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<p>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 9803/3750-07 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 1 - General Information 1-0 1-0 9803/3750-06 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 ............................................................. 1-3-5 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 ............................................................................................. 1-5-23 Slide Hammer Kit .................................................................................. 1-5-25 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 1-1-1 1-1-1 9803/3750-06 (1-14-01) Applications Introduction This manual contains topics that relate to some or all JCB Loadall machines in the 5A group. There are several machine model codes in the family. Machine Group Model Code Model Name 5A F 540-170 5A G 550-140 5A L 540-140 5A M 550-170 5A N 535-125 Hi Viz 5A P 535-140 Hi Viz 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. Information relating specifically to different variants of the same model is given in the applications tables and in the Topics throughout the manual where applicable. Use the applications tables to see which topics relate to which machine models and variants. Important: The machine model names are NOT referred to in the topics. You must refer to the applications tables for the applicable machine models. K Tables ( T 1-1-2) K Section 1 - General Information ( T 1-1-2) K Section 2 - Care and Safety ( T 1-1-3) K Section 3 - Routine Maintenance ( T 1-1-4) K Section B - Body and Framework ( T 1-1-5) K Section C - Electrics ( T 1-1-6) K Section E - Hydraulics ( T 1-1-7) K Section F - Transmission ( T 1-1-8) K Section G - Brakes ( T 1-1-9) K Section H - Steering ( T 1-1-10) K Section K - Engine ( T 1-1-11) K Section M - Electronic Data Systems ( T 1-1-12) Section 1-1 - General Information Applications Tables 1-1-2 1-1-2 9803/3750-06 (1-14-01) Tables Section 1 - General Information Machine models Topic Ref Title Variant 540-170 5AF 550-140 5AG 540-140 5AL 550-170 5AM 535-125 HiViz 5AN 535-140 HiViz 5AP 1-2 Use All Machines 1-3 Machine Identification All Machines 1-4 Torque Settings All Machines 1-5 Service Tools All Machines 1-6 Service Consumables All Machines 1-7 Fuel All Machines 1-8 Stall Speed Combinations All Machines Section 1-1 - General Information Applications Tables 1-1-3 1-1-3 9803/3750-06 (1-14-01) Section 2 - Care and Safety Machine models Topic Ref Title Variant 540-170 5AF 550-140 5AG 540-140 5AL 550-170 5AM 535-125 HiViz 5AN 535-140 HiViz 5AP 2-1 Safety Notices All Machines 2-2 General Procedures All Machines Section 1-1 - General Information Applications Tables 1-1-4 1-1-4 9803/3750-06 (1-14-01) Section 3 - Routine Maintenance Machine models Topic Ref Title Variant 540-170 5AF 550-140 5AG 540-140 5AL 550-170 5AM 535-125 HiViz 5AN 535-140 HiViz 5AP 3-1 Introduction All Machines 3-2 Service Schedules - Machines with SD and SF Engines Mechanical F.I. engines z z z z z z 3-3 Service Schedules - Machines with SE Engines Electronic F.I. engines z z z z 3-4 Fluids, Lubricants and Capacities All Machines 3-5 Cleaning the Machines All Machines 3-6 Inspection All Machines 3-7 Seat Belts All Machines 3-8 ROPS/FOPS (and OECD) Structure All Machines 3-9 Greasing All Machines 3-10 Heater and Air Conditioning All Machines 3-11 Brakes All Machines 3-12 Electrical System All Machines 3-13 Engine All Machines 3-14 Engine Air FIlter All Machines 3-15 Fuel System All Machines 3-16 Hydraulic System All Machines 3-17 Transmission All Machines 3-18 Tyres and Wheels All Machines 3-19 Wear Pads All Machines 3-20 Windscreen Washer All Machines 3-21 Access Panels All Machines 3-22 Fire Extinguisher All Machines Section 1-1 - General Information Applications Tables 1-1-5 1-1-5 9803/3750-06 (1-14-01) Section B - Body and Framework Machine models Topic Ref Title Variant 540-170 5AF 550-140 5AG 540-140 5AL 550-170 5AM 535-125 HiViz 5AN 535-140 HiViz 5AP B1 Fork Carriage z z z z z z B2 Cab Heating and Ventilation SYSTEM z z z z z z B3 Cab Air Conditioning SYSTEM z z z z z z B4 Load Moment Indicator (LMI) SYSTEM z z z z z z B5 Cab z z z z z z B6 Air Conditioning Condensor - Cooling Pack Mounted z z z z z z B7 Air Conditioning Condensor - Roof Mounted z z z z z z B8 Cab HV and HVAC Unit z z z z z z B9 Air Conditioning Binary Switch z z z z z z B10 Heater Valve z z z z z z B11 Fuel Tank z z z z z z B12 Chassis Panels z z z z z z B13 Boom 3 Stage z z z z 4 Stage z z B14 LMI Axle Transducer z z z z z z B15 Stabilisers z z z z z z B16 Longitudinal Load Moment Indicator Unit z z z z Section 1-1 - General Information Applications Tables 1-1-6 1-1-6 9803/3750-06 (1-14-01) Section C - Electrics Machine models Topic Ref Title Variant 540-170 5AF 550-140 5AG 540-140 5AL 550-170 5AM 535-125 HiViz 5AN 535-140 HiViz 5AP C1 Fuses and Relays z z z z z z C2 Schematics z z z z z z C3 Electrical Harness SYSTEM z z z z z z C4 Battery Charging SYSTEM z z z z z z C5 Alternator z z z z z z C6 Battery z z z z z z Section 1-1 - General Information Applications Tables 1-1-7 1-1-7 9803/3750-06 (1-14-01) Section E - Hydraulics Machine models Topic Ref Title Variant 540-170 5AF 550-140 5AG 540-140 5AL 550-170 5AM 535-125 HiViz 5AN 535-140 HiViz 5AP E1 Systems and Schematics z z z z z z E2 Parallel Hydraulic SYSTEM z z z z E3 Parallel Servo Hydraulic SYSTEM z z E4 Hydraulic Interlock SYSTEM z z E5 Parallel Control Valve - 6 Section To January 2009 z z To January 2009 z z E6 Parallel Control Valve - 5 Section From January 2009 From January 2009 E7 Parallel Control Valve - 2 Section z z E8 Servo Control Valves z z E9 Servo Solenoid Diverter Valve Block z z E10 Stabiliser Isolation Valve z z E11 Sway/Fan Selector Valve z z z z z z E12 Main Pump 110 l/min z z z z 170 l/min z z E13 Cooling Fan Motor z z z z z z E14 Extension Ram z z z z z z E15 Lift Rams z z z z z z E16 Tilt Ram z z z z z z E17 Displacement Ram z z z z z z E18 Sway Ram z z z z z z E19 Stabiliser Rams z z z z z z E20 Ram Maintenance z z z z z z Section 1-1 - General Information Applications Tables 1-1-8 1-1-8 9803/3750-06 (1-14-01) Section F - Transmission Machine models Topic Ref Title Variant 540-170 5AF 550-140 5AG 540-140 5AL 550-170 5AM 535-125 HiViz 5AN 535-140 HiViz 5AP F1 CONFIGURATION z z z z z z F2 Wheels and Tyres z z z z z z F3 Front Axles SD80 Pivot sway z z z z SD80 Trunnion sway z z F4 Rear Axles SD80 Pivot sway z z z z SD80 Trunnion sway z z F5 PS750 Gearbox SYSTEM z z z z z z F6 PS750 Mk IV Gearbox SYSTEM z z z z z z F7 PS764 Gearbox SYSTEM z z z z F8 PS750 Gearbox z z z z z z F9 PS750 Mk IV Gearbox z z z z z z F10 PS760 Gearbox z z z z F11 Bevel Gearbox z z z z z z F12 Torque Converter z z z z z z F13 Transmission Oil Cooler - Air Blast Intercooled engines z z z z z z F14 Transmission Oil Cooler - Liquid to Liquid Non intercooled engines z z z z z z F15 Propshafts z z z z z z F16 Transmission Speed Sensor z z z z z z F17 Engine Speed Sensor z z z z z z F18 Speedometer z z z z z z Section 1-1 - General Information Applications Tables 1-1-9 1-1-9 9803/3750-06 (1-14-01) Section G - Brakes Machine models Topic Ref Title Variant 540-170 5AF 550-140 5AG 540-140 5AL 550-170 5AM 535-125 HiViz 5AN 535-140 HiViz 5AP G1 Twin Axle Service Brakes SYSTEM (S1) z z G2 Twin Axle Service Brakes SYSTEM (S2) z z z z G3 External Park Brake SYSTEM PS750 gearbox z z z z z z G4 Internal Park Brake SYSTEM PS760 gearbox z z z z G5 Park Brake Calliper PS750 gearbox z z z z z z G6 Park Brake Disc PS750 gearbox z z z z z z G7 Park Brake Switch z z z z z z G8 Servo Exhauster Unit z z z z z z G9 Servo Unit - Twin Axle Brakes z z z z z z G10 Master Cylinder z z z z z z G11 Fluid Reservoir z z z z z z Section 1-1 - General Information Applications Tables 1-1-10 1-1-10 9803/3750-06 (1-14-01) Section H - Steering Machine models Topic Ref Title Variant 540-170 5AF 550-140 5AG 540-140 5AL 550-170 5AM 535-125 HiViz 5AN 535-140 HiViz 5AP H1 Steering SYSTEM z z z z z z H2 Manual Steer Mode SYSTEM z z z z z z H3 Auto Steer Mode SYSTEM z z z z z z H4 Hydraulic Steering Unit z z z z z z H5 Priority Valve z z z z z z H6 Power Track Rods z z H7 Steer Rams z z z z H8 Steering Column z z z z z z H9 Manual Steer Mode Valve z z z z z z H10 Auto Steer Mode Valve z z z z z z Section 1-1 - General Information Applications Tables 1-1-11 1-1-11 9803/3750-06 (1-14-01) Section K - Engine Machine models Topic Ref Title Variant 540-170 5AF 550-140 5AG 540-140 5AL 550-170 5AM 535-125 HiViz 5AN 535-140 HiViz 5AP K1 Stop and Start SYSTEM (Mechanical F.I. Engines) z z z z z z K2 Stop and Start SYSTEM (Electronic F.I. Engines) z z z z K3 Cold Start Heater SYSTEM Mechani cal F.I. Engines z z z z z z K4 Starter Motor z z z z z z K5 Cooling Pack - (Non Intercooled) z z z K6 Cooling Pack - (Intercooled Mechanical F.I. Engines) z z z z z z K7 Cooling Pack - (Electronic F.I. Engines) z z z z K8 Coolant Expansion Tank z z z z z z K9 Air Filter Vacuum Switch z z z z z z K10 Throttle Pedal and Cable z z z z z z K11 Throttle Position Sensor (TPS) z z z z K12 Exhaust Silencer z z z z z z K13 JCB Dieselmax (Mechanical F.I. Engines) z z z z z z K14 JCB Dieselmax (Electronic F.I. Engines) z z z z Section 1-1 - General Information Applications Tables 1-1-12 1-1-12 9803/3750-06 (1-14-01) Section M - Electronic Data Systems Machine models Topic Ref Title Variant 540-170 5AF 550-140 5AG 540-140 5AL 550-170 5AM 535-125 HiViz 5AN 535-140 HiViz 5AP M1 CANbus SYSTEM z z z z z z M2 Loadall Monitoring SYSTEM z z z z z z M3 Fault Code SYSTEM z z z z z z M4 Servicemaster SYSTEM z z z z z z M5 Servicemaster Tools z z z z z z M6 Electronic Control Unit Theory z z z z z z M7 Pulse Width Modulation Theory z z z z z z Section 1-2 - General Information 1-2-1 1-2-1 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (1-02-01) 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 Component Identification Plates ( T 1-3-5) K Typical Engine Identification Number ( T 1-3-5) K Transmission Identification Numbers ( T 1-3-6) K ROPS/FOPS and OECD Certification Plates ( T 1-3-7) Section 1-3 - General Information Machine Identification Related Topics 1-3-2 1-3-2 9803/3750-06 (1-02-01) 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 9803/3750-06 (1-02-01) 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) 7 Machine Serial Number (7 Digits) Each machine has a unique serial number. Standard Builds: 5AF = 540-170 5AM = 550-170 5AG = 550-140 5AN = 535-125 HiViz 5AL = 540-140 5AP = 535-140 HiViz 5AM = 550-170 JCB Dieselmax (Tier 3): R = Turbocharged and after-cooled, 97kW (130Hp) S = Turbocharged and after-cooled, 74.2kW (100Hp) T = Turbocharged, 63kW (85Hp) E = 3 Speed (PS750) G = 4 Speed (PS750) F = 3 Speed (PS760) H = 4 Speed (PS760) 7 = 2007 A = 2010 8 = 2008 B = 2011 9 = 2009 C = 2012 Section 1-3 - General Information Machine Identification Machine Identification Plate 1-3-4 1-3-4 9803/3750-06 (1-02-01) 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. Standard Builds: 5AF = 540-170 5AM = 550-170 5AG = 550-140 5AN = 535-125 HiViz 5AL = 540-140 5AP = 535-140 HiViz 5AM = 550-170 JCB Dieselmax (Tier 3): R = Turbocharged and after-cooled, 97kW (130Hp) S = Turbocharged and after-cooled, 74.2kW (100Hp) T = Turbocharged, 63kW (85Hp) E = 3 Speed (PS750) G = 4 Speed (PS750) F = 3 Speed (PS760) H = 4 Speed (PS760) Section 1-3 - General Information Machine Identification Component Identification Plates 1-3-5 1-3-5 9803/3750-06 (1-02-01) Component Identification Plates Typical Engine Identification Number Engine data labels 2A are located on the cylinder block at position 2C and rocker cover 2D (if fitted). The data label contains important engine information and includes the engine identification number 2E. 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 2B. C007280-C2 Fig 2. 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 1-3-6 1-3-6 9803/3750-06 (1-02-01) Transmission Identification Numbers The transmission components have a serial number stamped on a data plate A as shown. A710840-C1 Fig 3. Front Axle A710830-C1 Fig 4. Rear Axle 263370-C1 Fig 5. PS750 Powershift Transmission A401030-C2 Fig 6. PS760 Powershift Transmission Section 1-3 - General Information Machine Identification Component Identification Plates 1-3-7 1-3-7 9803/3750-06 (1-02-01) ROPS/FOPS and OECD Certification Plates 445911-5 Fig 7. 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. 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 1-3-8 1-3-8 9803/3750-06 (1-02-01) Page left intentionally blank Section 1-4 - General Information 1-4-1 1-4-1 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 1-5-23) K Slide Hammer Kit ( T 1-5-25) Section 1-5 - General Information Service Tools Numerical List 1-5-2 1-5-2 9803/3750-06 (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 39. ( T 1-5-15) - 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 36. ( T 1-5-15) - Female Connectors - see tool detail reference for content K Fig 38. ( T 1-5-15) - Hydraulic Hand Pump Equipment - see tool detail reference for content K Fig 42. ( T 1-5-16) - Male Adaptors BSP x BSP - see tool detail reference for content K Fig 32. ( T 1-5-14) - Male Cone Blanking Caps - see tool detail reference for content K Fig 37. ( T 1-5-15) - Pressure Test Point `T' Adaptors - see tool detail reference for content K Fig 34. ( T 1-5-14) - Pressure Test Point Adaptors - see tool detail reference for content K Fig 33. ( 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 63. ( T 1-5-22) 332/E7911 Exhaust fitting clamp K Fig 61. ( T 1-5-21) 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 46. ( T 1-5-17) 718/20235 USB PC Cable K Fig 64. ( T 1-5-22) 718/20236 Serial PC Cable K Fig 64. ( T 1-5-22) 718/20237 Machine Cable K Fig 64. ( T 1-5-22) 728/26500 USB DLA K Fig 64. ( T 1-5-22) 892/00011 Spool Clamp K Fig 49. ( T 1-5-18) 892/00167 Ram Protection Sleeve for 90 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/00180 Seal Fitting Tool - Hydraulic Steer Unit K Fig 50. ( T 1-5-18) 892/00229 Flow Meter K Fig 44. ( T 1-5-16) 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) 892/00334 Ram Seal Fitting Tool K Fig 54. ( T 1-5-20) 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) 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 59. ( T 1-5-21) Section 1-5 - General Information Service Tools Numerical List 1-5-3 1-5-3 9803/3750-06 (1-06-00) 892/00822 Splined Bolt Socket K Fig 58. ( T 1-5-21) 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 43. ( T 1-5-16) 892/00893 Torque Converter Alignment Tool K Fig 60. ( T 1-5-21) 892/00905 LMI Test Box K Fig 21. ( T 1-5-9) 892/00948 Nitrogen Charging Kit (without gauge) K Fig 48. ( T 1-5-17) 892/00949 Gauge K Fig 48. ( T 1-5-17) 892/00964 Test Point 1/8 BSP (Powershift) K Fig 40. ( T 1-5-16) 892/00965 Test Point 3/8 BSP (Powershift) K Fig 41. ( T 1-5-16) 892/01016 Ram Protection Sleeve for 25 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01017 Ram Protection Sleeve for 30 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01018 Ram Protection Sleeve for 40 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01019 Ram Protection Sleeve for 50 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01020 Ram Protection Sleeve for 50 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01021 Ram Protection Sleeve for 60 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01022 Ram Protection Sleeve for 60 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01023 Ram Protection Sleeve for 65 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01024 Ram Protection Sleeve for 70 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01025 Ram Protection Sleeve for 75 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01026 Ram Protection Sleeve for 80 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01027 Piston Seal Assembly Tool K Fig 56. ( T 1-5-20) 892/01174 Data Link Adaptor Kit K Fig 64. ( T 1-5-22) 892/01268 Digital Pressure Gauge 0-400 bar K Fig 45. ( T 1-5-16) 892/01271 Hose for Digital Pressure Gauge 892/01268 K Fig 45. ( T 1-5-16) 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 57. ( T 1-5-21) 992/04800 Flange spanner K Fig 62. ( T 1-5-21) 992/09100 Spool Clamp K Fig 49. ( T 1-5-18) 992/09300 Hexagon Spanner 55 mm A/F K Fig 55. ( T 1-5-20) Part Number: Description: Tool Detail Reference: Section 1-5 - General Information Service Tools Numerical List 1-5-4 1-5-4 9803/3750-06 (1-06-00) 992/09400 Hexagon Spanner 65 mm A/F K Fig 55. ( T 1-5-20) 992/09500 Hexagon Spanner 75 mm A/F K Fig 55. ( T 1-5-20) 992/09600 Hexagon Spanner 85 mm A/F K Fig 55. ( T 1-5-20) 992/09700 Hexagon Spanner 95 mm A/F K Fig 55. ( T 1-5-20) 992/09900 Hexagon Spanner 115 mm A/F K Fig 55. ( T 1-5-20) 992/10000 Hexagon Spanner 125 mm A/F K Fig 55. ( T 1-5-20) 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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (1-06-00) Fig 32. 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 33. 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 Fig 34. 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 1-5-15 1-5-15 9803/3750-06 (1-06-00) Fig 35. '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 36. 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 37. 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 38. 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 39. 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 1-5-16 1-5-16 9803/3750-06 (1-06-00) Fig 40. 892/00964 Test Point 1/8 BSP Fig 41. 892/00965 Test Point 3/8 BSP Fig 42. 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 43. 892/00881 Valve Spool Seal Fitting Tool Fig 44. 892/00229 Flow Meter TBA Fig 45. 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 1-5-17 1-5-17 9803/3750-06 (1-06-00) Fig 46. 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 47. 892/00301 Flow Test Adaptor Note: Components listed as follows also required: Item Description 1 892/00920 Adaptor 2 892/00302 Adaptor Fig 48. Nitrogen Charging Kit 892/00948 Charging Kit (without gauge) 892/00949 Gauge Section 1-5 - General Information Service Tools Tool Detail Reference 1-5-18 1-5-18 9803/3750-06 (1-06-00) Fig 49. Spool Clamps 992/09100 Spool Clamp 892/00011 Spool Clamp Fig 50. 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 51. 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 1-5-19 1-5-19 9803/3750-06 (1-06-00) Fig 52. 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 1-5-20 1-5-20 9803/3750-06 (1-06-00) Fig 53. 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 54. 892/00334 Ram Seal Fitting Tool Fig 55. 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 56. 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 1-5-21 1-5-21 9803/3750-06 (1-06-00) Fig 57. 992/04000 Torque Multiplier Fig 58. 892/00822 Splined Bolt Socket Fig 59. 892/00812 Drive Coupling Spanner Fig 60. 892/00893 Torque Converter Alignment Tool For use with 11" torque converters Fig 61. 332/E7911 Exhaust Fitting Clamp Fig 62. 992/04800 Flange Spanner Section 1-5 - General Information Service Tools Tool Detail Reference 1-5-22 1-5-22 9803/3750-06 (1-06-00) Fig 63. 320/20050 Lifting Bracket Kit Fig 64. 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 1-5-23 1-5-23 9803/3750-06 (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 65- A is compressed so that a section of its shank forms an 'upset' against the machine body/framework, leaving a durable thread 65-B. Fig 65. 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 1-5-23) 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 1-5-24). 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 1-5-24 1-5-24 9803/3750-06 (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 66-A. Fig 66. 3 Wind the body of the installation tool down the threaded mandrel until it touches the head of the rivet nut 67-B. Fig 67. 4 Insert the rivet nut (assembled to the tool) into the hole drilled in step 1. 5 Hold handle 68-C and at the same time draw the mandrel into the installation tool by turning nut 68-D. The rivet nut will contract in length and form an 'upset' (smooth bulge) seating itself against the body/ framework 68-E. Note: The thread of the rivet nut must not be stripped, take care when 'upsetting' the rivet nut. Fig 68. 6 Remove the installation tool. Section 1-5 - General Information Service Tools Slide Hammer Kit 1-5-25 1-5-25 9803/3750-06 (1-06-00) Slide Hammer Kit TB-003 Fig 69. 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 69-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 69-B and 69-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 69-A as shown. Use the spanner flats 69-D to securely fit the adaptor. 3 Fit an end stop 69-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' 69-E into the end stop. Again make sure that the threads are fully engaged. 5 Fit the 'slide hammer', item 69-F, onto the slide bar as shown. 6 Finally, fit another end stop, item 69-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 69-C. Repeat this step until the pivot pin is released. 8 To remove the slide hammer kit, reverse steps 2 to 7. Section 1-5 - General Information Service Tools Slide Hammer Kit 1-5-26 1-5-26 9803/3750-06 (1-06-00) Page left intentionally blank Section 1-6 - General Information 1-6-1 1-6-1 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 Fuel Specification Applicable Engines Service Requirements EN590 Diesel fuel types - Auto/C0/C1/C2/ C3/C4 SE, SD, SF 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 SE, SD, SF Engines. 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 SE, SD, SF Engines. Engines operated with these fuels will 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 SE, SD, SF Engines. 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 Service Requirements for use of B20 Biodiesel ( 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 9803/3750-06 (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 micro-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 9803/3750-06 (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 9803/3750-06 (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 9803/3750-06 (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 2. 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 2. 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 9803/3750-06 (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 9803/3750-06 (1-15-01) 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 9803/3750-06 (1-15-01) 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 9803/3750-06 (1-15-01) Specifications 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. Table 2. Engine Build Code SD SE SF SF Engine Stall Speeds r.p.m. Torque Converter Only 1820 2000 2000 2000 Hydraulics (M.R.V.) Only 2370 2350 2340 2340 Combined Converter + M.R.V. (1) (1) Combined stall tests are performed with the crowd service operated until the relief valve is lifted. 1300(2) (2) Make sure that the hydraulic oil temperature is 60 degrees C. 1725 1760(2) 1760(2) Build Specification Engine size: 85 h.p. (63 kW) Turbocharged z 100 h.p (74 kW) Turbocharged and Intercooled z 114 h.p. (85 kW) Turbocharged and Intercooled z 130 h.p. (97 kW) Turbocharged and Intercooled z Section 1-8 - General Information Stall Speed Combinations Specifications 1-8-4 1-8-4 9803/3750-06 (1-15-01) Page left intentionally blank Section 2 - Care and Safety 2-0 2-0 9803/3750-07 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 Labels .......................................................................................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 - 7 Connecting/Disconnecting Hydraulic Hoses ..........................................2-2 - 8 Quick Release Couplings ......................................................................2-2 - 9 Hydraulic Contamination .....................................................................2-2 - 11 Battery Disconnection/Connection ......................................................2-2 - 13 Removing and Replacing Components ...............................................2-2 - 14 Battery Charging System Precautions .................................................2-2 - 15 Hydraulic Rams ...................................................................................2-2 - 16 Page No. Contents Section 2 - Care and Safety 2 - ii 2 - ii Section 2-1 - Care and Safety 2-1-1 2-1-1 9803/3750-07 (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 9803/3750-07 (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 9803/3750-07 (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 9803/3750-07 (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 9803/3750-07 (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 incorrect or faulty lifting equipment. You must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations. INT-1-3-7_2 !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 9803/3750-07 (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 9803/3750-07 (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 9803/3750-07 (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 9803/3750-07 (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 9803/3750-07 (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 9803/3750-07 (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 9803/3750-07 (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 9803/3750-07 (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 9803/3750-07 (2-01-01) !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 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 !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 !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 Section 2-1 - Care and Safety Safety Notices Safety Check List 2-1-15 2-1-15 9803/3750-07 (2-01-01) !MWARNING Wheels and tyres are heavy. Take care when lifting or moving them. Store with care to ensure that they cannot fall and cause injury. 13-3-1-7_1 !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 Thank you very much for your reading. Please Click Here Then Get More Information. </p>