union since October 1996 and has sulphur
limited to a maximum of 0.05% by weight.
3
Ultra Low Sulphur Diesel - Reformulated mineral
derived, hydrocarbon fuels to EN590 or equivalent.
Now widely available in the UK, mainland Europe and
some parts of the USA. Sulphur limited to a maximum
of 0.005% by weight or
lower. K Sulphur
Content ( T 1-7-7)
4
Vegetable Oil -unmodified. Certain pure vegetable
oils (sunflower oil, rapeseed oil etc.)
5
Biodiesel - chemically modified vegetable oil. By
chemically modifying vegetable oils, methyl esters of
that oil are produced. These are collectively known as
"Fatty Acid Methyl Esters" (FAME) or "Vegetable Oil
Methyl Esters" (VOME).
Note: Refer also to additional information. K Usage and
Effects of Fuels ( T 1-7-6).
Section 1-7 - General Information
Fuel
Acceptable and Unacceptable Fuels
1-7-6
1-7-6
9803/3760-06 (1-08-00)
Usage and Effects of Fuels
Note: The information that follows does not indicate types
of fuel that are acceptable or unacceptable. K Acceptable
and Unacceptable Fuels ( T 1-7-3).
1
Low Sulphur Diesel
In its basic form because of the process of reducing
sulphur by removal of sulphur containing compounds
(which contribute to mechanical lubrication) an
increase in the wear rate of the fuel injection
equipment could occur. In view of this, the major fuel
producers add suitable lubricity improvers to enable
the FIE to run satisfactorily, with no acceleration in
wear rate. They must ensure that the lubricity
improvers do not themselves create residual deposits
that could block the fuel system e.g. filter, injectors
etc.
In addition to the lubrication effect there can also be a
further reduction in the aromatic content of the fuel
which can lead to shrinking/cracking of traditionally
nitrile rubber seals throughout the fuel injection
equipment that has previously been exposed to
higher sulphur level fuels. The major fuel producers
tend to maintain the total aromatic content to an
acceptable level (15% by volume).
2
Ultra Low Sulphur Diesel
Also known as `city diesel'. Available throughout the
UK and some parts of Europe since March 1999. This
fuel has a maximum sulphur content of 0.005% by
weight and a further reduction in the natural lubricity
and aromatic content than experienced with low
sulphur diesel. Major oil producers will add lubrication
improvers and also maintain the total aromatic
content to an acceptable level.
3
Unmodified Vegetable Oils
Burned in diesel engines neat or used as an extender
to mineral derived fuel. When these are subjected to
heat in the fuel injection system they form sticky
deposits that can be found inside the fuel pump and a
hard lacquer in the injectors where exposure to even
higher temperatures takes place.
4
Chemically Modified Vegetable Oils (FAME/VOME)
These fuels have been derived from a wide range of
vegetable oils and animal fats, resulting in better
stability, viscosity and cetane number than those
produced from unmodified vegetable oils, but it is
recognised that
there are potential problems
associated with the finished fuel characteristics.
These oils are less stable than mineral oil derived
fuels when stored and they will readily degrade
producing fatty acids, methanol and water, none of
which are desirable in the FIE. These effects are
known to be accelerated when the fuel is stored in the
presence of air and water together.
An extract `common statement' from the FIE
manufactures specifies that "The fuel injection
equipment manufacturers can accept no liability
whatsoever for failure attributable to operating their
products with fuels for which the products were not
designed, and no warranties or representations are
made as to the possible effects of running these
products with such fuels".
The three most common Fame types are RME -
Rapeseed methyl ester (preferred crop in Europe),
SME - Soyabean methyl ester (preferred crop in
USA). Less common FAME's can be derived from
animal fats (e.g. modified beef extracts) and
reclaimed cooking oils.
5
B20 Biodiesel
Biodiesel refers to pure fuel (FAME/VOL) before it is
blended with diesel fuel K Chemically Modified
Vegetable Oils (FAME/VOME) ( T 1-7-6). When
biodiesel is blended with diesel fuel it is referred to as
B5, B20 etc., where the number indicates the
percentage of biodiesel in the fuel, for example B5
contains 5% biodiesel.
Biodiesel has different characteristics than mineral
based fuels in that it is able to mix with water and
therefore will have a high water retention capacity -
this could lead to seals swelling, fuel system
corrosion and seal damage.
Biodiesels will `cloud' at higher temperatures than
mineral based fuels. To explain Cloud Point - the
lowest temperature at which fluid can flow and
performs its functions is referred to as Pour Point.
Just prior to reaching its Pour Point the diesel fluid
becomes `cloudy' due to crystallization of waxy
constituents - this is know as Cloud Point. Using
diesel at temperature below its cloud point can result
Section 1-7 - General Information
Fuel
Acceptable and Unacceptable Fuels
1-7-7
1-7-7
9803/3760-06 (1-08-00)
in filter clogging. To prevent this happening pre-
heating will be required.
Using B20 biodiesel can result in unburnt fuels
accumulating in the engine oil, ultimately this can
affect the engine oil efficiency and lead to engine
damage (with standard diesel any unburnt fuel
evaporates off the lubricating oil). Biodiesels must be
stored to exclude water absorption and oxidation.
The natural properties of biodiesel make it a good
medium for micro bacterial growth, these microbes
can cause fuel system corrosion and early fuel filter
blocking. It will be necessary to consult and seek
advice from your fuel supplier, the effectiveness of
conventional antibacterial additives when used in
biodiesel is still being investigated in the fuel industry.
A high percentage biodiesel mixture (>20%) can lead
to fuel gelling and filter blocking in low temperature
operation,
it may also effect the power and
performance of the engine.
To minimise the risk of engine damage when using a
B20 mix, there are additional service requirements.
K Service Requirements
for use of B20
Biodiesel ( T 1-7-4)
If the recommended actions are not taken there may
be the following consequences:- low temperature
filter clogging-
injectors
lacquering / sticking-
deterioration of seals and rubber hoses- corrosion of
metal parts in the fuel system- engine performance
problems. These risks will be increased if the fuel has
been poorly stored, that is deteriorated through
oxidation and / or water absorption.
Sulphur Content
High sulphur content can cause engine wear. (High
sulphur fuel is not normally found in North America,
Europe or Australia.) If you have to use high sulphur fuel
you must change the engine oil more frequently.
K Table 3. Sulphur Content ( T 1-7-7).
Low sulphur fuels must have the appropriate fuel lubricity
additives, these lubricity improvers must not create
residual deposits that block the fuel system, e.g. injectors,
filters etc. Contact your fuel Supplier.
!MCAUTION
A combination of water and sulphur will have a
corrosive chemical effect on fuel injection equipment.
It is essential that water is eradicated from the fuel
system when high sulphur fuels are used.
ENG-3-2
Table 3. Sulphur Content
Percentage of sulphur in
the fuel (%)
Oil Change Interval
Less than 0.5
Normal
0.5 to 1.0
0.75 of normal
More than 1.0
0.50 of normal
Section 1-7 - General Information
Fuel
Acceptable and Unacceptable Fuels
1-7-8
1-7-8
9803/3760-06 (1-08-00)
Effects of Fuel Contaminates
The effect of dirt, water and other contaminants in diesel
can be disastrous for injection equipment:
Dirt - A severely damaging contaminant. Finely
machined and mated surfaces such as delivery
valves and distributor rotors are susceptible to the
abrasive nature of dirt particles - increased wear will
almost inevitably lead to greater leakage, uneven
running and poor fuel delivery.
Water - water can enter fuel through poor storage or
careless handling, and will almost
inevitably
condense in fuel tanks. The smallest amounts of
water can result in effects that are just as disastrous
to the fuel injection pump as dirt, causing rapid wear,
corrosion and in severe cases, even seizure. It is
vitally important that water is prevented from reaching
the fuel injection equipment. The filter/water trap must
be drained regularly.
Wax - Wax is precipitated from diesel when the
ambient temperature falls below that of the fuel's
cloud point, causing a restriction in fuel flow resulting
in rough engine running. Special winter fuels may be
available for engine operation at temperatures below
0C (32F). These fuels have a lower viscosity and
limit wax formation.
Section 1-8 - General Information
1-8-1
1-8-1
9803/3760-06 (1-15-00)
Stall Speed Combinations
Introduction
If the operator reports poor machine performance the stall speed test is a very useful way to quickly and easily determining
if the engine, transmission or hydraulic system is faulty. Do the stall speed tests to help diagnose which system is at fault.
Refer to the applicable section (Hydraulics, Transmission or Engine) for details of the test procedures.
K Related Topics ( T 1-8-2)
K Specifications ( T 1-8-3)
Section 1-8 - General Information
Stall Speed Combinations
Related Topics
1-8-2
1-8-2
9803/3760-06 (1-15-00)
Related Topics
Table 1. Related Topics in This Publication
The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to
complete your procedures. Where applicable the text in this section contains cross references to this page to help you find
the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer
to Section 1 - Applications.
Sections Topic Titles
Sub Titles
1
K Machine Identification ( T 1-3-1)
2
ALL (Care and Safety)(1)
(1) You must obey all of the relevant care and safety procedures.
ALL
3
Service Schedules
ALL
Section 1-8 - General Information
Stall Speed Combinations
Specifications
1-8-3
1-8-3
9803/3760-06 (1-15-00)
Specifications
K Table 2. Stall Speed Combinations ( T 1-8-4).
Tests carried out at the factory record the correct engine
r.p.m. (stall speed) when under maximum load from the
transmission and hydraulic systems.
The figures relate to tests conducted at an ambient of 25
0C and barometric pressure of 100 kPa (sea level). Note
that changes in ambient temperature, pressure and
humidity and fuel grade will affect engine power and hence
the stall figures.
As an example, at 10,000 ft the power reduction of a
naturally aspirated engine could be 29% and for a turbo
engine 8%.
Note: The figures apply to `bedded-in' engines, i.e.
engines that have done a minimum of 250 working hours,
therefore they should not be used for pre-delivery
inspection (PDI) checks.
All figures are recorded with the transmission oil at 60C
(140 F) and the hydraulic oil at 55 C (131 F). Figures
achieved should be within +/- 100 rpm from the figures
given in the table.
Section 1-8 - General Information
Stall Speed Combinations
Specifications
1-8-4
1-8-4
9803/3760-06 (1-15-00)
Table 2. Stall Speed Combinations
Engine Build Code
SA
SB
SC
SC
SD
SE
SF
Engine Stall Speeds r.p.m.
Torque Converter Only
1798
1844
1850
2165
1820
2000
(2120(1))
(1) Machines with Variflow pump
2000
Hydraulics (M.R.V.) Only
2330
2315
2350
2350
2370
2350
2340
Combined Converter + M.R.V. (2)
(2) Combined stall tests on machines fitted with a hydraulic gearpump are performed with the crowd service operated
until the relief valve is lifted.
1347
1629
1655
1890
1300
1725
1760(3)
(3) Make sure that the hydraulic oil temperature is 60 degrees C.
Combined Converter + L.S.R.V.
LSP Variflow
1720(4)(5)(6)
(4) Make sure that the control valve block LSRV and variflow pump Delta P pressure is set correctly.
(5) Make sure that the hydraulic oil temperature is 50 degrees C.
(6) To obtain the combined stall figure make sure that the boom is unladen, the transmission is stalled and the control
lever is in the fully lower position.
LSP Electro Servo
1620(4)(5)(6)
Build Specification
Engine size:
85 h.p. Naturally Aspirated
z
85 h.p. Turbocharged
z
100 h.p. Turbocharged
z
100 h.p Turbocharged and
Intercooled
z
114 h.p Turbocharged and
Intercooled
z
125 h.p. Turbocharged and
Intercooled
z
z
130 h.p. Turbocharged and
Intercooled
z
Gearbox:
4 Speed Syncro Shuttle
z
z
z
4 Speed Powershift
z
z
z
z
6 Speed Powershift
z
z
Hydraulic System:
Gearpump
z
z
z
z
z
z
z
LSP Variflow
z
LSP Electro Servo
z
Copyright 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,
electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.
World Class
Customer Support
9803/3760-07
Publication No.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Section 2
Care and Safety
Service Manual - Side Engine Loadalls
Section 1 - General Information
Section 2 - Care and Safety
Section 3 - Routine Maintenance
Section B - Body and Framework
Section C - Electrics
Section E - Hydraulics
Section F - Transmission
Section G - Brakes
Section H - Steering
Section K - Engine
Section M - Electronic Data Systems
Section 2 - Care and Safety
2-0
2-0
9803/3760-07
Notes:
Page No.
Contents
Section 2 - Care and Safety
2 - i
2 - i
Safety Notices
Introduction ............................................................................................2-1 - 1
Important Information ............................................................................2-1 - 2
Safety Check List ...................................................................................2-1 - 3
Safety Decals ......................................................................................2-1 - 16
General Procedures
Introduction ............................................................................................2-2 - 1
Related Topics .......................................................................................2-2 - 2
Parking the Machine and Making it Safe ...............................................2-2 - 3
Boom Safety Strut .................................................................................2-2 - 4
Venting Hydraulic Pressure ...................................................................2-2 - 6
Connecting/Disconnecting Hydraulic Hoses ..........................................2-2 - 7
Quick Release Couplings ......................................................................2-2 - 8
Hydraulic Contamination .....................................................................2-2 - 10
Battery Disconnection/Connection ......................................................2-2 - 12
Removing and Replacing Components ...............................................2-2 - 13
Battery Charging System Precautions .................................................2-2 - 14
Hydraulic Rams ...................................................................................2-2 - 15
Page No.
Contents
Section 2 - Care and Safety
2 - ii
2 - ii
Section 2-1 - Care and Safety
2-1-1
2-1-1
9803/3760-07 (2-01-01)
Safety Notices
Introduction
In this publication and on the machine, there are safety
notices. Each notice starts with a signal word. The signal
word meanings are given below.
!MDANGER
Denotes an extreme hazard exists.
If proper
precautions are not taken, it is highly probable that the
operator (or others) could be killed or seriously
injured.
INT-1-2-1
!MWARNING
Denotes a hazard exists. If proper precautions are not
taken, the operator (or others) could be killed or
seriously injured.
INT-1-2-2
!MCAUTION
Denotes a reminder of safety practices. Failure to
follow these safety practices could result in injury to
the operator (or others) and possible damage to the
machine.
INT-1-2-3
Section 2-1 - Care and Safety
Safety Notices
Important Information
2-1-2
2-1-2
9803/3760-07 (2-01-01)
Important Information
T1-042
The Operator Manual
!MWARNING
You and others can be killed or seriously injured if you
operate or maintain the machine without first studying
the Operator Manual. You must understand and follow
the instructions in the Operator Manual. If you do not
understand anything, ask your employer or JCB
dealer to explain it.
INT-1-4-2
Do not operate the machine without an Operator Manual,
or if there is anything on the machine you do not
understand.
Treat the Operator Manual as part of the machine. Keep it
clean and in good condition. Replace the Operator Manual
immediately if it is lost, damaged or becomes unreadable.
Safety Warnings
In this publication and on the machine, there are safety
notices. Each notice starts with a signal word. The signal
word meanings are given below.
!MDANGER
Denotes an extreme hazard exists.
If proper
precautions are not taken, it is highly probable that the
operator (or others) could be killed or seriously
injured.
INT-1-2-1
!MWARNING
Denotes a hazard exists. If proper precautions are not
taken, the operator (or others) could be killed or
seriously injured.
INT-1-2-2
!MCAUTION
Denotes a reminder of safety practices. Failure to
follow these safety practices could result in injury to
the operator (or others) and possible damage to the
machine.
INT-1-2-3
This safety alert system
identifies
important safety messages
in
this
manual. When you see this symbol, be
alert, your safety is involved, carefuly
read the message that follows, and inform
other operators.
Section 2-1 - Care and Safety
Safety Notices
Safety Check List
2-1-3
2-1-3
9803/3760-07 (2-01-01)
Safety Check List
Safety - Yours and Others
INT-1-3-1_3
All machinary can be hazardous. When a machine is
correctly operated and properly maintained, it is a safe
machine to work with. But when it is carelessly operated or
poorly maintained it can become a danger to you (the
operator) and others.
In this manual and on the machine you will find warning
messages. Read and understand them. They tell you of
potential hazards and how to avoid them. If you do not fully
understand the warning messages, ask your employer or
JCB distributor to explain them.
But safety is not just a matter of responding to the
warnings. All the time you are working on or with the
machine you must be thinking what hazards there might be
and how to avoid them.
Do not work with the machine until you are sure that you
can control it.
Do not start any job until you are sure that you and those
around you will be safe.
If you are unsure of anything, about the machine or the job,
ask someone who knows. Do not assume anything.
Remember
BE CAREFUL
BE ALERT
BE SAFE
Common Rail (SE Engine) Specific
In addition to the general safety notices and general good
workshop practices issued in this section and throughout
the manual, there are specific points to note when
completing maintenance on SE engine equipment:
Diesel Fuel Quality
Important: The potential for engine damage due to the
use of incorrect or contaminated fuel is much greater with
common rail injection technology than with mechanical
injection systems.
For more information about cleanliness requirements and
fuel types refer to Section 1 - General Information.
!MCAUTION
Do not allow dirt to enter the fuel system. Before
disconnecting any part of the fuel system, thoroughly
clean around the connection. When a component has
been disconnected, for example a fuel pipe, always fit
protective caps and plugs to prevent dirt ingress.
Failure to follow these instruction will lead to dirt
entering the fuel system. Dirt in the fuel system will
seriously damage the fuel injection equipment and
could be expensive to repair.
ENG-1-7
Section 2-1 - Care and Safety
Safety Notices
Safety Check List
2-1-4
2-1-4
9803/3760-07 (2-01-01)
Effects of Contamination
Once inside the system, fuel circuit contaminants greatly
effect the performance and life of the fuel injection
equipment. For example, contaminants in the fuel pump
will develop internal wear to cause internal leakage and
hence lower discharges. Use of poor quality fuels and poor
maintenance could also lead to contaminants entering the
fuel injectors. There is a possibility of catastrophic
equipment failure if debris should prevent the injectors
from fully closing. The main contaminants can be classified
as follows: These contaminations can appear during
manufacture. assembly and operation.
Solid Particles - sand, fibres, metallic particles,
welding scale, sealing materials and wear particles
etc.
Liquid - usually water and incompatible oils and
gases.
Gases - Air, sulphur dioxide etc. which can create
corrosive compounds if dissolved in the fluid.
It is critical that the machine is thoroughly cleaned prior to
completing any maintenance work. The main filter is rated
at 2 micron = 0.002 mm (0.0007874 in).
Listed are a few typical comparisons of micron size:
Red Blood Cell = 8 microns (0.008 mm, 0.000315 in).
Human Hair = 70 microns (0.07 mm, 0.00275 in).
Grain of Salt = 100 microns (0.1 mm, 0.00394 in).
The smallest particle visible to the naked eye is 40
microns (0.00157 in) approximately.
Common Rail Safety Checklist
The following safety checklist is intended to help remind
you of safety procedures and practices relating to a
common rail SE engine.
SAFETY IS YOUR RESPONSIBILITY
Do make sure the engine and surrounding area has
been thoroughly cleaned prior to completing any
maintenance tasks. Refer to Section 1, Cleanliness
Requirements.
Do complete all work in accordance with the Service
Manual procedures.
Do disconnect both the battery positive (+) and
battery negative (-) cables prior to completing any
welding on the machine.
Do use the recommended grade of fuel (EN590). The
fuel injection pump, injector or other parts of the fuel
system can be damaged if you use a fuel or fuel
additives not recommended by JCB. Refer to Section
1 - Acceptable and Unacceptable Fuels.
Do make sure all the necessary new parts are
available before starting any maintenance work.
Do not `crack' the injector high pressure fuel lines to
bleed the fuel system. The system operates at
pressures in excess of 1200 bar (17400lbs/in2).
Do not steam clean the electronic control unit (ECU)
or the ECU connectors.
Do not touch the ECU connector pins, this will
eliminate the possibility of damage caused by
electrostatic discharge.
Do not leave any fuel connections `open' for any
extended period of time.
Do not open any new parts packaging until the part is
ready to be fitted. Unnecessary exposure will
increase the risk of contamination.
Do not reuse high pressure fuel pipes. Reusing the
pipes will lead to potential fuel leaks.
Do not attempt to remove and replace the rail
pressure sensor or high pressure valve. It is not
possible to refit these components without the risk of
fuel leaks. If the valve or sensor is diagnosed as faulty
then a new common rail assembly must be fitted.
Section 2-1 - Care and Safety
Safety Notices
Safety Check List
2-1-5
2-1-5
9803/3760-07 (2-01-01)
General Safety
T1-043
!MWARNING
To operate the machine safely you must know the
machine and have the skill to use it. You must abide by
all relevant laws, health and safety regulations that
apply to the country you are operating in. The
Operator Manual instructs you on the machine, its
controls and its safe operation; it is not a training
manual. If you are a new operator, get yourself trained
in the skills of using a machine before trying to work
with it. If you don't, you will not do your job well, and
you will be a danger to yourself and others.
INT-1-4-1
!MWARNING
Care and Alertness
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always be
alert for hazards.
INT-1-3-5
!MWARNING
Clothing
You can be injured if you do not wear the proper
clothing. Loose clothing can get caught in the
machinery. Wear protective clothing to suit the job.
Examples of protective clothing are: a hard hat, safety
shoes, safety glasses, a well fitting overall, ear-
protectors and industrial gloves. Keep cuffs fastened.
Do not wear a necktie or scarf. Keep long hair
restrained. Remove rings, watches and personal
jewellery.
INT-1-3-6_2
!MWARNING
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be aware
of medicines which can cause drowsiness.
INT-1-3-9_2
!MWARNING
Feeling Unwell
Do not attempt to operate the machine if you are
feeling unwell. By doing so you could be a danger to
yourself and those you work with.
8-1-2-4
!MWARNING
Mobile Phones
Switch off your mobile phone before entering an area
with a potentially explosive atmosphere. Sparks in
such an area could cause an explosion or fire
resulting in death or serious injury.
Switch off and do not use your mobile phone when
refuelling the machine.
INT-3-3-9
!MWARNING
Lifting Equipment
You can be injured if you use faulty lifting equipment.
Make sure that lifting equipment is in good condition.
Make sure that lifting tackle complies with all local
regulations and is suitable for the job. Make sure that
lifting equipment is strong enough for the job.
INT-1-3-7
!MWARNING
Raised Equipment
Never walk or work under raised equipment unless it
is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails or if
the control is operated (even with the engine stopped).
Make sure that no-one goes near the machine while
you install or remove the mechanical device.
13-2-3-7_3
!MWARNING
Raised Machine
NEVER position yourself or any part of your body
under a raised machine which is not properly
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be
killed.
INT-3-3-7_1
Section 2-1 - Care and Safety
Safety Notices
Safety Check List
2-1-6
2-1-6
9803/3760-07 (2-01-01)
!MDANGER
Lightning
Lightning can kill you. Do not use the machine if there
is lightning in your area.
5-1-1-2
!MWARNING
Machine Modifications
This machine is manufactured in compliance with
legislative and other requirements. It should not be
altered in any way which could affect or invalidate any
of these requirements. For advice consult your JCB
Distributor.
INT-1-3-10_2
Section 2-1 - Care and Safety
Safety Notices
Safety Check List
2-1-7
2-1-7
9803/3760-07 (2-01-01)
Operating Safety
!MWARNING
Machine Condition
A defective machine can injure you or others. Do not
operate a machine which is defective or has missing
parts. Make sure the maintenance procedures in this
manual are completed before using the machine.
INT-2-1-2_2
!MWARNING
Machine Limits
Operating the machine beyond its design limits can
damage the machine, it can also be dangerous. Do not
operate the machine outside its limits. Do not try to
upgrade the machine performance with unapproved
modifications.
INT-2-1-4
!MWARNING
Engine/Steering Failure
If the engine or steering fails, stop the machine as
quickly as possible. Do not operate the machine until
the fault has been corrected.
INT-2-1-5
!MWARNING
The engine has exposed rotating parts. Switch OFF the
engine before working in the engine compartment. Do
not use the machine with the engine cover open.
5-2-6-5
!MWARNING
Exhaust Gases
Breathing the machine exhaust gases can harm and
possibly kill you. Do not operate the machine in closed
spaces without making sure there is good ventilation.
If possible, fit an exhaust extension. If you begin to
feel drowsy, stop the machine at once and get into
fresh air.
INT-2-1-10_2
!MWARNING
You could be killed or seriously injured if you operate
a machine with a damaged or missing ROPS/FOPS. If
the Roll Over Protection Structure (ROPS)/Falling
Objects Protection Structure (FOPS) has been in an
accident, do not use the machine until the structure
has been renewed. Modifications and repairs that are
not approved by the manufacturer may be dangerous
and will invalidate the ROPS/FOPS certification.
INT-2-1-9_6
!MWARNING
Work Sites
Work sites can be hazardous. Inspect the site before
working on it. Look for potholes, weak ground, hidden
rocks etc. Check for utilities such as electric cables
(overhead and underground), gas and water pipes etc.
Mark the positions of the underground cables and
pipes. Make sure that you have enough clearance
beneath overhead cables and structures.
INT-2-2-1
!MWARNING
Communications
Bad communications can cause accidents. Keep
people around you informed of what you will be doing.
If you will be working with other people, make sure any
hand signals that may be used are understood by
everybody. Work sites can be noisy, do not rely on
spoken commands.
INT-2-2-3
!MWARNING
Parking
An incorrectly parked machine can move without an
operator. Follow the instructions in the Operator
Manual to park the machine correctly.
INT-2-2-4_2
!MWARNING
Banks and Trenches
Banked material and trenches can collapse. Do not
work or drive too close to banks and trenches where
there is danger of collapse.
INT-2-2-5
Section 2-1 - Care and Safety
Safety Notices
Safety Check List
2-1-8
2-1-8
9803/3760-07 (2-01-01)
!MWARNING
Ramps and Trailers
Water, mud, ice, grease and oil on ramps or trailers can
cause serious accidents. Make sure ramps and trailers
are clean before driving onto them. Use extreme
caution when driving onto ramps and trailers.
INT-2-2-6
!MWARNING
Safety Barriers
Unguarded machines in public places can be
dangerous. In public places, or where your visibility is
reduced, place barriers around the work area to keep
people away.
INT-2-2-8
!MDANGER
Sparks
Explosions and fire can be caused by sparks from the
exhaust or the electrical system. Do not use the
machine in closed areas where there is flammable
material, vapour or dust.
INT-2-2-10
!MWARNING
Hazardous Atmospheres
This machine is designed for use in normal out door
atmospheric conditions. It should not be used in an
enclosed area without adequate ventilation. Do not
use
the machine
in a potentially explosive
atmosphere, i.e. combustible vapours, gas or dust,
without first consulting your JCB Distributor.
INT-2-1-14
!MCAUTION
Regulations
Obey all laws, work site and local regulations which
affect you and your machine.
INT-1-3-3
!MWARNING
Practice
You or others can be killed or seriously injured if you
do unfamiliar operations without first practising them.
Practise away from the work site on a clear area. Keep
other people away. Do not perform new operations
until you are sure you can do them safely.
INT-2-1-1
!MWARNING
Reversing
Reversing at high speeds can cause accidents. Do not
reverse in a high gear with full throttle. Always drive at
a safe speed to suit working conditions.
INT-2-2-9_1
!MWARNING
Airborne particles of light combustible material such
as straw, grass, wood shavings, etc. must not be
allowed to accumulate within the engine compartment
or in the propshaft guards (when fitted). Inspect these
areas frequently and clean at the beginning of each
work shift or more often if required. Before opening
the engine cover, ensure that the top is clear of debris.
5-3-1-12_3
!MWARNING
Keep the machine controls clean and dry. Your hands
and feet could slide off slippery controls. If that
happens you could lose control of the machine.
2-2-3-6
!MWARNING
Visibility
Accidents can be caused by working in poor visibility.
Use your lights to improve visibility. Keep the road
lights, windows and mirrors clean.
Do not operate the machine if you cannot see clearly.
5-1-4-7
Section 2-1 - Care and Safety
Safety Notices
Safety Check List
2-1-9
2-1-9
9803/3760-07 (2-01-01)
!MWARNING
Electrical Power Cables
You could be electrocuted or badly burned if you get
the machine or its attachments too close to electrical
power cables.
You are strongly advised to make sure that the safety
arrangements on site comply with the local laws and
regulations concerning work near electric power lines.
Before you start using the machine, check with your
electricity supplier if there are any buried power
cables on the site.
There is a minimum clearance required for working
beneath overhead power cables. You must obtain
details from your local electricity supplier.
2-2-5-4
!MCAUTION
If you have an attachment which is not covered in the
Operator Manual do not install it, use it or remove it
until you have obtained, read and understood the
pertinent information. Install attachments only on the
machines for which they were designed.
5-5-1-1_2
!MWARNING
Use only the JCB approved attachments that are
specified for your machine. Operating with non-
specified attachments can overload the machine,
causing possible damage and machine instability
which could result in injury to yourself or others.
The use of non-approved attachments could invalidate
your warranty.
2-4-5-2_1
!MWARNING
Controls
You or others can be killed or seriously injured if you
operate the control levers from outside the machine.
Operate the control levers only when you are correctly
seated.
0179_2
!MWARNING
Fires
If your machine is equipped with a fire extinguisher,
make sure it is checked regularly. Keep it in the correct
machine location until you need to use it.
Do not use water to put out a machine fire, you could
spread an oil fire or get a shock from an electrical fire.
Use carbon dioxide, dry chemical or
foam
extinguishers. Contact your nearest fire department as
quickly as possible. Firefighters should use self-
contained breathing apparatus.
INT-3-2-7_2
!MWARNING
Should the machine start to roll over, you can be
crushed if you try to leave the cab. If the machine
starts to roll over, do not try and jump from the cab.
Stay in the cab, with your seat belt fastened.
INT-2-1-12
!MCAUTION
Fork Spacing
Loads can fall off incorrectly spaced forks. Always
space the forks correctly for the load. Make sure the
forks are completely under the load before lifting.
5-1-4-2
!MCAUTION
One-Fork Lifting
A load lifted on one fork can slip off. Never lift a load
with one fork.
5-1-4-3
!MCAUTION
Unloading
Never unload the forks by stopping the machine
suddenly. Follow the procedures in the Operator
Manual for unloading.
5-1-4-4_2
!MCAUTION
Uneven Ground
Loads stacked on uneven ground can topple. Never
stack loads on uneven ground.
5-1-4-5
Section 2-1 - Care and Safety
Safety Notices
Safety Check List
2-1-10
2-1-10
9803/3760-07 (2-01-01)
!MWARNING
Scaffolding
Overloaded scaffolding can collapse. Never load
scaffolding beyond the regulation capacity.
5-1-4-6
!MCAUTION
Overhead Clearance
A raised boom can strike overhead objects. Always
check for overhead clearance before raising the boom.
5-1-5-1
!MWARNING
Boom/Travelling
Operating the boom while travelling can cause
accidents. You will not have total control of the
machine. Never operate the boom while travelling.
5-1-5-2
!MDANGER
Forks/Working Platform
Using the forks alone as a working platform is
hazardous; you can fall off and be killed or injured.
Never use the forks as a working platform.
5-1-5-3
!MWARNING
Forks/Turning
The forks extend beyond the end of the boom. Make
sure there is enough clearance for the forks when
making turns.
5-1-5-4
!MWARNING
Entering/Leaving
Entering or leaving the cab or canopy must only be
made where steps and handrails are provided. Always
face the machine when entering and leaving. Make
sure the step(s), handrails and your boot soles are
clean and dry. Do not jump from the machine. Do not
use the machine controls as handholds, use the
handrails.
INT-2-1-7_1
!MWARNING
Controls
You or others can be killed or seriously injured if you
operate the control levers from outside the machine.
Operate the control levers only when you are correctly
seated in the machine.
0179
!MWARNING
Powershift Transmission
Do not change from a high gear to a low gear (for
instance, 4th to 1st) in one sudden movement when
the machine is moving. Otherwise the machine will
rapidly decelerate, you or others could be killed or
seriously injured. When selecting lower gears, allow
the engine speed to drop before each gear change.
2-1-1-9_1
!MCAUTION
Passengers
Passengers in or on the machine can cause accidents.
Do not carry passengers.
INT-2-2-2_1
Section 2-1 - Care and Safety
Safety Notices
Safety Check List
2-1-11
2-1-11
9803/3760-07 (2-01-01)
Maintenance Safety
!MWARNING
Communications
Bad communications can cause accidents. If two or
more people are working on the machine, make sure
each is aware of what the others are doing. Before
starting the engine make sure the others are clear of
the danger areas; examples of danger areas are: the
rotating blades and belt on the engine,
the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured if
these precautions are not taken.
INT-3-1-5
!MWARNING
Repairs
If your machine does not function correctly in any way,
get it repaired straight away. Neglect of necessary
repairs could result in an accident or affect your
health. Do not try to do repairs or any other type of
maintenance work you do not understand. To avoid
injury and/or damage get the work done by a specialist
engineer.
GEN-1-5_2
!MWARNING
Metal Splinters
You can be injured by flying metal splinters when
driving metal pins in or out. Use a soft faced hammer
or copper pin to remove and fit metal pins. Always
wear safety glasses.
INT-3-1-3_2
!MWARNING
Electrical Circuits
Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong
connection can cause injury and/or damage.
INT-3-1-4
!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of fluid. If
fluid penetrates your skin, get medical help
immediately.
INT-3-1-10_3
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service
hose line must be vented. Make sure the hose service
line has been vented before connecting or removing
hoses. Make sure the engine cannot be started while
the hoses are open.
INT-3-1-11_2
!MWARNING
Fuel
Fuel is flammable; keep naked flames away from the
fuel system. Stop the engine immediately if a fuel leak
is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel
which could cause a fire. There could be a fire and
injury if you do not follow these precautions.
INT-3-2-2_3
!MWARNING
Oil
Oil is toxic. If you swallow any oil, do not induce
vomiting, seek medical advice. Used engine oil
contains harmful contaminants which can cause skin
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves to
prevent skin contact. Wash skin contaminated with oil
thoroughly in warm soapy water. Do not use petrol,
diesel fuel or paraffin to clean your skin.
INT-3-2-3
Section 2-1 - Care and Safety
Safety Notices
Safety Check List
2-1-12
2-1-12
9803/3760-07 (2-01-01)
!MCAUTION
It is illegal to pollute drains, sewers or the ground.
Clean up all spilt fluids and/or lubricants.
Used fluids and/or lubricants, filters and contaminated
materials must be disposed of in accordance with
local regulations. Use authorised waste disposal sites.
INT-3-2-14
!MWARNING
Soft Ground
A machine can sink into soft ground. Never work
under a machine on soft ground.
INT-3-2-4
!MWARNING
Always wear safety glasses when dismantling
assemblies containing components under pressure
from springs. This will protect against eye injury from
components accidentally flying out.
GEN-6-2
!MCAUTION
Rams
The efficiency of the rams will be affected if they are
not kept free of solidified dirt. Clean dirt from around
the rams regularly. When leaving or parking the
machine, close all rams if possible to reduce the risk
of weather corrosion.
INT-3-2-10
!MCAUTION
Cleaning
Cleaning metal parts with incorrect solvents can cause
corrosion. Use only recommended cleaning agents
and solvents.
INT-3-2-11
!MWARNING
When using cleaning agents, solvents or other
chemicals, you must adhere to the manufacturer's
instructions and safety precautions.
GEN-1-9
!MCAUTION
'O' rings, Seals and Gaskets
Badly fitted, damaged or rotted 'O' rings, seals and
gaskets can cause leakages and possible accidents.
Renew whenever disturbed unless otherwise
instructed. Do not use Triochloroethane or paint
thinners near 'O' rings and seals.
INT-3-2-12
!MWARNING
Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the
hoses regularly. Do not use the machine if a hose or
hose fitting is damaged.
INT-3-3-2_4
!MCAUTION
Waxoyl contains turpentine substitute which is
flammable. Keep flames away when applying Waxoyl.
Waxoyl can take a few weeks to dry completely. Keep
flames away during the drying period.
Do not weld near the affected area during the drying
period. Take the same precautions as for oil to keep
Waxoyl off your skin. Do not breathe the fumes. Apply
in a well-ventilated area.
5-3-1-9
!MWARNING
Working Under the Machine
Make the machine safe before getting beneath it.
Ensure that any fitments on the machine are secure;
engage the park brake, remove the starter key,
disconnect the battery.
INT-3-3-8_2
Section 2-1 - Care and Safety
Safety Notices
Safety Check List
2-1-13
2-1-13
9803/3760-07 (2-01-01)
!MWARNING
Certain seals and gaskets (e.g. crankshaft oil seal) on
JCB machines contain fluoroelastomeric materials
such
as
Viton,
Fluorel
and
Technoflon.
Fluoroelastomeric materials subjected
to high
temperatures
can
produce
highly
corrosive
hydrofluoric acid. THIS ACID CAN SEVERELY BURN.
New fluoroelastomeric components at ambient
temperature require no special safety precautions.
Used
fluoroelastomeric
components
whose
temperatures have not exceeded 300C (572F) require
no special safety precautions.
If evidence of
decomposition (e.g. charring) is found, refer to the
next paragraph for safety instructions DO NOT TOUCH
COMPONENT OR SURROUNDING AREA.
Used fluoroelastomeric components subjected to
temperatures greater than 300C (572F) (e.g. engine
fire) must be treated using the following safety
procedure. Make sure that heavy duty gloves and
special safety glasses are worn:
1
Thoroughly wash contaminated area with 10%
calcium hydroxide or other suitable alkali
solution, if necessary use wire wool to remove
burnt remains.
2
Thoroughly wash contaminated area with
detergent and water.
3
Contain all removed material, gloves etc. used in
this operation in sealed plastic bags and dispose
of
in
accordance with Local Authority
Regulations.
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
INT-3-3-5_3
!MWARNING
Protect your eyes when grinding metal. Wear safety
glasses or goggles. Remove or protect any
combustible materials from the area which could be
ignited by sparks.
GEN-1-12
!MWARNING
To avoid burning, wear protective gloves when
handling hot components. To protect your eyes, wear
goggles when using a brush to clean components.
HYD-1-3_2
!MWARNING
Arc Welding
To prevent the possibility of damage to electronic
components, disconnect the battery and the alternator
before arc-welding on the machine or attached
implements.
If the machine is equipped with sensitive electrical
equipment, i.e. amplifier drivers, electronic control
units (E.C.U.s), monitor displays, etc., then disconnect
them before welding. Failure to disconnect the
sensitive electrical equipment could result
in
irreparable damage to these components.
Parts of the machine are made from cast iron; welds
on cast iron can weaken the structure and break. Do
not weld cast iron. Do not connect the welder cable or
apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to the
same component that is being welded, i.e. boom or
dipper, to avoid damage to pivot pins, bearings and
bushes. Attach the welder earth (ground) cable no
more than 0.6 metres (2 feet) from the part being
welded.
INT-3-1-15_2
!MWARNING
Counterweights
Your machine may be fitted with counterweights. They
are extremely heavy. Do not attempt to remove them.
INT-3-2-5
!MWARNING
Compressed air is dangerous. Wear suitable eye
protection and gloves. Never point a compressed air
jet at yourself or others.
0147_1
Section 2-1 - Care and Safety
Safety Notices
Safety Check List
2-1-14
2-1-14
9803/3760-07 (2-01-01)
!MWARNING
Accumulators
The accumulators contain hydraulic fluid and gas at
high pressure. Prior to any work being carried out on
systems incorporating accumulators, the system
pressure must be exhausted by a JCB distributor, as
the sudden release of the hydraulic fluid or gas may
cause injury.
INT-3-1-17
!MWARNING
Petrol
Do not use petrol in this machine. Do not mix petrol
with the diesel fuel; in storage tanks the petrol will rise
to the top and form flammable vapours.
INT-3-1-6
!MWARNING
The cooling system is pressurised when the coolant is
hot. When you remove the cap, hot coolant can spray
out and burn you. Make sure that the engine is cool
before you work on the cooling system.
9-3-3-1_2
!MCAUTION
Do not disconnect the battery while the engine is
running, otherwise the electrical circuits may be
damaged.
INT-3-1-14
!MWARNING
If you try to charge a frozen battery, or jump start and
run the engine, the battery could explode. Do not use
a battery if its electrolyte is frozen. To prevent the
battery electrolyte from freezing, keep the battery at
full charge.
0125
!MWARNING
Battery Gases
Batteries give off explosive gases. Keep flames and
sparks away from the battery. Do not smoke close to
the battery. Make sure there is good ventilation in
closed areas where batteries are being used or
charged. Do not check the battery charge by shorting
the terminals with metal; use a hydrometer or
voltmeter.
INT-3-1-8
!MDANGER
Electrolyte
Battery electrolyte is toxic and corrosive. Do not
breathe the gases given off by the battery. Keep the
electrolyte away from your clothes, skin, mouth and
eyes. Wear safety glasses.
INT-3-2-1_3
!MWARNING
Battery Terminals
The machine is negatively earthed. Always connect
the negative pole of the battery to earth.
When connecting the battery, connect the earth (-) lead
last.
When disconnecting the battery, disconnect the earth
(-) lead first.
INT-3-1-9
!MWARNING
An exploding tyre can kill. Inflated tyres can explode if
over-heated or over-inflated. Follow the instructions
given when inflating the tyres. Do not cut or weld the
rims. Use a tyre/wheel specialist for all repair work.
2-3-2-7_2
!MWARNING
Jacking
A machine can roll off jacks and crush you unless the
wheels have been blocked. Always block the wheels at
the opposite end of the machine that is to be jacked.
Do not work underneath a machine supported only by
jacks. Always support a jacked-up machine on axle
stands before working underneath it.
INT-3-2-8
Section 2-1 - Care and Safety
Safety Notices
Safety Check List
2-1-15
2-1-15
9803/3760-07 (2-01-01)
!MWARNING
Under no circumstances must the engine be run with
the transmission in gear and only one driving wheel
jacked clear of the ground, since the wheel on the
ground will move the machine.
INT-3-1-16
!MCAUTION
You must apply the park brake before you operate the
attachment.
13-3-1-17
!MCAUTION
Never use water or steam to clean inside the cab. The
use of water or steam could damage the on-board
computer and render the machine inoperable. Remove
dirt using a brush or damp cloth.
8-3-4-8
!MWARNING
Boom Maintenance Strut
A raised boom can drop suddenly and cause serious
injury. Before working under a raised boom, fit the
boom maintenance strut. See Boom Maintenance
Strut, MAINTENANCE section.
5-1-5-7_2
Section 2-1 - Care and Safety
Safety Notices
Safety Decals
2-1-16
2-1-16
9803/3760-07 (2-01-01)
Safety Decals
Introduction
T1-014_2
!MWARNING
Safety Labels
Safety labels on the machine warn you of particular
hazards. You can be injured if you do not obey the
safety instructions shown.
INT-1-3-11
Safety labels are strategically placed around the machine
to remind you of possible hazards.
If you need eye-glasses for reading, make sure you wear
them when reading the safety labels. Do not over-stretch
or place yourself in dangerous positions to read the safety
labels. If you do not understand the hazard shown on the
safety label, then refer to Safety Label Identification.
Note: The illustration(s) show a typical machine model.
Your machine may look different from the model shown.
Keep all safety labels clean and readable. Replace lost or
damaged safety labels. Make sure replacement parts
include safety labels where necessary. Each safety label
has a part number printed on it, use this number to order a
new safety label from your JCB distributor.
Section 2-2 - Care and Safety
2-2-1
2-2-1
9803/3760-07 (2-02-02)
General Procedures
Introduction
When work is done on the machine it is important that the correct care is taken. This will help to prevent personal injury
and reduce the risk of component failure.
As part of the procedures in this manual you will need to do some general procedures. Two examples of these general
procedures are; parking the machine and making it safe, and venting hydraulic pressure.
These procedures are given here as an alternative to again and again in the manual. Where applicable you will see a
cross reference to this section so that you can refer to the detailed procedures.
K Parking the Machine and Making it Safe ( T 2-2-3)
K Boom Safety Strut ( T 2-2-4)
K Installing ( T 2-2-4)
K Removing ( T 2-2-5)
K Venting Hydraulic Pressure ( T 2-2-6)
K Connecting/Disconnecting Hydraulic Hoses ( T 2-2-7)
K Introduction ( T 2-2-7)
K Connecting the Hoses ( T 2-2-7)
K Disconnecting the Hoses ( T 2-2-7)
K Quick Release Couplings ( T 2-2-8)
K Hydraulic Contamination ( T 2-2-10)
K Hydraulic Fluid Quality ( T 2-2-10)
K Effects of Contamination ( T 2-2-10)
K Cleaning Operation ( T 2-2-10)
K Contaminant Standards ( T 2-2-11)
K Filters ( T 2-2-11)
K Battery Disconnection/Connection ( T 2-2-12)
K Disconnection ( T 2-2-12)
K Connection ( T 2-2-12)
K Removing and Replacing Components ( T 2-2-13)
K Battery Charging System Precautions ( T 2-2-14)
K Hydraulic Rams ( T 2-2-15)
K Installation ( T 2-2-15)
K Caution During Use ( T 2-2-15)
K Maintenance, Inspection Points ( T 2-2-15)
Section 2-2 - Care and Safety
General Procedures
Related Topics
2-2-2
2-2-2
9803/3760-07 (2-02-02)
Related Topics
Table 1. Related Topics in This Publication
The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to
complete your procedures. Where applicable the text in this section contains cross references to this page to help you find
the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer
to Section 1 - Applications.
Sections Topic Titles
Sub Titles
1
General Information
ALL
Section 2-2 - Care and Safety
General Procedures
Parking the Machine and Making it Safe
2-2-3
2-2-3
9803/3760-07 (2-02-02)
Parking the Machine and Making it Safe
1
Position the machine on firm level ground. If possible
choose an area that is clean and dry. When possible
park the machine in a covered area if procedures
include work on the hydraulic or fuel systems.
2
Lower attachments to the ground and if necessary,
remove them. Refer to the correct documents and
procedures.
3
If necessary install the boom safety strut. K Boom
Safety Strut ( T 2-2-4)
4
Stop the engine and apply the park brake.
5
Vent the hydraulic pressure. K Venting Hydraulic
Pressure ( T 2-2-6)
6
Remove the starter key.
7
Let the machine cool sufficiently before you do work
on, or near to, the engine or hydraulic system.
8
If procedures include work on the electrical system
disconnect the battery. K Battery Disconnection/
Connection ( T 2-2-12)
!MWARNING
Communications
Bad communications can cause accidents. If two or
more people are working on the machine, make sure
each is aware of what the others are doing. Before
starting the engine make sure the others are clear of
the danger areas; examples of danger areas are: the
rotating blades and belt on the engine,
the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured if
these precautions are not taken.
INT-3-1-5
Section 2-2 - Care and Safety
General Procedures
Boom Safety Strut
2-2-4
2-2-4
9803/3760-07 (2-02-02)
Boom Safety Strut
Note: If you lift the boom to get access for maintenance,
you must install the maintenance strut on the boom.
Installing
!MWARNING
You could be killed or injured if the boom drops while
you are working under it. Fit the safety strut as
instructed before doing any maintenance work with
the boom raised.
Keep people away from the machine while you fit or
remove the strut.
5-3-1-2_1
Before installing the safety strut remove any load on the
forks and make sure that buckets or attachments are
empty.
1
Fully retract the boom (unless it necessary to extend
it for maintenance). Lift the boom sufficiently to install
the strut.
2
Stop the engine. Make sure the park brake is
engaged and the transmission is in neutral. Remove
the starter key.
!MCAUTION
You will have to climb onto the machine to fit or
remove the strut. Take care, especially if the machine
is wet. Remove mud and oil before climbing onto the
machine. Do not use the exhaust as a handhold. It can
burn you.
5-3-1-4_1
3
Remove the strut from its stowage position A.
4
Put the strut B around the lift ram piston rod. Use the
strap to attach it to the ram piston rod.
5
To prevent boom creeping down and causing injury
the boom must be lowered onto the strut.
Note: Lower the boom carefully, to prevent possible
damage to the strut. Stop as soon as the weight of the
boom is on the strut.
6
Disconnect
the battery
to prevent accidental
operation of the engine.
7
If necessary, put chocks against the two sides of the
wheels before you get below the machine.
263560-B1
Fig 1.
266520-B1
Fig 2.
Section 2-2 - Care and Safety
General Procedures
Boom Safety Strut
2-2-5
2-2-5
9803/3760-07 (2-02-02)
Removing
!MWARNING
You could be killed or injured if the boom drops while
you are working under it. Fit the safety strut as
instructed before doing any maintenance work with
the boom raised.
Keep people away from the machine while you fit or
remove the strut.
5-3-1-2_1
1
Lift the boom to remove the weight from the strut.
2
Stop the engine. Make sure the park brake is
engaged and the transmission is in neutral. Remove
the starter key.
!MCAUTION
You will have to climb onto the machine to fit or
remove the strut. Take care, especially if the machine
is wet. Remove mud and oil before climbing onto the
machine. Do not use the exhaust as a handhold. It can
burn you.
5-3-1-4_1
3
Remove the strut.
4
Attach the strut to its stowage position.
Section 2-2 - Care and Safety
General Procedures
Venting Hydraulic Pressure
2-2-6
2-2-6
9803/3760-07 (2-02-02)
Venting Hydraulic Pressure
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses
or couplings, vent the pressure trapped in the hoses in
accordance with the instructions given in this
publication.
HYD-1-5
Important: This procedure is only to be used before
disconnecting hydraulic hoses. Before removing other
hydraulic components refer to the correct Removal
procedure.
1
Park the machine and make it safe. K Parking the
Machine and Making it Safe ( T 2-2-3).
2
If necessary install the boom safety strut. K Boom
Safety Strut ( T 2-2-4). Stop the engine.
3
Carefully remove the hydraulic tank filler cap and vent
the hydraulic pressure as follows:
a For manually operated services, operate the
controls of the service to be disconnected.
b For electrical and pilot operated services, turn the
starter key to the ON position but DO NOT start
the engine.
Operate the controls of the service to be
disconnected.
Note: Make sure that the pressure is vented correctly.
Electrical and pilot services have a small quantity of
accumulated pressure available for venting.
4
Refit the hydraulic tank filler cap.
Section 2-2 - Care and Safety
General Procedures
Connecting/Disconnecting Hydraulic Hoses
2-2-7
2-2-7
9803/3760-07 (2-02-02)
Connecting/Disconnecting Hydraulic Hoses
Introduction
The following paragraphs describe how to connect and
disconnect hydraulic hoses safely.
Connecting the Hoses
1
Connect the hoses.
a For Quick Release Couplings refer to the correct
data. K Quick Release Couplings ( T 2-2-8)
b For all other hose connections, use correct tools
and ensure that connections are not cross-
threaded. Support the weight of the hose until the
connection
is made. Do not exceed the
recommended torque loading.
!MWARNING
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the
skin. Keep face and hands well clear of fluid under
pressure and wear protective glasses and gloves.
Hold a piece of cardboard close to suspected leaks
and then inspect the cardboard for signs of fluid. If
fluid penetrates your skin, get medical help
immediately.
INT-3-1-10_3
2
Check for leaks as follows:
a Start the engine.
b Operate the controls to pressurise the required
hose.
c Switch off the engine. Remove the starter key.
Check for signs of
leakage at the hose
connections.
Disconnecting the Hoses
1
Vent the hydraulic pressure as described on this
page.
2
Disconnect the hoses.
a For Quick Release Couplings see the procedures
in
this
section. K Quick
Release
Couplings ( T 2-2-8)
b For all other hose connections, plug both sides of
the connection to prevent loss of fluid.
3
Check for leaks. See step 2, K Connecting the
Hoses ( T 2-2-7)
Section 2-2 - Care and Safety
General Procedures
Quick Release Couplings
2-2-8
2-2-8
9803/3760-07 (2-02-02)
Quick Release Couplings
T4-001_2
Connecting and Disconnecting
Flat face quick release couplings allow the operator to
remove and install attachments swiftly and efficiently.
Generally, your machine pipework will be fitted with a
female coupling A and a male coupling B. The optional
attachment hoses will also be fitted with a female coupling
A and a male coupling B. K Fig 3. ( T 2-2-9).
The quick release couplings should be trouble free and
relatively easy to connect and disconnect, provided they
are kept clean and used correctly. The recommendations
listed below should always apply when using flat face
quick release couplings.
Finally, please read the correct fitting and releasing
procedures before installing or removing any optional
attachment fitted with quick release couplings.
Quick Release Couplings - Do's and Don'ts
Do wipe the two faces of the coupling and make sure
they are clean before connecting.
Do make sure the outside sleeve (female coupling) is
pulled back when disconnecting.
Do connect and disconnect a new coupling two or
three times to 'work' the PTFE seals - sometimes a
new coupling will stick if the seals have not been
'worked'.
Do use a spanner on the hexagon flats of the coupling
when fitting adaptors.
Do use a rubber or hide hammer to disconnect a
coupling if it sticks - sticking may occur if there is dirt
present in the coupling.
Don't attempt to re-connect a damaged half coupling
- this will destroy the seals and necessitate replacing
both half couplings.
Don't leave the coupling where it may be run over by
a machine or otherwise crushed - this will distort the
coupling sleeve and prevent correct connection and
disconnection.
Don't clamp on the smooth diameter of the coupling
when fitting adaptors - always use the hexagon.
Don't try to turn the sleeve (female coupling) when the
coupling has been disconnected - the locking ball will
wedge underneath the sleeve and destroy the
coupling.
Don't damage the faces of the couplings - this can
prevent connection and disconnection, or damage
seals and cause leakage.
Don't try to dismantle the couplings - they are non
serviceable parts. If a coupling is damaged it should
be replaced with a new one.
!MWARNING
Hydraulic fluid at pressure can injure you. Make the
machine safe before connecting or disconnecting
quick release couplings; stop the engine and then
operate the attachment control a few times to vent
residual hydraulic pressure in the attachment hoses.
2-4-1-11
!MWARNING
The external surfaces of the couplings must be clean
before connecting or disconnecting. Ingress of dirt
will cause fluid leaks and difficulty in connecting or
disconnecting. You could be killed or seriously injured
by faulty Quick Release Couplings.
2-4-1-15
Before connecting or removing any hydraulic hose,
residual hydraulic pressure trapped in the service hose line
must be vented. Make sure the hose service line has been
vented before connecting or removing hoses.
Section 2-2 - Care and Safety
General Procedures
Quick Release Couplings
2-2-9
2-2-9
9803/3760-07 (2-02-02)
Connecting Quick Release Couplings
1
Remove any residual hydraulic pressure trapped in
the service line hose.
2 Wipe the two faces of the male and female couplings
and make sure they are clean.
3 Make sure that ball 3-C in the female coupling is
located in one of its slots.
4
Fit the male coupling into the female coupling; To
ensure that the coupling is not accidentally released,
rotate sleeve 3-E half a turn and make sure that the
locking ball 3-C does not align with the slot 3-D.
Disconnecting Quick Release Couplings
1
Remove any residual hydraulic pressure trapped in
the service line hose.
2
Align the slot 3-D with ball 3-C.
3
Pull back sleeve 3-E to release the coupling.
Fig 3.
Section 2-2 - Care and Safety
General Procedures
Hydraulic Contamination
2-2-10
2-2-10
9803/3760-07 (2-02-02)
Hydraulic Contamination
TE-002_2
Hydraulic Fluid Quality
Construction machinery uses a large volume of fluid in the
hydraulic system for power transmission, equipment
lubrication, rust prevention and sealing. According to a
survey conducted by a pump manufacturer, seventy per
cent of the causes of problems in hydraulic equipment
were attributable to inadequate maintenance of the quality
of the hydraulic fluid. Therefore, it is obvious that control of
the quality of the hydraulic fluid helps prevent hydraulic
equipment problems and greatly improves safety and
reliability. Furthermore from an economic angle it extends
the life of the hydraulic fluid if quality is maintained.
Effects of Contamination
Once inside the system, hydraulic circuit contaminants
greatly effect the performance and life of hydraulic
equipment. For example, contaminants in a hydraulic
pump develop internal wear to cause internal leakage and
hence lower discharges. Wear particles generated will
circulate with the hydraulic fluid to cause further
deterioration in the performance of this and other
equipment. Contaminants also enter principal sliding
sections of the equipment causing temporary malfunction,
scuffing, sticking and leakage and can lead to major
problems.The main contaminants can be classified as
follows:
1
Solid Particles - sand, fibres, metallic particles,
welding scale, sealing materials and wear particles
etc.
2
Liquid - usually water and incompatible oils and
greases.
3
Gases - Air, sulphur dioxide etc. which can create
corrosive compounds if dissolved in the fluid.
These contaminants can appear during manufacture,
assembly and operation.
Cleaning Operation
The purpose of cleaning oil is to remove contaminants of
all types and sludge by filtering hydraulic fluid through a
cleaning unit. K Fig 4. ( T 2-2-10). General Bulletin 011
also refers.
Procedure
Connect the cleaning unit in place of the hydraulic filter.
K Fig 4. ( T 2-2-10). Run the system for sufficient time to
pump all the hydraulic fluid through the unit. Disconnect
the cleaning unit and reconnect the filter. Top up the
system with clean hydraulic fluid as required.
Fig 4. Cleaning Unit
Section 2-2 - Care and Safety
General Procedures
Hydraulic Contamination
2-2-11
2-2-11
9803/3760-07 (2-02-02)
Contaminant Standards
Dirt that damages your system is in many cases too small
to be seen with the eye. The particle size is measured in
microns.
1 micron = 0.001 mm (0.0000394 in).
Listed below are a few typical comparisons:
Red Blood Cell = 8 microns (0.008 mm, 0.000315 in)
Human Hair = 70 microns (0.07 mm, 0.00275 in)
Grain of Salt = 100 microns (0.1 mm, 0.00394 in)
Smallest particle visible to the naked eye is 40 microns
(0.00157) approximately.
Standards will often be quoted to ISO (International
Standards Organisation) for which literature can be
obtained.
Filters
The filter assembly fitted to all product ranges is designed
to filter all the contamination that is generated through use
to the required level of cleanliness. The filter must be
serviced to the requirements of the machine Service
Schedules.
To ensure optimum performance and reliability it is
important that the machines hydraulic system is serviced
periodically
in accordance with the manufacturers
requirements.
Section 2-2 - Care and Safety
General Procedures
Battery Disconnection/Connection
2-2-12
2-2-12
9803/3760-07 (2-02-02)
Battery Disconnection/Connection
!MWARNING
Keep metal watch straps and any metal fasteners on
your clothes, clear of the positive (+) battery terminal.
Such items can short between the terminal and nearby
metal work. If it happens you can get burned.
5-2-2-4
Disconnection
1 Get access
to
the battery. See K Related
Topics ( T 2-2-2)
2
Remove the leads. Disconnect the earth (-) terminal
first.
Connection
1
Check the battery.
a
If the terminal is dirty, clean the post.
797650
Fig 5.
b
If the terminal post is corroded and generates
white powder wash the terminal with hot water. If
considerable corrosion is detected, clean with a
wire brush or abrasive paper.
c After cleaning, apply a thin coat of petroleum jelly
to the terminal.
2
Re-connect the leads. Connect the earth (-) terminal
last.
3
Close and lock the access panels.
Section 2-2 - Care and Safety
General Procedures
Removing and Replacing Components
2-2-13
2-2-13
9803/3760-07 (2-02-02)
Removing and Replacing Components
Introduction
T3-062_2
Clean the machine using water and or steam. Do not allow
mud, debris etc. to build upon the machine.
Before carrying out any service procedures that require
components to be removed:
1
Cleaning must be carried out either in the area of
components to be removed or, in the case of major
work, or work on the fuel system, the whole engine
and surrounding machine must be cleaned.
2 When cleaning is complete move the machine away
from the wash area, or alternatively, clean away the
material washed from the machine.
Important: When removing components be aware of any
dirt or debris that may be exposed. Cover any open ports
and clean away the deposits before proceeding.
Detergents
Avoid using full strength detergent - always dilute
detergents as per the manufacturer's recommendations,
otherwise damage to the paint finish may occur.
Always adhere to local regulations regarding the disposal
of debris created from machine cleaning.
Pressure Washing and Steam Cleaning
!MWARNING
When using a steam cleaner, wear safety glasses or a
face shield as well as protective clothing. Steam can
cause serious personal injury.
13-3-2-10_2
!MCAUTION
The engine or certain components could be damaged
by high pressure washing systems; special
precautions must be taken if the engine is to be
washed using a high pressure system.
Ensure that the alternator, starter motor and any other
electrical components are shielded and not directly
cleaned by the high pressure cleaning system.
ENG-3-3
Important: Do not aim the water jet directly at bearings, oil
seals or electrical and electronic components such as the
engine electronic control unit (ECU), alternator or fuel
injectors.
Use a low pressure water jet and brush to soak off caked
mud or dirt.
Use a pressure washer to remove soft dirt and oil.
Note: The machine must always be greased after
pressure washing or steam cleaning.
Original Components
Always Install new oil seals, gaskets, etc.
Components showing obvious signs of wear or damage
should be replaced with new ones.
Before re-installing original components do the following:
Clean components using the applicable cleaning
materials.
Inspect components for signs of excessive wear or
defects.
Check the component specifications such as wear
limits where applicable.
New Components
Ensure that the correct new components are installed. Do
not substitute components from another machine.
Components may look the same but may not be
interchangeable. Refer to the JCB parts systems.
Section 2-2 - Care and Safety
General Procedures
Battery Charging System Precautions
2-2-14
2-2-14
9803/3760-07 (2-02-02)
Battery Charging System Precautions
Obey the procedures below to prevent damage to the
alternator and battery.
1
Ensure that
the battery negative terminal
is
connected to the earthing cable.
2
Never make or break connections to the battery or
alternator, or any part of the charging circuit whilst the
engine is running. Disregarding this instruction will
result in damage to the regulator or rectifying diodes.
3 Main output cables are 'live' even when the engine is
not running. Take care not to earth connectors in the
moulded plug if it is removed from the alternator.
4 When arc welding on the machine, protect the
alternator by removing the moulded plug (or if
separate output cables fitted, remove the cables).
5
If slave starting is necessary, connect the second
battery in parallel without disconnecting the vehicle
battery from the charging circuit. The slave battery
may then be safely removed after a start has been
obtained. Take care to connect batteries positive to
positive, negative to negative.
Section 2-2 - Care and Safety
General Procedures
Hydraulic Rams
2-2-15
2-2-15
9803/3760-07 (2-02-02)
Hydraulic Rams
Installation
1
Precautions when installing the ram on the machine.
a When installing and removing from the machine,
suspend the ram safely.
b Suspending the ram by the piping is not only
dangerous, but can also cause damage to the
cylinder.
c Secure the piston rod with a band. It is very
dangerous if the rod extends unexpectedly. Also,
the rod can be damaged and become unusable.
2 Welding after installing the ram may result in damage.
a
If electric welding is done even at a point away
from the ram, there may be sparking inside the
ram and it will become necessary to replace the
ram with a new one.
3 When painting the machine, mask the ram.
a
If paint adheres to the rod surface or to the wiper
ring and the ram is operated, the wiper ring will not
function properly and foreign matter and paint can
easily enter the ram. This will cause damage to
the seals, drastically shortening the life of the ram.
4
Install the ram only when it is clean.
Caution During Use
1
Use only under designated conditions.
a
If hydraulic oil other than the designated oil is
used, the seals quickly degenerate and become
damaged. If the relief valve is set at a value higher
than specified, it may cause ram damage and is
dangerous.
b
In high temperature environments (approx. 90C
and above) or low temperature environments
(below -20C), seals quickly become damaged.
Special seal materials are necessary so check to
see if the ram that you are using is suitable or not.
c The number one cause of ram oil leakage is rod
damage. Be careful not to damage the rod.
2 Warm up sufficiently before beginning work.
a
In cold conditions the rod seals may be frozen, so
if the ram is operated at maximum pressure and
maximum speed, the seals will be damaged.
b There is a large amount of air in a new ram or one
which has been left for a long time, so the ram will
not operate smoothly. Also, if pressure is applied
suddenly without bleeding
the air, high
temperatures will be generated due to adiabatic
compression and the seals may burn.
c Before beginning work, always move the ram at
full stroke with no load and expel air from the
cylinder.
3 When stopping or storing, do it at a safe and fixed
position.
a The installed ram cannot maintain the same
position for a long period of time, because the oil
inside the ram may leak and the hydraulic oil
volume decreases as it cools. Stop or store the
machine in a safe and fixed position.
Maintenance, Inspection Points
1
Carry out daily maintenance and inspection.
a The key point for correct long-term ram function is
daily maintenance and inspection. Carry out
maintenance and inspection so that the ram
functions fully at all times. Always remove any
mud, water, dust or oil film adhering to the rod and
keep it in normal condition. However, when
cleaning the wiper ring and seals, do not get them
wet with water but wipe clean with a rag. To
prevent rust forming during storage, the amount of
exposed ram piston rod should be kept to a
minimum. If leaving for more than one week,
apply a light coating of suitable grease or
petroleum jelly to the exposed part of the ram
piston rod.
2
Use genuine JCB parts when replacing parts.
Section 2-2 - Care and Safety
General Procedures
Hydraulic Rams
2-2-16
2-2-16
9803/3760-07 (2-02-02)
a
If parts other than genuine JCB parts are used,
the desired results may not be obtained. Use only
genuine JCB parts.
3
Caution during dismantling and reassembly.
a Dismantling the ram while it is still installed on the
machine can be dangerous as unexpected
movements of the machine can occur. Remove
the ram from the machine and then dismantle.
b
If reassembled with dirty hands, foreign matter
can enter the ram causing a shorter life span and
also the other hydraulic equipment may be
damaged. Reassemble in a clean state.
c Follow the instructions in the diagrams regarding
torque tightening for screwed parts. If the torque is
too high or too low, it can cause damage.



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