JCB 540-170 TELESCOPIC HANDLER Service Repair Manual

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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
 
 
 
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