General Information
1
Care & Safety
2
Routine Maintenance
3
R
Attachments
Service Manual 3CX, 4CX, 214, 215, 217 & VARIANTS
Backhoe Loader From M/c No. 460001 To 499999 499 999 920001 On 900001 On (N.Am only) PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMEN DEPARTMENT T OF JCB SERVICE; © WORLD PARTS CENTRE, STAFFORDSHIRE, STAFFORDSH IRE, ST14 7BS, ENGLAND Tel. (01889) 590312 PRINTED IN ENGLAND Publication No. 9803/3270 & 9803/3270U
A
Body & Framework
B
Electrics
C
Controls
D
Hydraulics
E
Transmission
F
Brakes
G
Steering
H
Engine
K
Introduction 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, procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 1 2 3 machine.
= = =
General Information - includes torque settings and service tools. Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. Routine Maintenance - includes service schedules and recommended lubricants for all the
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: A B
= =
Attachments Body & Framework
...etc.
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual. All sections are listed on the front cover; tabbed divider cards align directly with individual sections sections on the front cover for rapid reference. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.
9803/3270
Issue 1 SXXXXXX
SXX XX XX
S XX XXX X
General Information
Section 1
Section 1
i
i
Contents Ma c h in e Id e n t if ic a t io n P la t e
1-1
Ty p ic a l Ve h ic le Id e n t if ic a ti tio n Nu m b e r (VIN)
1-1
Ty p ic a l E n g in e Id e n t if ic a t io n Nu m b e r
1-1
S e ria l P la t e s
1-2
To rq u e S e t t in g s
2-1
S e rv ic e To o ls Nu m e ric a l Lis t
3-1
S ervice Too Too ls - B o d y & Fra m e w o rk - Ele c t ric s - H y d ra u lic s - Tra n s m is s io n - E n g in e S e a lin g a n d R e t a in in g C o m p o u n d s
9803/ 9803 /3270
Page No.
4-1 4-4 4-6 4 - 10 4 - 17 5-1
Iss ue 2
General Information
S ec tion tion 1
S ec tion tion 1
1- 1
1 -1
Machine Identification Plate Your machine has an identification plate mounted on the loa der tow er. The The se ria ria l numbers o f the ma chine and its major units units a re sta mped o n the plate. plate. The se ria ria l numbe r of ea ch ma jor unit unit is is a lso sta mped 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 sta mp o ut the o ld numbe r. This will prevent the wrong unit number being quoted when replacement parts are ordered. The ma chine a nd eng ine s erial erial numbers c an help ident ident ify exac tly tly the type of eq ui uipment pment you have.
Typical Vehicle Identification Number (VIN) SLP SLP
3CX
T
S
V
E
0460 046000 001 1
A
B C
D
E
F
G
A
World Manufacturer Identification
B
Machine Model
C
S tee r Type (T= 2WS 2WS , F= 4WS 4WS )
D
Build Buil d Type (S (S = Sideshift, Sideshift, C = Centremount, L=Loa der)
E
Year of Manufacture: R = 1994 S = 1995 T = 1996 V = 1997 W = 1998 X = 1999 Y = 2000
1 2 3 4 5 6 7
= = = = = = =
2001 2002 2003 2004 2005 2006 2007
F
Manufac Manufac turer turer Loc Loc ation (E (E = England England )
G
P roduc t Identifica Identifica tion tion Numbe r (P (P IN) IN)
S218131
U.K. and R.O.W. Typical Engine Identification Number Number AB
50262 U 500405 P
A A
B
C
D
E
Eng ine Typ e AB = 4 cylinder cylinder turbo
North America
9803 /3270
B
B uil uild Numbe r
C
Co untry of Origin Origin
D
Engine Sequence Number
E
Year of Manufacture
A246740
Issue 1
General Information
S ec tion tion 1
S ec tion tion 1
1- 2
1 -2
Serial Plates A
Front Axle Axle (2WS (2WS ma ch ine)
B
Front Axle Axle (4WS (4WS ma ch ine)
C
Rear Axle (2WS machine)
D
Rear Axle (4WS machine)
E
S ync ro Shuttle Transm iss ion
F
P ow ershift ershift Transm iss ion
G
Engine
D
S259110
E A S257580
S143031
F
B S259100
S146790
C G S156571
9803 /3270
S260120
Issue 1
General Information
Section 1
Section 1
2- 1
2 -1
Torque Settings Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third.
UNF Grade Grade 'S' Bolts B o lt S iz e in
(m m )
He x a g o n (A/F) in
1 /4 5 /1 6 3 /8 7 /1 6 1 /2 9 /1 6 5 /8 3 /4 7 /8 1 1 1 /4 1 1 /2
(6. 3 ) (7. 9 ) (9. 5 ) (1 1. 1) (1 2. 7) (1 4. 3) (1 5. 9) (1 9. 0) (2 2. 2) (2 5. 4) (3 1. 7) (3 8. 1)
7 /1 6 1 /2 9 /1 6 5 /8 3 /4 13/16 15/16 1 1 /8 15/16 1 1 /2 1 7 /8 2 1 /4
Nm 14 28 49 78 117 170 238 407 650 970 1940 3390
To rq u e S e t t in g s kg f m
lb f ft
1. 4 2. 8 5. 0 8. 0 12 . 0 17 . 3 24 . 3 41 . 5 66 . 3 99 . 0 19 8 . 0 34 5 . 0
10 20 36 58 87 125 175 300 480 715 1430 2500
To rq u e S e t t in g s kg f m
lb f ft
Metric Grade 8.8 Bolts B o lt S iz e (m m ) M5 M6 M8 M10 M12 M16 M20 M24 M30 M36
(5 ) (6 ) (8 ) (1 0) (1 2) (1 6) (2 0) (2 4) (3 0 ) (3 6 )
He x a g o n (A/F) mm 8 10 13 17 19 24 30 36 46 55
Nm 7 12 28 56 98 244 476 822 1633 2854
0. 7 1. 2 3. 0 5. 7 10 25 48 84 16 6 29 1
5 9 21 42 72 180 352 607 1205 2105
Rivet Nut Bolts/Screws B o lt S iz e
M3 M4 M5 M6 M8 M10 M12
(m m )
To rq u e S e t t in g s (fo r s t e e l riv e t n u t s ) Nm kg f m lb f ft
(3 ) (4 ) (5 ) (6 ) (8 ) (1 0 ) (1 2 )
1. 2 3. 0 6. 0 10. 0 24. 0 48. 0 82. 0
0. 12 0. 3 0. 6 1. 0 2. 5 4. 9 8. 4
0. 9 2. 0 4. 5 7. 5 18. 0 35. 5 60. 5
Note: All bolts bolts use d o n J CB mac hines hines a re high tensil tensile a nd must not be replac replac ed b y bo lts o f a lesse r tensil tensile s pecifica pecifica tion. tion.
9803/ 9803 /3270
Iss ue 1
Section 1
General Information
3- 1
Section 1 3 -1
Servic Service e Tools Numerical Numerical List List Page No. 1406/00 11 1406/00 14 1406/00 18 1406/00 21 1406/00 29 1604/00 03 1604/00 04 1604/00 06 1604/00 08 1606/00 03 1606/00 04 1606/00 07 1606/00 08 1606/00 09 1606/00 12 1606/00 14 1606/00 15 1606/00 17 1612/00 06 4101/06 51 4101/02 50 4101/04 51 4102/05 02 4102/05 51 4102/09 33 4102/12 12 4102/19 51 4102/23 09 4103/21 09 4104/02 51 4104/02 53 4104/12 03 4104/12 06 4104/1 310 4104/1 538 4201/4 906 816/00 017 816/00 189 816/00 190 816/00 193 816/00 196 816/00 197 816/00 294 816/00 439 816/00 440 816/15 007 816/15 008 816/15 118 816/20 008 816/20 013 816/50 005 816/50 043 816/55 038 816/55 040 816/60 096 825/00 410 825/99 833 826/01 099 826/01 101 826/01 102 826/01 103 826/01 104 9803/ 9803 /3270
B o n d e d Wa s h e r B o n d e d Wa s h e r B o n d e d Wa s h e r B o n d e d Wa s h e r B o n d e d Wa s h e r Ma le Ad a p t e r Ma le Ad a p t e r Ma le Ad a p t e r Ad a p t e r Ma le Ad a p t e r Ma le Ad a p t e r Ma le Ad a p t e r Ma le Ad a p t e r Ma le Ad a p t e r Ma le Ad a p t e r Ma le Ad a p t e r Ma le Ad a p t e r Ma le Ad a p t e r Ad a p t e r R e t a in e r (Hig h S t re n g t h ) Th re a d lo c ke r a n d S e a le r Th re a d lo c ke r H ig h S t re n g t h G a s ke t in g H ig h S t re n g t h Th re a d lo c ke r C le a r S ilic o n e S e a la n t Mu lt i-G a s ke t Th re a d s e a l B la c k P o ly u re t h a n e S e a la n t U lt ra Fa st s t Ad h e s iv e (310m l) Ac t iv a t o r (Ae rs o l) Ac t iv a t o r (B o t t le ) Ac t iv e Wip e 205 (250g ) Ac t iv e Wip e 205 (30 m l) Ha n d C le a n e r J C B C le a n e r &D e g re a s e r B la c k P rim e r 206J (3 (30m l) Ad a p t e r B la n kin g C a p B la n kin g C a p B la n kin g C a p B la n kin g C a p B la n kin g C a p B la n kin g C a p Ma le Ad a p t e r Ma le Ad a p t e r Ma le Ad a p t e r Ma le Ad a p t e r P re s s u re Te s t Ad a p t e r Ad a p t e r Ad a p t e r Ad a p t e r Ad a p t e r P re s s ure Te s t ' T' Ad a p t e r P re s s ure Te s t ' T' Ad a p t e r Ad a p t e r C ro w fo o t Wre n c h Ad a p t e r fo r 825/00410 R ive t Nu t R ive t Nu t R ive t Nu t R ive t Nu t R ive t Nu t
4 - 6,
4 - 6,
4 - 6, 4 - 6,
4-7 4-7 4-7 4-7 4-7 4-7 4-7 4-7 4-6 4-7 4-7 4-7 4-7 4-7 4-7 4-7 4-7 4-7 4-6 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 4-1 5-1 5-1 4-8 4-8 4-8 4-8 4-8 4-8 4-8 4-7 4-7 4-7 4-7 4-6 4-6 4-6 4-8 4-8 4-6 4-6 4-8 4-4 4-4 4-1 4-1 4-1 4-1 4-1
Page No. 8 26/01105 8 92/00011 8 92/00041 8 92/00047 8 92/00048 8 92/00049 8 92/00051 8 92/00055 8 92/00056 8 92/00057 8 92/00058 8 92/00059 8 92/00060 8 92/00071 8 92/00074 8 92/00075 8 92/00076 8 92/00077 8 92/00078 892/ 892/0013 00137 7 8 92/00167 8 92/00174 8 92/00179 8 92/00180 8 92/00182 8 92/00223 8 92/00224 8 92/00225 8 92/00253 8 92/00255 8 92/00256 8 92/00257 8 92/00258 8 92/00259 8 92/00260 8 92/00261 8 92/00262 8 92/00263 8 92/00264 8 92/00265 8 92/00268 8 92/00269 8 92/00270 8 92/00271 8 92/00272 8 92/00273 8 92/00274 8 92/00275 8 92/00276 8 92/00277 8 92/00278 8 92/00279 8 92/00282 8 92/00283 8 92/00284 8 92/00285 8 92/00286 8 92/00293 8 92/00294 8 92/00295 8 92/00298 8 92/00301
R iv e t Nu t 4-1 S p o o l C la m p 4-8 D e -g la z in g To o l 4 - 17 Ad a p t e r 4-8 Ad a p t e r 4-8 Ad a p t e r 4-8 Ad a p t e r 4-8 B la n kin g P lug 4-8 B la n kin g P lug 4-8 B la n kin g P lug 4-8 B la n kin g P lug 4-8 B la n kin g P lug 4-8 B la n kin g P lug 4-8 Ma le Ad a p t e r 4-7 Fe m a le C o n n e c t o r 4-8 Fe m a le C o n n e c t o r 4-8 Fe m a le C o n n e c t o r 4-8 Fe m a le C o n n e c t o r 4-8 C o nne c to r 4-6 Micro-Bore cro-Bore Hose Hose 1/4in. 4in. BSP , 3 Metr Metres es 4 - 7 R a m S e a l P ro r o t ec ec t io io n S le le e ve ve 90 90 m m 4 - 9 Me a s u rin g C u p 4 - 12 B e a rin g P re s s 4 - 10 S e a l Fit t in g To o l 4-9 B e a rin g P a d D riv e r 4 - 12 Ha n d P u m p 4-7 Im p uls e E xt ra c t o r 4 - 11 Ad a p t e r fo r Ex t ra c t o r 4 - 11 P re s s u re Te s t Kit 4-6 P re s s u re Te s t Ad a p t e r 4-6 P re s s u re Te s t Ad a p t e r 4-6 P re s s u re Te s t Ad a p t e r 4-6 P re s s u re Te s t Ad a p t e r 4-6 P re s s u re Te s t Ad a p t e r 4-6 P re s s u re Te s t Ad a p t e r 4-6 P re s s u re Te s t Ad a p t e r 4-6 P re re s s ur ure Te st s t ' T' Ad a pt pt e r 4 - 6, 4 - 7 P re s s u re Te s t ' T' Ad a p t e r 4-6 P re s s u re Te s t ' T' Ad a p t e r 4-6 P re s s u re Te s t ' T' Ad a p t e r 4-6 Flo w Mo n it o rin g U n it 4-6 S e n s o r He a d 4-6 Lo a d Va lv e 4-6 Ad a p t e r 4-6 Ad a p t e r 4-6 S e n s o r He a d 4-6 Ad a p t e r 4-7 Ad a p t e r 4-6 Ad a p t e r 4-6 Ad a p t e r 4-6 G a ug e 4-7 G a ug e 4-7 S hunt 4-4 To o l Kit C a s e 4-4 Ta c h o m e t e r 4-4 Hy d ra ra ul ulic Oi Oil Te mp mp er era tu t u re P ro ro be be 4-4 S u rfa c e Te m p e ra t ure P ro ro b e 4-4 C o n n e c t o r P ip e 4-6 C o n n e c t o r P ip e 4-6 En d Flo a t S e t t in g To o l 4 - 10 Flu ke Me t e r 4-4 Flo w Te s t Ad a p t e r 4 - 10 Iss ue 3
Section 1
General Information
Section 1
3- 2
3 -2
Servic Service e Tools Numerical Numerical List List Page No. 892/003 02 892/ 892/00309 00309 892/003 33 892/003 34 892/003 35 892/007 06 892/008 12 892/008 17 892/008 18 892/008 19 892/008 22 892/008 25 892/008 36 892/008 42 892/008 43 892/008 44 892/008 45 892/008 46 892/008 47 892/008 48 892/008 49 892/008 81 892/008 82 892/008 91 892/009 16 892/009 18 892/009 20 892/009 22 892/009 40 892/009 48 892/009 49 * 892/009 56 892/009 64 892/009 65 892/009 66 * 892/010 16 * 892/010 17 * 892/010 18 * 892/010 19 * 892/010 20 * 892/010 21 * 892/010 22 * 892/010 23 * 892/010 24 * 892/010 25 * 892/010 26 * 892/010 27 921/526 00 926/155 00 990/000 83 992/040 00 992/048 00 992/076 08 992/076 09 992/076 10 992/076 11 992/076 12 992/076 13 992/091 00 992/092 00 9803/ 9803 /3270
F lo w Te s t Ad a p t e r 4 - 10 ARV Test Kit Kit 4-7 He a v y D ut y S o c ke t 4 - 11 G la n d S e a l Fit t in g To o l 4-9 AR V C ar a rt rid g e R e m o v a l To o l 4-7 Te s t P ro b e 4 - 6, 4 - 7 D riv e C o u p lin g S p a n n e r 4 - 10 He a v y D ut y S o c ke t 4 - 11 He a v y D ut y S o c ke t 4 - 11 He a v y D ut y S o c ke t 4 - 11 S p lin e d B o lt S o c ke t 4 - 12 E n d Flo a t S e t t in g To o l 4 - 10 Lift in g Wire As s e m b ly 4 - 17 G la s s Lift e r 4-2 Fo ld in g S t a n d 4-1 Lo n g Kn ife 4-3 C a rt rid g e G u n 4-1 G la s s Ex t ra c t o r (H a n d le s ) 4-2 Ny lo n S p a t u la 4-3 Wire S t a rt e r 4-2 B ra id e d C u t t in g Wire 4-3 S p o o l S e a l Fit t in g To o l 4-7 Alt e rn a t o r P u lle y S o c ke t 4-5 Wh e e l Hu b Se S e a l - Fit t in g To ol ol 4 - 11 C lu lu t c h P a c k S p prrin g C om o m p rre e ss s s or or 4 - 12 S e t t in g To o l Kit 4 - 15 F lo w Te s t Ad a p t e r 4 - 10 12. 2” T/C Alig n m e n t To o l 4 - 10 S p e e d S e n s o r Te s t La m p 4-4 C h a rg in g Kit 4-9 P re s s u re G a u g e 4-9 Tim in g P in 4 - 17 Te s t P o in t (1/8B S P ) 4 - 15 Te s t P o in t (3/8B S P ) 4 - 15 Te s t P o in t (1/4B S P 4 - 15 R a m S e a l P ro r o te t e c ti tio n S lle e ev ev e 25 25 m m 4-9 R a m S e a l P ro r o te t e c ti tio n S lle e ev ev e 30 30 m m 4-9 R a m S e a l P ro r o te t e c ti tio n S lle e ev ev e 40 40 m m 4-9 R a m S e a l P ro r o te t e c ti tio n S lle e ev ev e 50 50 m m 4-9 R a m S e a l P ro r o te t e c ti tio n S lle e ev ev e 50 50 m m 4-9 (slew ram) R a m S e a l P ro r o te t e c ti tio n S lle e ev ev e 60 60 m m 4-9 R a m S e a l P ro r o te t e c ti tio n S lle e ev ev e 60 60 m m 4-9 (slew ram) R a m S e a l P ro r o te t e c ti tio n S lle e ev ev e 65 65 m m 4-9 R a m S e a l P ro r o te t e c ti tio n S lle e ev ev e 70 70 m m 4-9 R a m S e a l P ro r o te t e c ti tio n S lle e ev ev e 75 75 m m 4-9 R a m S e a l P ro r o te t e c ti tio n S lle e ev ev e 80 80 m m 4-9 P is t o n S e a l As s e m b ly To o l 4-9 S p a c e r Kit 4 - 15 R ub b e r S p a c e r B lo c ks 4-3 E n d Flo a t S e t t in g To o l 4 - 10 To rq ue Mu lt ip lie r 4 - 12 Fla n g e S p a n n e r 4 - 12 B e a rin g Ad a p t e r 4 - 10 B e a rin g Ad a p t e r 4 - 10 B e a rin g Ad a p t e r 4 - 10 B e a rin g Ad a p t e r 4 - 10 B e a rin g Ad a p t e r 4 - 10 B e a rin g Ad a p t e r 4 - 10 S p o o l C la m p 4-8 C h a rg in g To o l 4-1
Page No. 9 92/09300 9 92/09400 9 92/09500 9 92/09600 9 92/09700 9 92/09900 9 92/10000 9 92/12300 9 92/12400 9 92/12600 9 92/12800 9 92/12801 9 93/55700 9 93/59500 9 93/68100 9 93/69800 9 93/70100 9 93/70111 9 93/78200 9 93/85700 7 210/0001 7 210/0002 7 210/0003 7 212/0001 7 212/0002 7 212/0003 7 212/0004 7 213/0001 7 213/0002 7 213/0003 7 213/0004 7 213/0005 7 213/0006 7 213/0007 7 213/0008 7 214/0001 7 214/0002 7 214/0003 7 214/0004 7 216/0001 7 216/0002 7 216/0003 7 216/0004 7 218/0001 7 218/0002 7 218/0003 7 218/0004 7 219/0001 7 219/0002 7 219/0003 7 219/0004 7 219/0005 7 219/0006 7 219/0007 7 219/0008
Ra m S p a nne r Ra m S p a nne r Ra m S p a nne r Ra m S p a nne r Ra m S p a nne r Ra m S p a nne r Ra m S p a nne r 12V Mo b ile O v e n S t a t ic O v e n - 2 C a rt rid g e S t a t ic O v e n - 6 C a rt rid g e C u t -O u t Kn ife " L" B la d e s D ire c t G la z in g Kit Im p uls e Ex t ra c t o r Ad a p t e r S lid e Ha m m e r Kit S e a l Kit P o w er e rs hi h if t En En d fl flo a t C he h e ck c kin g Ki Kit B re a kb a c k To rq ue ue Wre n c h Ma in s h a ft Airlin e Ad a p t e r B a t t e ry Te s t e r D u m m y P lu g Wire S ea ea l (1 . 4 - 2. 2 m m d ia .) .) Wire S ea ea l (2 . 2 - 2. 9 m m d ia .) .) 2 Wa y S o c ke t C o n n e c t o r 2 Wa y P in H o u s in g 2 Wa y S o c ke t R e t a in e r 2 Wa y P in R e t a in e r 3 Wa y S o c ke t C o n n e c t o r 3 Wa y P in H o u s in g 3 Wa y S o c ke t R e t a in e r 3 Wa y P in R e t a in e r 3 Wa y S oc o c ke ke t C on on n e c to to r (D T) 3 Wa y P in H o u s in g (D T) 3 Wa y S o c ke t R e t a in e r (D T) 3 Wa y P in R e t a in e r (D T) 4 Wa y S o c ke t C o n n e c t o r 4 Wa y P in H o u s in g 4 Wa y S o c ke t R e t a in e r 4 Wa y P in R e t a in e r 6 Wa y S o c ke t C o n n e c t o r 6 Wa y P in H o u s in g 6 Wa y S o c ke t R e t a in e r 6 Wa y P in R e t a in e r 8 Wa y S o c ke t C o n n e c t o r 8 Wa y P in H o u s in g 8 Wa y S o c ke t R e t a in e r 8 Wa y P in R e t a in e r 10 Wa y S o c ke t C o n n e c t o r 10 Wa y P in Ho u s in g 10 Wa y S o c ke t R e t a in e r 10 Wa y P in R e t a in e r 14 Wa y S o c ke t C o n n e c t o r 14 Wa y P in Ho u s in g 14 Wa y S o c ke t R e t a in e r 14 Wa y P in R e t a in e r
4-8 4-8 4-8 4-8 4-8 4-8 4-8 4-1 4-2 4-2 4-2 4-2 5-1 4 - 11 4-3 4-6 4 - 16 4 - 15 4 - 15 4-4 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5 4-5
Issue 4*
Section 1
General Information
3- 3
Section 1 3 -3
Servic Service e Tools Numerical Numerical List List The follow follow ing p arts a re replac replac ement items for ki kits and w ould normally be included in the kit numbers quoted on pages 1/3-1 a nd 1/3-2. 1/3-2.
Service Tools Numerical List
Page No.
Rep lac eme nt item for kit kit no . 892/00180 892/001 81
4-9
Rep lac eme nt 892/002 01 892/002 02 892/002 03 892/002 54
items for kit kit no . 892/00253 R e p la c e m e n t G a u g e R e p la c e m e n t G a u g e R e p la c e m e n t G a u g e R e p la c e m e n t Ho s e
4 4 4 4
Rep lac eme nt 892/003 40 892/003 41 892/003 43 892/003 45 993/683 00
items for kit kit no . 892/00309 Te s t B lo c k B o d y S e t t in g B o d y S p a nne r An t i-C av a v it a ti tio n Lo c k O u t B un un g Ad ju s t in g P in
4-7 4-7 4-7 4-7 4-7
Rep lac eme nt 993/681 01 993/681 02 993/681 03 993/681 04 993/681 05 993/681 06 993/681 07 993/681 08 993/681 09 993/ 993/6811 68110 0 993/681 11
items for kit kit no . 993/68100 S lid e Ha m m e r En d S t o p s Ad a p t o r - M20 x 5/8" UN UNF Ad a p t o r - M20 x 1" U NF Ad a p t o r - M20 x M20 Ad a p t o r - M20 x M24 B a r - M2 0 x M2 0 X 80 0 MM Ad a p t o r - M20 x 7/8" UN UNF Ad a p t o r - M20 x M12 Adaptor - M20 x 5/ 5/8" UNF (Shoulder) Shoulder) Ad a p t o r - M20 x 1/2" UN UNF
4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4-3 4 -3 4-3
9803/ 9803 /3270
-
6 6 6 6
Iss ue 1
General Information
Section 1
Section 1
4-1
4-1
Service Tools (cont'd) Section B - Body & Framework
826/01099 826/01101 826/01103 826/01102 826/01104 826/01105
M6 x 16mm Rivet Nut M6 x 19mm Rivet Nut M8 x 18mm Rivet Nut M8 x 21mm Rivet Nut M10 x 23mm Rivet Nut M10 x 26mm Rivet Nut
Installation Tool Available from: Bollhoff Fastenings Ltd. Midacre The Willenhall Estate Rose Hill Willenhall West Midlands, WV13 2JW S261210
Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc.
JCB part 892/00845
number
-
Hand Cleaner - special blend for the removal of polyurethane adhesives.
JCB part number - 4104/1310 (454g; 1 lb tub)
S186270
S186240
Folding Stand for Holding Glass essential for preparing new glass prior to installation. 12V Mobile Oven - 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).
JCB part number - 992/12300 S186250
9803/3270
JCB part 892/00843
number
-
S186280
Issue 1
Section 1
General Information
Section 1
4-2
4-2
Service Tools (cont'd) Section B - Body & Framework 240V Static Oven - available with 2 or 6 cartridge capacity - required to pre-heat adhesive prior to use. No plug supplied. Note: 110V models available upon request - contact JCB Technical Service.
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.
JCB part number: 992/12400 - 2 Cartridge x 240V 992/12600 - 6 Cartridge x 240V
JCB part number - 892/00842
S186300
S186260
Wire Starter - used to access braided cutting wire (below) through original polyurethane seal. Cut-Out Knife - used to remove broken glass.
JCB part number - 992/12800 JCB part number - 892/00848 S186310
S186340
'L' Blades - 25 mm (1 in) cut - replacement blades for cut-out knife (above).
JCB part number - 992/12801 (unit quantity = 5 off)
Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass.
JCB part number - 892/00846 S186320
9803/3270
S186350
Issue 1
General Information
Section 1
Section 1
4-3
4-3
Service Tools (cont'd) Section B - Body & Framework Long Knife - used to give extended reach for normally inaccessible areas.
Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool (above).
JCB part number - 892/00844 JCB part number - 892/00849 (approx 25 m length)
S186360
S186330
Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame.
JCB part number - 926/15500 (unit quantity = 500 off)
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.
JCB part number - 892/00847 S186470
Slide Hammer Kit - 993/68100 1 :993/68101 Slide Hammer 2 :993/68102 End Stops 3 :993/68103 Adaptor - M20 x 5/8" UNF 4 :993/68104 Adaptor - M20 x 1" UNF 5 :993/68105 Adaptor - M20 x M20
6 7 8 9 10 11
S186550
:993/68106 :993/68107 :993/68108 :993/68109 :993/68110 :993 :9 93/6 /681 8111 11 2
11
1
Adaptor - M20 x M24 Bar - M20 x M20 X 800MM Adaptor - M20 x 7/8" UNF Adaptor - M20 x M12 Adaptor - M20 x 5/8" UNF (Shoulder) Adap Ad apto torr - M2 M20 0 x 1/ 1/2" 2" UN UNF F 2
3
6
2
5
4
9 10 8 7
S196910
9803/3270
Issue 1
General Information
Section 1
Section 1
4-4
4-4
Service Tools (cont'd) Section C - Electrics
AVO Test Kit 1
892/00283
Tool Kit Case
2
892/00298
Fluke Meter 85
3
892/00286
Surface Temperature Probe
4
892/00284
V en tu r e
5
892/00282
100 amp Shunt - open type
6
892/00285
Hydraulic Temperature Probe
Mi cr ot ac h Mi
Di gi ta l Di
Tachometer
S188231
993/85700
Battery Tester
892/00882
Socket fo for Al Alternator Pu Pulley Nu Nut
S239510
825/00410 825/99833
*892/00940
15 mm Crowfoot Wrench Adapter
S216200
9803/3270
S216770
Speed Se Sensor Te Test La Lamp
S298910
Issue 2*
General Information
Section 1
Section 1
4-5
4-5
Service Tools (cont'd) Section C - Electrics
2A 2B 2C 2D 3A 3B 3C 3D 4A 4B 4C 4D 5A 5B 5C 5D
:7212/0002 :7212/0004 :7212/0003 :7212/0001 :7213/0002 :7213/0004 :7213/0003 :7213/0001 :7213/0006 :7213/0008 :7213/0007 :7213/0005 :7214/0002 :7214/0004 :7214/0003 :7214/0001
Electrical Repair Kit 2 Way Pin Housing 2 Way Pin Retainer 2 Way Socket Retainer 2 Wa Way So Socket Co Connector 3 Way Pin Housing 3 Way Pin Retainer 3 Way Socket Retainer 3 Wa Way So Socket Co Connector 3 Way Pin Housing (DT) 3 Way Pin Retainer (DT) 3 Way Socket Retainer (DT) 3 Wa Way So Socket Co Connector (D (DT) 4 Way Pin Housing 4 Way Pin Retainer 4 Way Socket Retainer 4 Wa Way So Socket Co Connector
6A 6B 6C 6D 7A 7B 7C 7D 8A 8B 8C 8D 9A 9B 9C 9D 10 11 12
:7216/0002 :7216/0004 :7216/0003 :7216/0001 :7218/0002 :7218/0004 :7218/0003 :7218/0001 :7219/0002 :7219/0004 :7219/0003 :7219/0001 :7219/0006 :7219/0008 :7219/0007 :7219/0005 :7210/0001 :7210/0002 :7210/0003
6 Way Pin Housing 6 Way Pin Retainer 6 Way Socket Retainer 6 Wa Way So Socket Co Connector 8 Way Pin Housing 8 Way Pin Retainer 8 Way Socket Retainer 8 Wa Way So Socket Co Connector 10 Way Pin Housing 10 Wa Way Pin Re Retainer 10 Wa Way So Socket Re Retainer 10 Wa Way So Socket Co Connector 14 Way Pin Housing 14 Wa Way Pin Re Retainer 14 Wa Way So Socket Re Retainer 14 Wa Way So Socket Co Connector Dummy Plug Wir ire e Seal (1.4 - 2.2 mm dia.) Wir ire e Seal (2.2 - 2.9 mm dia.)
1
S188380
9803/3270
Issue 1
General Information
Section 1
Section 1
4-6
4-6
Service Tools (cont'd) Section E - Hydraulics
Hydraulic Circuit Pressure Test Kit 892/00253 :892 :8 92/0 /002 0201 01 :892 :8 92/0 /002 0202 02 :892 :8 92/0 /002 0203 03 :892/00254 993/69800
S267300
892/00706
Pressure Te Test Ki Kit Repl Re plac acem emen entt Gaug Gauge e 0-20 0-20 bar bar (0 (0-3 -300 00 lbf lbf/i /in n2 ) Repl Re plac acem emen entt Gaug Gauge e 0-40 0-40 bar bar (0 (0-6 -600 00 lbf lbf/i /in n2 ) Repl Re plac acem emen entt Gaug Gauge e 0-40 0-400 0 bar bar (0-6 (0-600 000 0 lbf/ lbf/in in2 ) Replacement Ho Hose Seal Se al Kit Kit fo forr 892/ 892/00 0025 254 4 (ca (can n also also be us used ed wi with th probe 892/00706) Test Probe
S188121
S188131
Pressure Test Adapters Pressure Test 'T' Adapters 892/00262 892/00 262 816/55 816 /55038 038 816/55 816 /55040 040 892/00 892 /00263 263 892/00 892 /00264 264 892/ 89 2/00 0026 265 5
1/4 in M BS BSP P x 1/4 in F BS BSP P x Tes Testt Poin Pointt 3/8 in M BS BSP P x 3/8 in F BS BSP P x Tes Testt Poin Pointt 1/2 in M BS BSP P x 1/2 in F BS BSP P x Tes Testt Poin Pointt 5/8 in M BS BSP P x 5/8 in F BS BSP P x Tes Testt Poin Pointt 3/4 in M BS BSP P x 3/4 in F BS BSP P x Tes Testt Poin Pointt 1 in M BSP BSP x 1 in in F BSP BSP x Tes Testt Poi Point nt
892/00 892/ 0025 255 5 892/ 89 2/00 0025 256 6 892/ 89 2/00 0025 257 7 892/ 89 2/00 0025 258 8 816/ 81 6/15 1511 118 8 892/ 89 2/00 0025 259 9 892/ 89 2/00 0026 260 0 892/ 89 2/00 0026 261 1
1/4 in 1/4 in BSP BSP x Tes Testt Poi Point nt 3/8 3/ 8 in in BSP BSP x Tes Testt Poi Point nt 1/2 1/ 2 in in BSP BSP x Tes Testt Poi Point nt 5/8 5/ 8 in in BSP BSP x Tes Testt Poi Point nt 3/4 3/ 4 in in BSP BSP x Tes Testt Poi Point nt 1 in in BSP BSP x Tes Testt Poi Point nt 1.1/ 1. 1/4 4 in in BSP BSP x Te Test st Po Poin intt 5/8 5/ 8 in in UNF UNF x Tes Testt Poi Point nt
S200141
Flow Test Equipment 892/00 892/ 0026 268 8 892/00 892 /00269 269 892/ 89 2/00 0029 293 3 892/00270 1406 14 06//00 0021 21 1604 16 04/0 /000 006 6 1612 16 12/0 /000 006 6 892/ 89 2/00 0027 271 1 892/ 89 2/00 0027 272 2 816/ 81 6/20 2000 008 8 892/ 89 2/00 0027 275 5 892/ 89 2/00 0027 276 6 892/ 89 2/00 0027 277 7 892/ 89 2/00 0027 273 3 892/ 89 2/00 0029 294 4 1606 16 06/0 /001 015 5 892/ 89 2/00 0007 078 8 1604 16 04/0 /000 008 8 1606 16 06/0 /001 012 2 816/ 81 6/20 2001 013 3
9803/3270
Flow Mon Flow Monit itor orin ing g Uni Unitt Senso Se nsorr Head Head 0 - 100 100 l/min l/min (0 - 22 UK UK gal/m gal/min) in) Conn nne ect cto or Pip Pipe Load Va Valve Bond nde ed Was Washe herr Adap Ad apte terr 3/4 3/4 in M x 3/ 3/4 4 in in M BS BSP P Adap Ad apte terr 3/4 3/4 in F x 3/ 3/4 4 in in M BS BSP P Adap Ad apte terr 3/4 3/4 in F x 5/ 5/8 8 in in M BS BSP P Adap Ad apte terr 5/8 5/8 in F x 3/ 3/4 4 in in M BS BSP P Adap Ad apte terr 3/4 3/4 in F x 1/ 1/2 2 in in M BS BSP P Adap Ad apte terr 1/2 1/2 in F x 3/ 3/4 4 in in M BS BSP P Adap Ad apte terr 3/4 3/4 in F x 3/ 3/8 8 in in M BS BSP P Adap Ad apte terr 3/8 3/8 in F x 3/ 3/4 4 in in M BS BSP P Sens Se nsor or He Head ad 0 - 38 380 0 l/m l/min in Conn nne ect cto or Pip Pipe Adap Ad apte terr 1.1/ 1.1/4 4 in M BSP BSP x 1 in in M BSP BSP Conn Co nnec ecto torr 1 in F x 1 in in F BS BSP P Adap Ad apte terr 1 in in M x 1 in in M BSP BSP Adap Ad apte terr 1 in M x 3/ 3/4 4 in in M BS BSP P Adap Ad apte terr 3/4 3/4 in F x 1 in in M BS BSP P
S188151
Issue 1
General Information
Section 1
Section 1
4-7
4-7
Service Tools (cont'd) Section E - Hydraulics
Components for Valve Block A.R.V. Testing *For 4CX Variable Flow machines use 25/201103 892/ 89 2/0 008 0881 81
Val alv ve Spo poo ol Seal Fitting Tool
1 2 3 4 5 6
892/00 892/ 0030 309 9 : 892/00340 : 892/00341 : 993/68300 : 892/00343 : 89 892/00345 892/00335
A.R .R..V. Pre res ssur ure e Tes estt Ki Kitt Test Block Body Setting Body Adjusting Pin Spanner Anti-cavitation Lo Lock Out Bung A.R.V. Cartridge Removal Tool 6 4
2
S261220
1
3 5 S196700
Hand Pump Equipment 892/00223 892/00 892 /00137 137 892/00 892 /00274 274 892/00 892 /00262 262 892/00706 892/ 89 2/00 0027 278 8 892/ 89 2/00 0027 279 9
Hand Pump MicroMic ro-bor bore e Hos Hose e 1/4 1/4 in BSP x 3 met metres res Adapte Ada pterr 1/4 1/4 in in M BSP x 3/8 3/8 in M BSP BSP Ta Taper per 1/4 in M BSP x 1/4 1/4 in in F BSP x Test Test Poi Point nt Test Pr Probe Gaug Ga uge e 0 - 40 ba barr (0 (0 - 60 600 0 lb lbf/ f/in in2 ) Gaug Ga uge e 0 - 400 400 ba barr (0 (0 - 60 6000 00 lb lbf/ f/in in2 )
Bonded Washers 1406/0011 1406/0018 1406/0014 1406/0021 1406/0029
1/4 in. BSP 1/2 in. BSP 5/8 in. BSP 3/4 in. BSP 1.1/4 in. BSP S188140
S193850
Male Adapters - BSP x NPT (USA only)
Male Adapters - BSP x BSP
816/00 816/ 0043 439 9 816/ 81 6/00 0044 440 0 816/ 81 6/15 1500 007 7 816/ 81 6/15 1500 008 8
1606/0 1606 /000 003 3 1604 16 04/0 /000 003 3 892/ 89 2/00 0007 071 1 1606 16 06/0 /000 004 4 1606 16 06/0 /000 007 7 1604 16 04/0 /000 004 4 1606 16 06/0 /001 017 7 1606 16 06/0 /000 008 8 1606 16 06/0 /000 009 9 1604 16 04/0 /000 006 6 1606 16 06/0 /001 012 2 1606 16 06/0 /001 014 4 1606 16 06/0 /00 015
3/8 3/8 1/2 1/ 2 3/8 3/ 8 1/2 1/ 2
iin. n. x in. x in. in. x in. in. x in.
1/4 1 /4 in in.. 1/4 in 1/4 in.. 3/8 in 3/8 in.. 3/8 in 3/8 in..
3/8 in. 3/8 in. x 1/ 1/4 in. in. 3/8 3/ 8 in. in. x 3/ 3/8 in. in. 3/8 3/ 8 in. in. x 3/8 3/8 in in.. tap taper er 1/2 1/ 2 in. in. x 1/ 1/4 in. in. 1/2 1/ 2 in. in. x 3/ 3/8 in. in. 1/2 1/ 2 in. in. x 1/ 1/2 in. in. 5/8 5/ 8 in. in. x 1/ 1/2 in. in. 3/4 3/ 4 in. in. x 3/ 3/8 in. in. 3/4 3/ 4 in. in. x 1/ 1/2 in. in. 3/4 3/ 4 in. in. x 3/ 3/4 in. in. 3/4 3/ 4 in in.. x 1 in in.. 3/4 3/ 4 in in.. x 1. 1.1/ 1/4 4 in in.. 1 in. in. x 1.1 1.1/4 /4 in in..
S193860
9803/3270
Issue 2*
General Information
Section 1
Section 1
4-8
4-8
Service Tools (cont'd) Section E - Hydraulics
Female Cone Blanking Plug 892/00055 1/4 in in. BS BSP 892/00056 3/8 in in. BS BSP 892/00057 1/2 in in. BS BSP 892/00058 5/8 in in. BS BSP 892/00059 3/4 in in. BS BSP 892/00060 1 in. BSP
Male Cone Blanking Cap 816/00294 1/4 in in. BS BSP 816/00189 3/8 in in. BS BSP 816/00190 1/2 in in. BS BSP 816/00197 5/8 in in. BS BSP 816/00196 3/4 in in. BS BSP 816/00193 1 in. BSP
S193880
S193870
S193890
892/00 892/ 0004 047 7 892/ 89 2/00 0004 048 8 892/ 89 2/00 0004 049 9 816/ 81 6/50 5004 043 3 892/ 89 2/00 0005 051 1 816/ 81 6/50 5000 005 5 816/ 81 6/60 6009 096 6 816/ 81 6/00 0001 017 7
3/8 in. 3/8 in. BSP BSP (A) (A) x 1/4 1/4 in in.. BSP BSP (B) (B) 1/2 1/ 2 in. in. BSP BSP (A) (A) x 1/4 1/4 in in.. BSP BSP (B) (B) 5/8 5/ 8 in. in. BSP BSP (A) (A) x 1/4 1/4 in in.. BSP BSP (B) (B) 3/4 3/ 4 in. in. BSP BSP (A) (A) x 1/4 1/4 in in.. BSP BSP (B) (B) 1 in. in. BS BSP P (A) (A) x 1/4 1/4 in in.. BSP BSP (B (B)) 1/2 1/ 2 in. in. BSP BSP (A) (A) x 1/2 1/2 in in.. BSP BSP (B) (B) 3/4 3/ 4 in. in. BSP BSP (A) (A) x 3/4 3/4 in in.. BSP BSP (B) (B) 1 in. in. BS BSP P (A) (A) x 1 in in.. BSP BSP (B (B))
992/09 992/ 0910 100 0 892/ 89 2/00 0001 011 1
Excava Exca vato torr Sp Spoo ooll Cl Clam amp p Spool Cla lam mp
S193900
Female Connectors 892/00 892/ 0007 074 4 892/ 89 2/00 0007 075 5 892/ 89 2/00 0007 076 6 892/ 89 2/00 0007 077 7
iin. n. BS BSP P in. BS in. BSP P in. BS in. BSP P in. BS in. BSP P
x 3/ 3/8 8 x 1/ 1/2 2 x 5/ 5/8 8 x 3/ 3/4 4
iin. n. BS BSP P in. BS in. BSP P in. BS in. BSP P in. BS in. BSP P
Hexagon Spanners for Ram Pistons and End Caps 992/09300 55mm A/ A/F 992/09400 65mm A/ A/F 992/09500 75mm A/ A/F 992/09600 85mm A/ A/F 992/09700 95mm A/ A/F 992/09900 115mm A/F 992/10000 125mm A/F
S216210
9803/3270
3/8 3/8 1/2 1/ 2 5/8 5/ 8 3/4 3/ 4
S193930
Issue 1
General Information
Section 1
Section 1
4-9
4-9
Service Tools (cont'd) Section E - Hydraulics
7mm 11o
S216230
20mm
892/00 892 /00180 180
892/ 89 2/00 0018 181 1
Seal Fitti Seal Fitting ng Too Tooll for for fitti fitting ng 'O' 'O' ring ring and king ring to Danfoss Orbitrol Unit
10mm
5mm R
Repl Re plac acem emen entt Pla Plast stic ic Bo Boss ss
m 3 m
110mm 175mm 3o
R 1 .4 m m
892/ 89 2/01 0102 027 7
Pist Pi ston on Se Seal al As Asse semb mbly ly To Tool ol 338500
892/ 89 2/00 0033 334 4
Ram Ra m Sea Seall Fit Fitti ting ng To Tool ol
S216250
S338410
Ram Seal Protection Sleeves
*892/0094 *892/0 0948 8 *892/00949
Charging Chargi ng Kit Kit (wit (withou houtt gauge gauge)) Gauge
892/01 892/ 0101 016 6 892/ 89 2/01 0101 017 7 892/ 89 2/01 0101 018 8 892/ 89 2/01 0101 019 9 892/ 89 2/01 0102 020 0 892/ 89 2/01 0102 021 1 892/ 89 2/01 0102 022 2 892/ 89 2/01 0102 023 3 892/ 89 2/01 0102 024 4 892/ 89 2/01 0102 025 5 892/ 89 2/01 0102 026 6 892/ 89 2/00 0016 167 7
For 25 For 25 mm mm Rod Rod Di Diam amet eter er Forr 30 Fo 30 mm mm Rod Rod Di Diam amet eter er Forr 40 Fo 40 mm mm Rod Rod Di Diam amet eter er Forr 50 Fo 50 mm mm Rod Rod Di Diam amet eter er Forr 50 mm Fo mm Rod Rod Diam Diamet eter er (sl (slew ew ram ram)) Forr 60 Fo 60 mm mm Rod Rod Di Diam amet eter er Forr 60 mm Fo mm Rod Rod Diam Diamet eter er (sl (slew ew ram ram)) Forr 65 Fo 65 mm mm Rod Rod Di Diam amet eter er Forr 70 Fo 70 mm mm Rod Rod Di Diam amet eter er Forr 75 Fo 75 mm mm Rod Rod Di Diam amet eter er Forr 80 Fo 80 mm mm Rod Rod Di Diam amet eter er Forr 90 Fo 90 mm mm Rod Rod Di Diam amet eter er
S308271
9803/3270
Issue 3*
General Information
Section 1
Section 1
4 - 10
4 - 10
Service Tools (cont'd) Section F - Transmission
892/ 89 2/0 002 0295 95
892/ 89 2/00 0082 825 5
End En d Flo Float at Se Sett ttin ing g Too ooll
Reve Re vers rse e Cl Clut utch ch En End d Flo Float at Se Sett ttin ing g To Tool ol (Powershift transmission only)
S190760
S188190
990/ 99 0/0 000 0083 83
End En d Flo Float at Se Sett ttin ing g Too ooll 892/ 89 2/00 0081 812 2
Driv Dr ive e Coup Coupli ling ng Spa Spann nner er for for fro front nt and rear axle yoke couplings and for 4WD output coupling on Syncro Shuttle
S188180
892/ 89 2/0 001 0179 79
S196720
A B C
Bearin Bear ing g Pre Pres ss (us (use e wit with h appropriate adapters)
892/00 892/ 0092 920 0 892/ 89 2/00 0030 301 1 892/ 89 2/00 0030 302 2
S188210 S188200
992/07 992/ 0760 608 8 992/ 99 2/07 0760 609 9 992/ 99 2/07 0761 610 0 992/ 99 2/07 0761 611 1 992/ 99 2/07 0761 612 2 992/ 99 2/07 0761 613 3
Bearin Bear ing g Ad Adap apte terr Bear Be arin ing g Ad Adap apte terr Bear Be arin ing g Ad Adap apte terr Bear Be arin ing g Ad Adap apte terr Bear Be arin ing g Ad Adap apte terr Bear Be arin ing g Ad Adap apte terr
892/00 892 /00922 922
Flow Te Flow Test st Ad Adap apte terr Flow Fl ow Te Test st Ad Adap apte terr Flow Fl ow Te Test st Ad Adap apte terr
A
B
C
12.2” 12. 2” Torq Torque ue Conv Convert erter er Alig Alignme nment nt Too Tooll
S188160 S267260
9803/3270
Issue 1
General Information
Section 1
Section 1
4 - 11
4 - 11
Service Tools (cont'd) Section F - Transmission
892/00224 Impulse Extractor Set for Hub Bearing Seals
S197070
S261230
Torque Measuring Tool for Wheel Hub Seals Manufacture locally, procedures in this manual show checking the wheel hub seal using a rolling force. However, the torque can be measured using above locally manufactured tool. Bearing rolling torque is 12 to 22 Nm (9 to 16 lbf ft) excluding seal drag. Maximum permissible including seal drag is 40 Nm (29.5 lbf ft).
892/00225 892/00891 Fitting Tool Assembly for Wheel Hub Seals
993/ 99 3/5 595 9500 00
Adapter - Im Impulse Ex Extractor Small 17mm to 25mm Medium Medi um 25mm to 45mm 45mm Large 45mm to to 80 80mm Adap aptter - Imp mpul uls se Ext xtra rac cto torr (sync ncro ro shuttle and powershift transmission)
S227760
S216290
892/00 892/ 0081 817 7 892/ 89 2/00 0081 818 8 892/ 89 2/00 0081 819 9 892/ 89 2/00 0033 333 3
9803/3270
17 mm A/ A/F F 22 mm A/ A/F F 15 mm A/ A/F F 19 mm A/ A/F F
x 3/ 3/4i 4in. n. x 3/ 3/4i 4in. n. x 1/ 1/2i 2in. n. x 3/ 3/4i 4in. n.
squ s quar are e squar squ are e squar squ are e squar squ are e
dri d rive ve drive dri ve drive dri ve drive dri ve
Issue 1
General Information
Section 1
Section 1
4 - 12
4 - 12
Service Tools (cont'd) Section F - Transmission
992/04000 Torque Multiplier (use (use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts)
S197030
992/04800 Flange Spanner - for locking pinion flange while pinion nut is slackened or torque set 892/00174 Measuring Cup - Pinion Head Bearing S190770
S197040
892/00822 Splined Bolt Socket for driveshafts
S197060
892/00916
S216310
Clutch pack spring compresso compressorr 892/ 89 2/00 0018 182 2
Bear Be arin ing g Pad Pad Dr Driv iver er
S259320
9803/3270
Issue 1
Section 1 4 - 13
General Information
Section 1 4 - 13
Service Tools (cont'd) Section F - Transmission
Fixture for Syncro Shuttle & Powershift Gearbox removal & replacement Manufacture locally - items 1 to 4 on this and next page. Note: When removing/replacing a Syncro Shuttle Gearbox, use items 1, 2 and 3.
When removing/replacing a Powershift Gearbox, use items 1 and 4.
Fixture - Item 1
9803/3270
Issue 1
Section 1
General Information
Section 1
4 - 14
4 - 14
Service Tools (cont'd) Section F - Transmission
Fixture - Item 2
Fixture - Item 4 Fixture - Item 3
9803/3270
Issue 1
General Information
Section 1
Section 1
4 - 15
4 - 15
Service Tools (cont'd) Section F - Transmission
* Solid Spacer Setting Kit
1
3
2 S316260
1 892/00918 2 993/70111 3 921/52600 Comprises of: 921/52601 921/52602 921/52603 921/52604 921/52605 921/52606 921/52607 921/52608 921/52609 921/52610 921/52611 921/52612 921/52613 921/52614 921/52615 921/52616 921/52617 921/52618 921/52619 921/52620 921/52621 921/52622 921/52623 921/52624 921/52625 921/52626
Setting Tool Kit Breakback To Torque Wr Wrench Spacer Kit Spacer 12.75 Spacer 12.80 Spacer 12.85 Spacer 12.90 Spacer 12.95 Spacer 13.00 Spacer 13.05 Spacer 13.10 Spacer 13.15 Spacer 13.20 Spacer 13.25 Spacer 13.30 Spacer 13.35 Spacer 13.40 Spacer 13.45 Spacer 13.50 Spacer 13.55 Spacer 13.60 Spacer 13.65 Spacer 13.70 Spacer 13.75 Spacer 13.80 Spacer 13.85 Spacer 13.90 Spacer 13.95 Spacer 14.00
S316250
* Test Point 1
892 89 2/0 /009 0964 64
Tes estt po poin intt (1/ 1/8 8 BSP SP)) Po Powe wers rshi hift ft
2
892 89 2/0 /009 0965 65
Tes estt po poin intt (3/ 3/8 8 BSP SP)) Po Powe wers rshi hift ft
3
892 89 2/0 /009 0966 66
Tes estt po poin intt (1/ 1/4 4 BSP SP)) Sy Sync ncro ro Shu hutt ttle le
S197010
993/ 3/78 7820 200 0 * 99
Main Ma insh shaf aftt Airli Airline ne Adap Adapto torr (Powershift Transmission Only)
These test points can be left in position after testing.
9803/3270
Issue 2*
General Information
Section 1
Section 1
4 - 16
4 - 16
Service Tools (cont'd) Section F - Transmission
1
993/ 99 3/70 7010 100 0
Powe wers rshi hift ft End ndfl flo oat Ch Chec eck kin ing g Kit Kit (Includes items 2 to 13)
1 7
4
2
993/70101
Base Plate
3
993/70160
Yoke Assy
4
993/70130
Mainshaft Ad Adapter
5
993/70104
Mainshaft Pillar
6
993/70106
Layshaft/Reverser Pi Pillar
7
993/70120
Layshaft Se Setting As Assy
11 3
12
6
5 10 8
6 13
8
993/70140
Reverser Se Setting As Assy
2
9† 13 1391 91/3 /330 305 5
Caps pscr crew ew (M8 (M8x x20 20)) Fla Flang nged ed
10 82 826/ 6/01 0141 417 7
Sets tscr crew ew (M1 (M10 0x3 x30) 0) Fla Flang nged ed
11 99 993/ 3/70 7011 111 1
Sett Se ttin ing g Wre Wrenc nch h (th (this is is no nott par partt of of the the ki kit) t)
9
A191642
A191642
12† 12 † 99 993/ 3/70 7011 112 2
Inpu In putt Sh Shaf aftt Pi Pill llar ar
13† 13 † 99 993/ 3/70 7015 150 0
Inpu In putt Se Sett ttin ing g As Assy sy
†If these items are not in your kit they can be ordered separately but the base plate 2 will have to be drilled to secure item 12, see A and B. Measurements are in mm. Apply JCB JCB Threadlocker And Sealer Sealer and tighten item 9 to 25-30 Nm (18-22 lbf ft).
8.5
10
20
15 12
B B
36 17 81.75 96.35
9
9803/3270
A191643
Issue 2
General Information
Section 1
Section 1
4 - 17
4 - 17
Service Tools (cont'd) Section K - Engine
892/00836 Lifting Wire Assembly (for engine removal) S192390
S219080
892/00 892 /00041 041
De-glazi De-gl azing ng Too Tooll for for Cylind Cylinder er Bore Bores s (to (to assist bedding-in of new piston rings)
A314530
*892/0 *89 2/0093 0936 6
Timing pin for Timing for fuel fuel inje injecti ction on pump pump (AK, AM, AR)
*892 *8 92/0 /010 104 4
Adapto Adap torr for for comp compre ress ssio ion n test testin ing g (AK, AM, AR)
For details of other engine service tools refer to Perkins Service Manual, Publication No. 9806/0100 or 9806/2140 for low emission engines.
9803/3270
Issue 3*
Section 1
General Information
Section 1
5-1
5-1
Sealing and Retaining Compounds JCB Multi-Gasket
JCB High Strength Threadlocker
JCB Retainer (High Strength)
A medium strength strength sealant suitable suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65mm diameter.
4102/1212
50ml
A high strength locking locking fluid for use with threaded threaded components. Gasketing for all sizes of flange where the strength of the joint is important.
4102/0551
50ml
For all retaining parts which are unlikely to be dism di sman antl tled ed..
4101 41 01/0 /065 651 1
50ml 50 ml
JCB Threadlocker and Sealer
A high strength locking locking fluid for sealing and retaining nuts, bolts, and screws up to 50mm diameter, and for hydraulic fittings up to 25mm diameter.
4101/0250 4101/0251
10ml 50ml
Threadseal
A medium strength strength thread sealing compound.
4102/1951
50ml
Threadlocker
A locking fluid for use use on threads larger larger than 50mm dia.
4101/0451
50ml
Activator
A cleaning primer which which speeds the curing rate of anaerobic products.
4104/0251 4104/0253
Aersol (1ltr) Bottle (200ml)
Cleaner / Degreaser
For degreasing components prior to use of anaerobic adhesives and sealants.
4104/1557
400ml
For one pane of glass, comprises items marked † below plus applicator nozzle etc.
993/55700
† Ultra Fast Adhesive
For direct glazing
4103/2109
310 ml
† Active Wipe 205
For direct glazing
4104/1206 4104/1203
30 ml 250 g
† Black Primer 206J
For direct glazing
4201/4906
30 ml
Clear Silicone Sealant
To seal butt jointed glass
4102/0933
Black Polyurethane Sealant
To finish exposed edges of laminated glass
4102/2309
310 ml
JCB Cleaner & Degreaser
For degreasing components prior to use of anaerobic adhesives and sealants.
4104/1538
Aerosol
Direct Glazing Kit
9803/3270
Issue 3
Care & Safety
Section 2
Section 2
i
i
Contents
9803/3270
Page No.
Safety Notices
1-1
General safety
2-1
Operating safety
3-1
Maintenance safety
4-1
Issue 1
Care & Safety
Section 2 1-1
Section 2 1-1
Safety Notices 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.
! DANGER 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
! WARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-2
! CAUTION 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
9803/3270
Issue 1
Care & Safety
Section 2
Section 2
2-1
2-1
All const construct ruct ion and agri agricult cult ural equi equipmen pmentt can be hazardous. When a JCB 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. 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 GEN-1-6
General Safety
! WARNING
! WARNING
Decals You can be injured if you do not obey the decal safety instructions. Keep decals clean. Replace unreadable or missing decals with new ones before operating the machine. Make sure replacement parts include warning decals where necessary.
Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job.
INT-1-3-4
INT-1-3-7
! WARNING
! WARNING
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.
Raised Attachments Raised attachments can fall and injure you. Do not walk or work under raised attachments unless they are safely blocked.
INT-1-3-5
INT-1-3-8
! WARNING 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. INT-1-3-6
9803/3270
Issue 1
Care & Safety
Section 2
Section 2
3-1
3-1
Operating Safety
! WARNING
! WARNING
Machine Condition A defective machine can can injure you or others. Do Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this handbook are completed before using the machine.
ROPS/FOPS Structure The machine is fitted with a Roll Over Protection Structure (ROPS) and a Falling Objects Protection Structure (FOPS). You could be killed or seriously injured if you operate the machine with a damaged or missing ROPS/FOPS. If the ROPS/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-2-1-2
! WARNING Controls You or others can be killed or seriously injured if you operate the control levers from outside the cab. Operate the control levers only when you are correctly seated inside the cab.
INT-2-1-9/3
! WARNING
INT-2-1-3
! WARNING 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.
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
INT-2-1-4
! WARNING
! WARNING
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.
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-2-1-5
INT-2-2-6
! WARNING
! DANGER
Engine The engine has exposed rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open.
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-2-1-6/1
! WARNING Entering/Leaving Always face the machine when entering and leaving the cab. Use the step(s) and handrails. 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
! WARNING
INT-2-2-10
! WARNING Powershift Transmissi Transmission on Do not change from a high gear to a low gear (for instance, 4th to 1st) in one sudden movement whilst 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
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. Get out of the cab into fresh air. INT-2-1-10
9803/3270
Issue 2
Care & Safety
Section 2
Section 2
4-1
4-1
Maintenance Safety
! WARNING Repairs 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
! WARNING Battery A battery with frozen electrolyte can explode if it is used or charged. Do not use a machine with a frozen battery. To help prevent the battery from freezing, keep the battery fully charged. INT-3-1-7
! WARNING Modifications and Welding Modifications Non-approved modifications can cause injury and damage. Parts of the machine are made f rom cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Contact your JCB distributor for advice before modifying the machine. INT-3-1-2/1
! WARNING 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
! WARNING Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or drift to remove and fit metal pins. Always wear safety glasses. INT-3-1-3
! WARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.
! WARNING 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
! WARNING
INT-3-1-4
! WARNING 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
! WARNING 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.
Hydraulic Fluid Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your f ace close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immediately. INT-3-1-10/1
! DANGER Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open. INT-3-1-11/1
INT-3-1-6
9803/3270
Issue 1
Care & Safety
Section 2
Section 2
4-2
4-2
Maintenance Safety (cont'd)
! WARNING Diesel Fuel Diesel fuel is flammable; keep naked flames away from the machine. Do not smoke while refuelling the machine or working on the engine. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions.
! CAUTION 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
INT-3-2-2
! WARNING 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
! WARNING Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground.
! CAUTION Cleaning Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents. INT-3-2-11
! CAUTION '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 Triochloroetha ne or paint thinners near 'O' rings and seals. INT-3-2-12
! WARNING
INT-3-2-4
! WARNING Tyres and Rims Over-inflated or over-heated tyres can explode. Follow the instructions in this handbook for inflating the tyres. Do not weld or cut rims. Get a tyre/wheel specialist to do any repair work. INT-3-2-6
Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the operator's cab 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 elecrical 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-3-2-7/1
! WARNING Hot Coolant The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the radiator cap. Let the system cool before removing the radiator cap. To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap. INT-3-2-9
! WARNING
! WARNING Jacking A machine can roll off jacks and crush you unless the wheels have been chocked. Always chock 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
Always wear safety glasses when dismantl dismantling ing assemblies containing components under pressure from springs. This will protect against eye injury from components accidently flying out. GEN 6-2
9803/3270
Issue 1
Care & Safety
Section 2
Section 2
4-3
4-3
Maintenance Safety (cont'd)
! WARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: - Dama mag ged en end d fit fitti ting ngs s - Cha hafe fed d out uter er cover ers s - Ba Ball lloo oone ned d ou oute terr co cove vers rs - Ki Kink nked ed or cr crus ushe hed d ho hose ses s - Em Embe bedd dded ed arm armou ouri ring ng in in oute outerr cove covers rs - Di Disp spla lace ced d en end d fi fitt ttin ings gs..
! WARNING To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a wire brush to clean components. HYD 1-3
! WARNING
! WARNING
JCB Extradig Dipper Lubricant JCB Extradig dipper lubricant contains 1.53% lead. The repeated swallowing of very small quantities can cause chronic lead poisoning. Do not smoke or touch food while handling this lubricant. Dispose of waste (rags etc.) in accordance with local regulations.
Safety Strut Raised loader arms can drop suddenly and cause serious injury. Before working under raised loader arms, fit the loader arm safety strut.
! WARNING
INT-3-3-2
2-1-1-6
! WARNING A rais raised ed and badl badly y suppo supported rted mach machine ine can fal falll on you. Position the machine on a firm, level surface before raising one end. Ensure the other end is securely chocked. Do not rely solely on the machine hydraulics or jacks to support the machine when working under it. Disconnect the battery, to prevent the engine being started while you are beneath the machine. GEN-1-1
! WARNING 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.
2-1-1-8
Fluoroelastomeric Materials 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 300°C 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 300°C (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
Ensure Ens ure tha thatt compo componen nents ts have have coo cooled led the then n remov remove e and and place material into plastic bags.
2
Thorou Tho roughl ghly y was wash h conta contamin minate ated d area area wit with h 10% 10% calc calcium ium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.
! WARNING
3
Make the machine safe before working underneath it. Park the machine on level ground, lower the arms. Apply the parking brake, put the transmission in neutral and stop the engine. Chock both sides of all four wheels.
Thoroughl Thorou ghly y wash wash cont contami aminat nated ed area area wit with h deter detergen gentt and and water.
4
Cont Co ntain ain all all remo remove ved d mater materia ial, l, glov gloves es etc etc.. used used in this this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.
Disconnect the battery, to prevent the engine being started while you are beneath the machine.
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
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
GEN-1-2
If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately. INT-3-3-5/1
9803/3270
Issue 1
Routine Maintenance
Section 3
Section 3
i
i
Contents
9803/3270
Page No.
Lubricants Health & Safety
1-1
Lubricants & Capacities
1-2
Service Schedules
2-1
Loader Arm Safety Strut - Fitting and Removing
3-1
Engine Panels - Removing and Fitting a Side Panel - Removing and Fitting the Access Panel - Removing and Fitting the Engine Cover
4-1 4-1 4-1
Greasing - Loader Arms - Backhoe - Kingpost - Front Axle (2-Wheel Drive Machines) - Front Axle (4-Wheel Drive Machines) - Front Axle (All Wheel Steer Machines) - Rear Axle (All Wheel Steer Machines) - Extending Dipper - Front and Rear Propshafts - 6-in-1 Clamshovel - Backhoe Quick-Hitch - Loader Quick-Hitch - Stabilisers (Centremount Machines) - Hydraulic Pump Driveshaft - Knuckle (if fitted) - Backhoe Quick Hitch (Hydraulic)
5-1 5-2 5-2 5-3 5-3 5-4 5-4 5-5 5-5 5-6 5-6 5-6 5-6 5-7 5-7 5-7
Tyres and Wheels - Tyre Inflation - Checking the Wheel Nut Torques
6-1 6-1
Brakes - Checking The Foot Brake Fluid Level
7-1
Engine Air Filter - Changing the Elements
8-1
Engine Oil and Filter - Checking the Oil Level - Changing the Oil and Filter
9-1 9-1
Engine Cooling System - Checking the Coolant - Changing the Coolant - Adjusting the Fan Belt - Cleaning the Cab Heater Filter
10 - 1 10 - 1 10 - 2 10 - 2
Fuel system - Types of fuel - Fuel standards - Low temperature fuels - Filling the tank - Draining the filter - Changing the filter element - Draining the sediment bowl - Bleed the system
11 - 1 11 - 1 11 - 1 11 - 1 11 - 2 11 - 2 11 - 3 11 - 3
Issue 3
Routine Maintenance
Section 3
Section 3
ii
ii
Contents
9803/3270
Page No.
Syncro shuttle transmission - Checking the oil level - Changing the oil and filter
12 - 1 12 - 1
Powershift transmission - Checking the oil level - Changing the oil and filter
13 - 1 13 - 1
Hydraulic system - Checking the fluid level - Hydraulic tank cap - Changing the filter element
14 - 1 14 - 1 14 - 2
Front and rear axle (all wheel steer machines) - Checking the differential oil level - Changing the differential oil - Checking the hub oil levels - Changing the hub oil
15 - 1 15 - 1 15 - 2 15 - 2
Front and rear axle (two wheel steer machines) - Checking the oil level - Changing the oil
15 - 3 15 - 3
Issue 1
Section 3 1-1
Routine Maintenance
Section 3
Lubricants - Health and Safety
1-1
Hygiene JCB lubricants are not a health risk when used properly for their intended purposes.
2
Apply a barrier cream to the skin before handling used oil.
However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.
3
Note the following when removing oil from skin: a Wash your skin thoroughly with soap and water.
Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination.
b Using a nail brush will help. c Use special hand cleansers to help clean dirty hands.
Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following.
Storage Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers.
Waste Disposal
d Never use petrol, diesel fuel, or paraffin for washing. 4
Avoid skin contact contact with oil soaked soaked clothing.
5
Don't keep oily rags in pockets.
6
Wash dirty clothing before re-use.
7
Throw away oil-soaked shoes.
First Aid - Oil
All waste products should be disposed disposed of in accordance with all the relevant regulations.
Eyes. In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention.
The collection and disposal of used oil should be in accordance with any local regulations. Never pour used oil into sewers, drains or on the ground.
Swallowing. If oil is swallowed do not induce vomiting. Get medical advice.
Handling
Skin. In the case of excessive skin contact, wash with soap and water.
New Oil.
There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices. Used Oil.
Used engine crankcase lubricants contain harmful contaminants.
Spillage Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.
Fires Extinguish with carbon dioxide, dry chemical or foam. Firefighters should use self-contained breathing apparatus.
Here are precautions to protect your health when handling used oil: 1
Avoid prolong prolonged, ed, excessi excessive ve or repeate repeated d skin contact with used oils.
9803/3270
Issue 2
Routine Maintenance
Section 3 1-2
Section 3 1-2
Lubricants & Capacities
3CX, 4CX AND VARIANTS ITEM
CAPACITY FLUID/LUBRICANT Litres UK Gal
INTERNATIONAL SPECIFICATION
†Fuel Tank (with toolbox) 110 24.2 Diesel Oil ASTM D975-66T Nos. 1D, 2D †Fuel Tank (without toolbox) 150 33 Diesel Oil ASTM D975-66T Nos. 1D, 2D Fuel Tank (All later m/c’s) 130 28.6 Diesel Oil ASTM D975-66T Nos. 1D, 2D †Initial build machines only, all machines built after Feb. 1997 have a 130 litre (28.6 gal.) capacity tank. * Engine (Oil) ➀ 2 Wheel Steer Machines - Build AA - Build AA (Hot Climate) - Build AB
9.7 11.0 10
JCB 15W/40 Multigrade
SAE15W/40
-10 °C to 50 °C (14 °F to 122 °F)
API CF4/SG
2.1 2.4 2.2
JCB Super Universal Agricultural -15 °C to 30 °C (5 °F to 86 °F)
SAE10W/30 API CE/SF SAE10W API CD/SF
4 Wheel Steer Machines - Build AB
10.0
2.2
JCB Torque Converter Fluid -18 °C to 0 °C (0 °F to 32 °F)
2 Wheel Steer Machines - Build AR - Build AK
11.0 10
2.4 2.2
JCB Super Multigrade 15W/40 -10°C to +50°C (14°F to 122°F)
SAE15W/40 CF-4/SG
4 Wheel Steer Machines - Build AK
10.0
2.2
JCB Super Multigrade 10W/30 -15°C to +40°C (5°F to 104°F)
SAE10W/30 CF-4/SG
Engine (Coolant)
23.0
5.1
JCB Four Seasons Antifreeze & Summer Coolant/Water (see Coolant Mixtures)
ASTM D3306, BS6580 BS6580
Syncro Shuttle (2WD) ➁
14.4
3.2
JCB Special Transmission Fluid
ESP-M2C 33G
Syncro Shuttle (4WD) ➁
15.4
3.4
Friction modified oil ils s MUST NOT be used (eg. Dexron ATF type)
Powershift ➁
14.75
3.25
JCB Special Transmission Fluid
15.4
3.4
Friction modified oil ils s MUST NOT be used (eg. Dexron ATF type).
13
2.86
JCB HD90 Gear Oil (without LS LSD) JCB Special Gear Oil Plus (with LSD)
Housing (4WS) ➅
18
3.96
Must be be su suitable fo for us use wi with lilimited sl slip di diffe ferrentials (L (LSD).
Hubs (x2)
2.0
0.44
Front Axle (4WD) Housing (2WS)
ESP-M2C 33G
API-GL-5 API-GL-4
JCB Special Gear Oil Plus API-GL-4 Must be suitable for use with oil immersed brakes and limited slip differentials (LSD).
Rear Axle (4WS) Housing Hubs (x2) Rear Axle (2WS)
18 2.0 23
3.96 0.44 5.0
Brake System - Standard - Servo
1.2 1.4
0.26 0.31
JCB Light Hydraulic Fluid ISO VG15 ! CAUTION: DO NOT USE ORDINARY BRAKE FLUID
Hydraulic System ➂
130
28.6
JCB High Performance Hydraulic Oil
ISO VG46
(Above 38 °C, 100 °F) JCB Hydraulic Fluid HP32 (Below 38 °C, 100 °F)
9803/3270
ISO VG32
Issue 3
Routine Maintenance
Section 3 1-3
Section 3 1-3
Lubricants & Capacities
ITEM
CAPACITY FLUID/LUBRICANT Litres UK Gal
Grease Points
---
INTERNATIONAL SPECIFICATION
JCB HP Grease
Lithium complex NLGI No.2 consistency including extreme pressure additives or JCB Special MPL-EP Grease ➃ Lithium based NLGI No.2 consistency including extreme pressure additives
Extending Dipper
---
Waxoyl ➄
Electrical connections
---
As a corrosion and moisture inhibitor all exposed connections should be coated liberally with petroleum jelly.
Power Sideshift Chains
---
JCB Chai Chain n Lubricant Lubricant
9803/3270
Issue 3
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