JCB 8014 MINI EXCAVATOR Service Repair Manual SN 1282000 to 1283999.pdf
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Serv Servic ic e Manual Manual
8014, 8016, 8018 Section 1 - General General Inform ation Section 2 - Care Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track Track and Runn ing Gea Gear r Section Se ction K - Engine
717260
Publication No.
9803/9350-3
World Class Customer Support 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. Issued by JCB Technical Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Sect Sect ion 0 - Servi Servi ce Manu Manu al
Notes:
0-0
9803/9350-3
0-0
Open front screen
Secti on 1
General neral Inform nf orma ation ti on Section 1 - General General Inform ation Section 2 - Care Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track Track and Runn ing Gea Gear r Section Se ction K - Engine
717260
Publication No.
9803/9350-3
World Class Customer Support 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Secti Secti on 1 - Gene General ral Infor mation
Notes:
1-0
9803/9350-3
1- 0
Secti Secti on 1 - Gene General ral Infor mation Contents
Contents
Page No.
Introduction About this Manual ...................... ................................................................ 1-1 Machine Model and Serial Number .......................................................1-1 Using this Manual ..................................................................................1-1 Units of Measurement .............................................................. ............. 1-1 Left Side, Right Side ..............................................................................1-1 Using the Machine .................................................................................1-1 Cross References ..................................................................................1-1 Identifying Your Machine Identification Plates ................................................................... ................ 1-3 Data Plate ..............................................................................................1-3 Typical Product Identification Number (PIN) ......................................... 1-3 Typical Engine Identification Number ....................................................1-3 ROPS, TOPS and FOGS ............................................................ ..........1-3 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-5 Introduction ............................................................................................1-5 Bolts and Screws ...................................................................................1-5 Hydraulic Connections ............................................................................... 1-9 'O' Ring Face Seal System ....................................................................1-9 'Torque 'Torque Stop' Stop' Hose System ......................................................... ........1........ 1-12 12 Service Tools Numerical List .......................................................................................... 1-13 Tool Detail Detail Reference ...... ....................................................... ................. 1-16 Section B - Frame and Bodywork ........................................................1-16 Section C - Electrics ............................................................................1-20 Section E - Hydraulics .........................................................................1-21 Section K - Engine ...............................................................................1-26 Service Consumables Sealing and Retaining Compounds ......................................................... 1-27 Terms and Definiti ons Colour Coding .......................................................................................... 1-29 Hydraulic Schematic Colour Codes .....................................................1-29
1-i
1-i
Secti Secti on 1 - Gene General ral Infor mation Contents
Contents
1- i i
Page No.
1- i i
Secti Secti on 1 - Gene General ral Infor mation
Introduction Ab A b ou t t h i s Manu al Machi Machi ne Model and Serial Serial Number This manual provides information for the following model(s) in the JCB machine range:
machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication.
Units of Measurement Measurement
– JCB 8014 serial number 1156000 1156000 to 1156999. 1156999.
T1-001_2
– JCB 8014 serial number 1282000 to 1283999.
In this publication, the S.I. system of units is used. For example, liquid capacities are given in litres. The Imperial units follow in parentheses ( ) eg 28 litres (6 gal).
– JCB 8014 serial number 1505500 to 1506499 – JCB 8016 serial number 1155000 1155000 to 1155999. 1155999. – JCB 8014 serial number 1505500 to 1506499
Left Side, Righ Righ t Side
– JCB 8018 serial number 1046000 to 1047999. – JCB 8018 serial number 1319000 to 1324999.
In this manual, 'left' A 'left' A and and 'right' B mean your left and right when you are seated correctly in the machine.
Using th is Manual INT-1-2-5_3
This manual is arranged to give you a good understanding of the machine and its safe operation. It also contains maintenance information and specification data. Read this manual from front to back before using the machine for the first time. Particular attention must be given to all the safety aspects of operating and maintaining the machine.
B
Do not operate the machine without an Operator Manual. A
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.
Fig 1.
Using the Machine If there is anything you are not sure about, ask your JCB distributor or employer. Do not guess, you or others could be killed or seriously injured. General warnings in this chapter are repeated throughout the book, as well as specific warnings. Read all the safety statements regularly, so you do not forget them. Remember that the best operators are the safest operators.
T1-002_2
To use the machine efficiently and 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. This 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.
The illustrations in this manual are for guidance only. Where the machines differ, the text and or the illustration will specify.
Cross References References
The manufacturer's policy is one of continuous improvement. The right to change the specification of the
In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The
1-1
T1-004_2
9803/9350-3
1- 1
Secti Secti on 1 - Gene General ral Infor mation Introduction About this Manual number of the page upon which the subject begins, is indicated within the brackets. For example: Cross Refere Re ferences nces ( 1-1) 1-1)..
1-2
9803/9350-3
1- 2
Secti Secti on 1 - Gene General ral Infor mation
Identifying Your Machine Identi Identi fic ation Plates Plates Data Plate
Typical Engine Identification Number
Your machine has a Data Plate A Plate A attached attached to the left hand front face of the machine.
If the engine is replaced by a new one, the data plate serial number will be wrong. Either stamp the new number on the plate or stamp out the old one. This will prevent the wrong number being quoted when you order replacement parts.
JCB COMPACT PRODUCTS LIMITED HAREWOOD ESTATE, LEEK ROAD, CHEADLE, STOKE ON TRENT, UNITED KINGDOM, ST10 2JU.
A
WEIGHT Kg
R E
M
R G I I F S T E R E D
ENGINE POWER kW @ RPM
a
b
c
d
e
GJ
50316
J
000001
Y
YEAR OF MANUF. VIN Vehicle Ident. Ident. No. PIN Prod.Ident. No.
a
Engine Type
b
Engine Parts List
c
Country of Manufacture
d
Engine Serial Number
e
Year of Manufacture
ROPS, TOPS and FOGS
!
Fig Fig 1.
Modified and wrongly repaired ROPS, TOPS & FOGS Structures are dangerous. Do not modify the TOPS Structur e. Do not att empt to repair the ROPS, ROPS, TOPS TOPS & FOGS Struc tu re. If th e ROPS, ROPS, TOPS TOPS & FOGS FOGS Stru Stru ctu re has been been in an accident, do not use the machine until the structure has been inspected and repaired. This must be done by a qualified person. For assistance, contact your JCB dealer. Failure to take precautions could result in death or injury to the operator. operator.
Typical Product Identification Number (PIN) 1
2
3
4
5
JCB
08014
T
8
1156500
1
WARNING
World Manufacturer Identification (JCB)
5-3-1-7_2
2
Machine Type and Model (5 Digits)
3
Random Check Letter
4
Year of Manufacture (7 = 2007, 8 = 2008, 9 = 2009)
5
Machine Serial Number (1156500). (1156500).
1-3
Machines built to ROPS and TOPS standards have an identification label fitted to the cab. Fi g 2. ( 1-4) 1-4).. A bolt on falling object guard is available which also carries a certified label. This label certifies the cab to FOGS standard. Fi g 3. ( 1-4)
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1- 3
Secti Secti on 1 - Gene General ral Infor mation Identifying Your Machine Identification Plates
Fig Fig 2.
Fig Fig 3.
1-4
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Secti Secti on 1 - Gene General ral Infor mation Standard Standard Torq ue Settings Zinc Plated Fasteners and Dacromet Fasteners
Standard Tor Torqu que e Sett Settin ings gs Zinc Plated Fasteners and Dacromet Fasteners T11-002
Introduction
Bolts and Screws
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.
Use the following torque setting tables only where no torque setting is specified in the text.
The two types of fasteners can be readily identified by colour and part number suffix. Ta Table ble 1. Fastener Types Types ( 1-5) 1-5)..
Fastener Type
Table 1. Fastener Fastener Types Co l o u r Par t No . Su f f i x
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
Zinc and Yellow
Golden finish
'Z' (e.g. 1315/3712Z)
Dacr Dacrom omet et
Mott Mottle led d silv silver er fini finish sh 'D' 'D' (e.g (e.g.. 1315 1315/3 /371 712D 2D))
Condition 2 – Zinc flake (Dacromet) fasteners
Note: As 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 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.
– Lubricated zinc and yellow plated fasteners – Where there is a natural lubrication. For example, cast iron components
Verbus Ripp Bo lts
Note: All Note: All bolts used on JCB machines machines are are high tensile 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.
1-5
Fig 1. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.
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Secti Secti on 1 - Gene General ral Infor mation Standard Standard Torq ue Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torqu Torqu e Settings - UNF Grade 'S' Fasteners Hex ag o n (A /F) Co n d i t i o n 1
B o l t Si ze
Co n d i t i o n 2
in.
mm
i n.
Nm
kgf m
l b f ft
Nm
kgf m
l b f 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
Table 3. Torqu Torqu e Settings - Metric Grade 8.8 Fasteners Fasteners Hex ag o n (A /F) Co n d i t i o n 1
B o l t Si ze
Co n d i t i o n 2
ISO Metric Th r ead
mm
mm
Nm
kg f m
l b f ft
Nm
kg f m
l b f 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
1-6
9803/9350-3
1- 6
Secti Secti on 1 - Gene General ral Infor mation Standard Standard Torq ue Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Metric Grade 10.9 10.9 Fasteners Hex ag o n (A /F) Co n d i t i o n 1
B o l t Si ze
Co n d i t i o n 2
ISO Metric Th r ead
mm
mm
Nm
kg f m
l b f ft
Nm
kg f m
l b f 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
Table 5. Metric Metric Grade 12.9 12.9 Fasteners Hex ag o n (A /F) Co n d i t i o n 1
B o l t Si ze
Co n d i t i o n 2
ISO Metric Th r ead
mm
mm
Nm
kg f m
l b f ft
Nm
kg f m
l b f 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
1-7
9803/9350-3
1- 7
Secti Secti on 1 - Gene General ral Infor mation Standard Standard Torq ue Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torqu Torqu e Setting Setting s - Rivet Rivet Nut Bolts /Screws Bolt Size ISO Metric Th r ead
mm
Nm
kg f m
l b f ft
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
Table 7. Torqu Torqu e Settin Settin gs - Internal Hexagon Headed Cap Screws (Zinc) (Zinc) Bolt Size
1-8
ISO Metric Thread
Nm
kg f m
l b f ft
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
9803/9350-3
1- 8
Secti Secti on 1 - Gene General ral Infor mation Standard Standard Torq ue Settings Hydraulic Connections
Hydraulic Connections T11-003
'O' Ring Face Seal Seal System Ad apt or s Sc rew ed i nt o Valv e Bl oc ks 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. Torqu Torqu e Setting Setting s - BSP BSP Adaptors BSP Adaptor Hexagon (A/F) Size
1-9
in.
mm
Nm
kg f m
l b f ft
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
Table 9. Torqu e Setting Setting s - SAE SAE Connecti Connecti ons Hexagon (A/F) SAE Port
SAE Tube Size
Thread Size
mm
Nm
kg f m
l b f ft
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
9803/9350-3
1- 9
Secti Secti on 1 - Gene General ral Infor mation Standard Standard Torq ue Settings Hydraulic Connections Hoses Screwed Screwed into Adapto rs
Fig Fig 2. Hoses 2-B screwed 2-B screwed into adaptors 2-A seal 2-A seal onto an `O' ring 2-C which 2-C which is compressed into a 45° seat machined into the face of the adaptor port.
B SP SP Ho Ho se se Si Si ze ze
1-10
Note: Dimension 2-D will 2-D will vary depending upon the torque applied.
Table 10. BSP BSP Hose - Torqu Torqu e Settings Hex ag ag on on (A (A /F /F)
i n.
mm
Nm
kg f m
l b f ft
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
9803/9350-3
1-10
Secti Secti on 1 - Gene General ral Infor mation Standard Standard Torq ue Settings Hydraulic Connections Ad apt or s i nt o Co mp on ent Con nec ti on s w it h B on ded Washers Wash ers Table 11. BSP Adaptors wi th Bon ded Washers Washers - Torqu Torqu e Setting Setting s BSP Size
1-11
in .
Nm
kg f m
l b f ft
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
9803/9350-3
1-11
Secti Secti on 1 - Gene General ral Infor mation Standard Standard Torq ue Settings Hydraulic Connections
'Torqu 'Torqu e Stop' Hose Syst em
Fig Fig 3. `Torque Stop' Hoses 3-B screwed 3-B screwed into adaptors 3-A seal 3-A seal onto an 'O' ring 3-C which 3-C which is compressed into a 45° seat machined in the face of the adaptor port. To To prevent the 'O' ring being damages as a result of over tightening, 'Torque 'Torque
Stop' Hoses have an additional shoulder 3-D, 3-D, which acts as a physical stop. Note: Minimum dimension 3-E fixed 3-E fixed by shoulder 3-D. 3-D.
Table 12. BSP `Torqu `Torqu e Stop' Hose - Torqu Torqu e Settin Settin gs B SP SP Ho Ho se se Si Si ze ze Hex ag ag on on (A (A /F /F)
1-12
in.
mm
Nm
kg f m
l b f ft
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
9803/9350-3
1-12
Secti Secti on 1 - Gene General ral Infor mation
Serv Servic ice e Too Tools ls Numeric Numeric al List 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. Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full
details of all tools, including the content of kits and sets, refer to Tool Detail Reference, Section Section 1. 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.
Part Number
Des c r i p t i o n
-
Bonded Washers - see Tool Detail Reference (Sectio (Sectio n 1) for 1) for content
E
-
1) for content Female Cone Blanking Plugs - see Tool Detail Reference (Section 1) for
E
-
Female Connectors - see Tool Detail Reference (Section (Section 1) for 1) for content
E
-
Hydraulic Flow Test Equipment - see Tool Detail Reference (Section (Section 1) for 1) for content
E
-
Hydraulic Hand Pump Equipment - see Tool Detail Reference (Sectio (Sectio n 1) for 1) for content
E
-
Male Adapters - BSP x BSP - see Tool Detail Reference (Section (Section 1) for 1) for content
E
-
Male Adapters - BSP x NPT (USA only) - see Tool Detail Reference (Section 1) for 1) for content
E
-
Male Cone Blanking Caps - see Tool Detail Reference (Section 1) for 1) for content
E
-
Pressure Test Points - Adaptors - see Tool Detail Reference (Section (Section 1) for 1) for content
E
-
Pressure Test Points - 'T' Adaptors - see Tool Detail Reference (Section (Section 1) for 1) for content
E
-
Rivet Nut Tool - see Tool Detail Reference (Section (Section 1) for 1) for content
B
331/ 331/22 2296 966 6
Pump Pump Driv Drive e Ali Align gnme ment nt Tool ool
E
331/ 331/31 3106 069 9
Test est Bloc Block k for for A.R. A.R.V V.
E
4104/ 104/13 131 10
Hand and Clean leaner er
B
892/00039
Spool Cl Clamp
E
892/ 892/00 0004 041 1
De-g De-gla lazi zing ng Tool ool
K
892/0 92/001 0137 37
Micro icro--Bore Bore Hos Hose e
E
892/00223
Hand Pump
E
892/00 892/00253 253
Hydrau Hydraulic lic Circui Circuitt Pres Pressur sure e Test Test Kit - see see Tool Detail Reference (Sectio (Sectio n 1) for 1) for content
E
892/00254
Hose
E
892/00271
Adapter
E
892/00272
Adapter
E
892/00273
Adapter
E
892/00274
Adapter
E
892/00275
Adapter
E
1-13
See Sec t i o n
9803/9350-3
1-13
Secti Secti on 1 - Gene General ral Infor mation Service Tools Numerical List Part Number
Des c r i p t i o n
892/00276
Adapter
E
892/00277
Adapter
E
892/00279
Gauge
E
892/00280
Gauge
E
892/00281
AVO Meter
C
892/ 892/00 0028 284 4
Digi Digita tall Tac Tacho home mete ter r
C
892/ 892/00 0028 285 5
Hyd. Hyd. Oil Oil Tem Tempe pera ratu ture re Prob Probe e
C
892/00298
Fluke Me Meter
C
892/ 892/00 0033 334 4
Ram Ram Sea Seall Fitt Fittin ing g Too Tooll
E
892/00346
Gauge
E
892/00347
Connector
E
892/00706
Test Pr Probe
E
892/0 92/008 0842 42
Glass lass Lift ifter
B
892/ 892/00 0084 843 3
Fold Foldin ing g Sta Stand nd for for Hol Holdi ding ng Gla Glass ss
B
892/0 92/008 084 45
Cartr artriidge dge Gun
B
892/ 892/00 0084 846 6
Glas Glass s Extr Extrac acto torr (Han (Handl dles es))
B
892/0 92/008 084 47
Nylon ylon Spatu patula la
B
892/0 92/008 0848 48
Wire ire Starte arter r
B
892/ 892/00 0084 849 9
Brai Braide ded d Cut Cutti ting ng Wire Wire
B
892/01 892/01016 016
Ram Protec Protectio tion n Slee Sleeve ve for for 25 mm mm Rod Rod Diam Diamete eter r
E
892/01 892/01017 017
Ram Protec Protectio tion n Slee Sleeve ve for for 30 mm mm Rod Rod Diam Diamete eter r
E
892/01 892/01018 018
Ram Protec Protectio tion n Slee Sleeve ve for for 40 mm mm Rod Rod Diam Diamete eter r
E
892/01 892/01019 019
Ram Protec Protectio tion n Slee Sleeve ve for for 50 mm mm Rod Rod Diam Diamete eter r
E
892/01 892/01020 020
Ram Prot Protect ection ion Slee Sleeve ve for for 50 mm Rod Diam Diamete eterr (slew (slew ram) ram)
E
892/01 892/01021 021
Ram Protec Protectio tion n Slee Sleeve ve for for 60 mm mm Rod Rod Diam Diamete eter r
E
892/01 892/01022 022
Ram Prot Protect ection ion Slee Sleeve ve for for 60 mm Rod Diam Diamete eterr (slew (slew ram) ram)
E
892/01 892/01023 023
Ram Protec Protectio tion n Slee Sleeve ve for for 65 mm mm Rod Rod Diam Diamete eter r
E
892/01 892/01024 024
Ram Protec Protectio tion n Slee Sleeve ve for for 70 mm mm Rod Rod Diam Diamete eter r
E
892/01 892/01025 025
Ram Protec Protectio tion n Slee Sleeve ve for for 75 mm mm Rod Rod Diam Diamete eter r
E
892/01 892/01026 026
Ram Protec Protectio tion n Slee Sleeve ve for for 80 mm mm Rod Rod Diam Diamete eter r
E
892/ 892/01 0102 027 7
Pist Piston on Seal Seal Asse Assemb mbly ly Tool ool
E
926/ 926/15 1550 500 0
Rubb Rubber er Space pacerr Blo Block cks s
B
992/0 92/028 2800 00
ARV Ext Extract ractor or
E
992/ 992/04 0400 000 0
Torqu orque e Mul Multi tipl plie ier r
F
992/ 992/09 0930 300 0
Hexa Hexago gon n Spa Spann nner er 55mm 55mm A/F A/F
E
992/ 992/09 0940 400 0
Hexa Hexago gon n Spann panner er 65mm 65mm A/F A/F
E
992/ 992/09 0950 500 0
Hexa Hexago gon n Spann panner er 75mm 75mm A/F A/F
E
1-14
See Sec t i o n
9803/9350-3
1-14
Secti Secti on 1 - Gene General ral Infor mation Service Tools Numerical List Part Number
Des c r i p t i o n
992/ 992/09 0960 600 0
Hexa Hexago gon n Spann panner er 85mm 85mm A/F A/F
E
992/ 992/09 0970 700 0
Hexa Hexago gon n Spann panner er 95mm 95mm A/F A/F
E
992/ 992/09 0990 900 0
Hexa Hexago gon n Spa Spann nner er 115mm 15mm A/F A/F
E
992/ 992/10 1000 000 0
Hexa Hexago gon n Spa Spann nner er 125m 125mm m A/F A/F
E
992/10100
Spool Cl Clamp
E
992/1 92/123 2300 00
12V Mobil obile e Ove Oven n
B
992/ 992/12 1240 400 0
24V 24V Sta Stati tic c Ove Oven n (2 (2 Car Cartr trid idge ge))
B
992/1 92/128 2800 00
Cut-O ut-Out ut Knife nife
B
992/12801
'L' 'L' Blade ades
B
993/ 993/68 6810 100 0
Slid Slide e Ham Hamme merr Kit Kit - see see Tool Detail Reference (Section (Section 1) for 1) for content
B
1-15
See Sec t i o n
9803/9350-3
1-15
Secti Secti on 1 - Gene General ral Infor mation Service Tools Tool Detail Reference
Tool oo l Detail Detail Referenc Reference e Secti Secti on B - Frame and Bodyw ork
Fig 1. 993/6 993/6810 8100 0 Slide Hammer Kit 1
993 993/681 /68101 01
Slide lide Hamme ammer r
7
993/68107
Bar - M20 x M20 X 800 mm
2
993/68102
End Stops
8
993/ 993/68 6810 108 8
Adap Adapto torr - M20 M20 x 7/8" 7/8" UNF UNF
3
993/ 993/68 6810 103 3
Adap Adapto torr - M20 M20 x 5/8 5/8"" UNF UNF
9
993/6 93/681 8109 09
Adapt daptor or - M20 M20 x M12 M12
4
993/ 993/68 6810 104 4
Adap Adapto torr - M20 M20 x 1" UNF UNF
10
993/ 993/68 681 110
Adap Adapto torr - M20 M20 x 5/8 5/8"" UNF UNF (Sh (Shou ould lder er))
5
993/ 993/68 6810 105 5
Adap Adapto torr - M20 M20 x M20 M20
11
993/ 993/68 681 111
Adap Adapto torr - M20 M20 x 1/2 1/2"" UNF UNF
6
993/ 993/68 6810 106 6
Adap Adapto torr - M20 M20 x M24 M24 1
826/0 26/010 1099 99
M6 x 16 16 mm mm Riv Rivet et Nut
826/0 26/01 1101 101
M6 x 19 19 mm mm Riv Rivet et Nut
826/0 26/01 1102 102
M8 x 18 18 mm mm Riv Rivet et Nut
826/0 26/01 1103 103
M8 x 21 21 mm mm Riv Rivet et Nut
826/ 826/01 0110 104 4
M10 M10 x 23 mm Rive Rivett Nut Nut
826/01 826/01105 105A A
M10 x 26 mm Rivet Rivet Nut Nut
-
Installation Tool available from: Bollhoff Fastenings Ltd (www.bollhof.com (www.bollhof.com))
2
Fig 2. Rivet Rivet Nut Tool Tool
1-16
9803/9350-3
1-16
Secti Secti on 1 - Gene General ral Infor mation Service Tools Tool Detail Reference
Fig 3. 892/0 892/0084 0842 2 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 6. 892/0 892/0084 0846 6 Glass Extractor (Handles) Used with braided cutting wire to cut out broken glass. Fig 9. ( 1-18) 1-18)..
Fig 7. 892/ 892/008 00847 47 Nylon Nylon Spatula Spatula
Fig 4. 892/ 892/008 00843 43 Foldi Foldi ng Stand
General tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge.
Essential for preparing new glass prior to installation.
Fig 8. 892/00 892/00848 848 Wire Wire Starter Starter Used to access braided cutting wire through original polyurethane seal. Fig 9. ( 1-18) 1-18)..
Fig 5. 892/ 892/008 00845 45 Cartrid Cartrid ge Gun Hand operated. Essential for the application of sealants, polyurethane materials etc.
1-17
9803/9350-3
1-17
Secti Secti on 1 - Gene General ral Infor mation Service Tools Tool Detail Reference
Fig 9. 892/00 892/00849 849 Braided Cutti ng Wire
Fig 12. 992/124 992/12400 00 Static Static Oven 240V
Consumable heavy duty cut-out wire used with the glass extraction tool. Fig 6. ( 1-17) 1-17).. Approx 25 m length.
Required to pre-heat adhesive prior to use. No plug supplied. 110V models available upon request - contact JCB Note: 110V Technical Service.
Fig 10. 926/15 926/15500 500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.
Fig 13. 992/12 992/12800 800 Cut-Out Knife Used to remove broken glass.
Fig 11. 992/12 992/12300 300 Mobil Mobil e 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).
1-18
Fig 14. 992/12 992/12801 801 'L' B lades 25 mm (1 in.) cut. Replacement blades for cut-out knife. Fig 13. ( 1-18) 1-18).. Unit quantity = 5 off.
9803/9350-3
1-18
Secti Secti on 1 - Gene General ral Infor mation Service Tools Tool Detail Reference
Fig 15. 4104/1310 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub).
1-19
9803/9350-3
1-19
Secti Secti on 1 - Gene General ral Infor mation Service Tools Tool Detail Reference
Secti Secti on C - Electri Electri cs
Fig 16. 892/0 892/0029 0298 8 Fluke Meter Meter
Fig 17. 892/ 892/002 00285 85 Hydraulic Temperature Probe
Fig 18. 892/00 892/00284 284 Venture Micro tach Digital Tachometer
1-20
9803/9350-3
1-20
Secti Secti on 1 - Gene General ral Infor mation Service Tools Tool Detail Reference
Secti Secti on E - Hydr Hydr aulics Male Adapters - BSP x BSP 160 1606/20 6/2052 52
3/8 3/8 in. in. x 1/ 1/4 in. in.
1604 1604/0 /000 003A 3A 3/8 3/8 in. in. x 3/8 3/8 in. in. 892/ 892/00 0007 071 1
3/8 3/8 in. in. x 3/8 3/8 in. in. tap taper er
160 1606/00 6/0004 04
1/2 1/2 in. in. x 1/ 1/4 in. in.
1606 1606/0 /000 007A 7A 1/2 1/2 in. in. x 3/8 3/8 in. in. Fig 19. 19. Male Male Adaptors Adaptors
1604 1604/0 /000 004A 4A 1/2 1/2 in. in. x 1/2 1/2 in. in. 160 1606/00 6/0017 17
5/8 5/8 in. in. x 1/ 1/2 in. in.
160 1606/00 6/0008 08
3/4 3/4 in. in. x 3/ 3/8 in. in.
Male Male Adap Adapte ters rs - BS BSP P x NP NPT (USA (USA only only))
1606 1606/0 /000 009 9
3/4 3/4 in. in. x 1/2 1/2 in. 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
1606/0015
1 in. x 1.1/4 in.
892/ 892/00 0025 255 5
1/4 1/4 in. in. BSP BSP x Tes Testt Poin Pointt
892/ 892/00 0025 256 6
3/8 3/8 in. in. BSP BSP x Tes Testt Poin Pointt
892/ 892/00 0025 257 7
1/2 1/2 in. in. BSP BSP x Tes Testt Poin Pointt
892/ 892/00 0025 258 8
5/8 5/8 in. in. BSP BSP x Tes Testt Poin Pointt
816/ 816/15 151 118
3/4 3/4 in. in. BSP BSP x Tes Testt Poi Point nt
892/ 892/00 0025 259 9
1 in in BSP BSP x Tes Testt Poi Point nt
892/ 892/00 0026 260 0
1.1/ 1.1/4 4 in. in. BS BSP P x Test est Poi Point nt
892/ 892/00 0026 261 1
5/8 5/8 in. in. UNF UNF x Tes Testt Poi Point nt
816/55 816/55045 045
1/4 in. M BSP BSP x 1/4 1/4 in. in. F BSP x Test Test Point Point
816/55 816/55038 038
3/8 in. M BSP BSP x 3/8 3/8 in. in. F BSP x Test Test Point Point
816/55 816/55040 040
1/2 in. M BSP BSP x 1/2 1/2 in. in. F BSP x Test Test Point Point
892/00 892/00263 263
5/8 in. M BSP BSP x 5/8 5/8 in. in. F BSP x Test Test Point Point
892/00 892/00264 264
3/4 in. M BSP BSP x 3/4 3/4 in. in. F BSP x Test Test Point Point
892/ 892/00 0026 265 5
1 in. in. M BSP BSP x 1 in. in. F BSP BSP x Test est Poin Pointt
892/00 892/00266 266
1.1/4 1.1/4 in. in. M BSP x 1.1/4 1.1/4 in. F BSP BSP x Test Test Point Point
892/00 892/00267 267
1.1/4 1.1/4 in. in. M BSP x 1.1/2 1.1/2 in. F BSP BSP x Test Test Point Point
1/2 in. x 3/8 in.
Fig 20. Pressure Test Test Adapters
Fig 21. Pressure Test Test 'T' Adapters
1-21
9803/9350-3
1-21
Secti Secti on 1 - Gene General ral Infor mation Service Tools Tool Detail Reference
Fig 22. 22. 'T' 'T' Adapters
892/00047
3/8 in in. BS BSP A) (B ) (A ) x 1/4 in. BSP (B
892/00048
1/2 in in. BS BSP A) (B ) (A ) x 1/4 in. BSP (B
892/00049
5/8 in in. BS BSP A) (B ) (A ) x 1/4 in. BSP (B
816/50043
3/4 in in. BS BSP A) (B ) (A ) x 1/4 in. BSP (B
892/00051
1 in in. BS BSP A) (B ) (A ) x 1/4 in. BSP (B
816/50005
1/2 in in. BS BSP A) (B ) (A ) x 1/2 in. BSP (B
816/60096
3/4 in in. BS BSP A) (B ) (A ) x 3/4 in. BSP (B
816/00017
1 in in. BS BSP A) (B ) (A ) x 1 in. BSP (B
892/ 892/000 00055 55A A 1/4 1/4 in. in. BS BSP P 892/ 892/000 00056 56A A 3/8 3/8 in. in. BS BSP P 892/00057
1/2 in. BSP
892/ 892/000 00058 58A A 5/8 5/8 in. in. BS BSP P 892/ 892/000 00059 59A A 3/4 3/4 in. in. BS BSP P Fig 23. Female Female Blanking Caps
892/00060
1 in. BSP
816/90045
1/4 in. BSP
816/ 816/001 00189 89A A 3/8 3/8 in. in. BS BSP P 816/ 816/001 00190 90A A 1/2 1/2 in. in. BS BSP P
Fig 24. Male Cone Blanking Caps
816/90022
5/8 in. BSP
816/90274
3/4 in. BSP
816/90205
1 in. BSP
892/ 892/00 0007 074 4
3/8 3/8 in. in. BS BSP P x 3/8 3/8 in. in. BS BSP P
892/ 892/00 0007 075 5
1/2 1/2 in. in. BS BSP P x 1/2 1/2 in. in. BS BSP P
892/ 892/00 0007 076 6
5/8 5/8 in. in. BS BSP P x 5/8 5/8 in. in. BS BSP P
892/ 892/00 0007 077 7
3/4 3/4 in. in. BS BSP P x 3/4 3/4 in. in. BS BSP P
1406/0011
1/4 in. BSP
1406/00 6/001 18
1/2 in. BSP
1406/00 6/001 14
5/8 in. BSP
1406/00 6/002 21
3/4 in. BSP
140 1406/00 6/0029 29
1.1/4 .1/4 in. in. BSP
Fig 25. 25. Female Female Connectors Connectors
Fig 26. 26. Bonded Washers Washers
1-22
9803/9350-3
1-22
Secti Secti on 1 - Gene General ral Infor mation Service Tools Tool Detail Reference
Fig 27. Ram Protectio n Sleeves Sleeves
892/ 892/01 0101 016 6
For For 25 25 mm mm Rod Rod Diam Diamet eter er
892/ 892/01 0101 017 7
For For 30 30 mm mm Rod Rod Diam Diamet eter er
892/ 892/01 0101 018 8
For For 40 40 mm mm Rod Rod Diam Diamet eter er
892/ 892/01 0101 019 9
For For 50 50 mm mm Rod Rod Diam Diamet eter er
892/ 892/01 0102 020 0
For For 50 50 mm Rod Rod Dia Diame mete terr (sl (slew ew ram) ram)
892/ 892/01 0102 021 1
For For 60 60 mm mm Rod Rod Diam Diamet eter er
892/ 892/01 0102 022 2
For For 60 60 mm Rod Rod Dia Diame mete terr (sl (slew ew ram) ram)
892/ 892/01 0102 023 3
For For 65 65 mm mm Rod Rod Diam Diamet eter er
892/ 892/01 0102 024 4
For For 70 70 mm mm Rod Rod Diam Diamet eter er
892/ 892/01 0102 025 5
For For 75 75 mm mm Rod Rod Diam Diamet eter er
892/ 892/01 0102 026 6
For For 80 80 mm mm Rod Rod Diam Diamet eter er
892/ 892/00 0016 167 7
For For 90 90 mm mm Rod Rod Diam Diamet eter er
7mm 11o
20mm
10mm
Fig 28. 892/ 892/003 00334 34 Ram Ram Seal Fittin g Tool 5mm
m 3 m R
110mm 175mm o 3
Fig 29. Hexagon Hexagon Spanners for Ram 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/ A/F
1-23
R 1 .4 m m
Fig 30. 892/ 892/010 01027 27 Pisto Pisto n Seal Assembly Tool
9803/9350-3
1-23
Secti Secti on 1 - Gene General ral Infor mation Service Tools Tool Detail Reference 892/ 892/00 0026 268 8
Flow Flow Moni Monito tori ring ng Unit Unit
892/00 892/00269 269
Sensor Sensor Head Head 0 - 100 100 l/mi l/min n (0 (0 - 22 UK UK gal/ gal/min min))
892/00 892/00273 273
Sensor Sensor Head Head 0 - 380 l/min l/min (0 (0 - 85.5 85.5 UK gal/ gal/min min))
892 892/002 /00293 93
Conn Connec ecto torr Pip Pipe e
892/00270
Load Va Valve
140 1406/00 6/0021 21
Bon Bonded ded Wash asher
1604/00 1604/0006A 06A Adapte Adapterr 3/4 3/4 in M x 3/4 in in M BSP BSP
Fig 31. 31. Flow Test Test Equipment
1 2
3
1612 1612/2 /205 054 4
Adap Adapte terr 3/4 3/4 in F x 3/4 3/4 in in M BS BSP P
892/ 892/00 0027 271 1
Adap Adapte terr 3/4 3/4 in F x 5/8 5/8 in in M BS BSP P
892/ 892/00 0027 272 2
Adap Adapte terr 5/8 5/8 in F x 3/4 3/4 in in M BS BSP P
816/ 816/20 2000 008 8
Adap Adapte terr 3/4 3/4 in F x 1/2 1/2 in in M BS BSP P
892/ 892/00 0027 275 5
Adap Adapte terr 1/2 1/2 in F x 3/4 3/4 in in M BS BSP P
892/ 892/00 0027 276 6
Adap Adapte terr 3/4 3/4 in F x 3/8 3/8 in in M BS BSP P
892/ 892/00 0027 277 7
Adap Adapte terr 3/8 3/8 in F x 3/4 3/4 in in M BS BSP P
1606 1606/0 /001 015 5
Adap Adapte terr 1.1 1.1/4 /4 in M BS BSP P x 1 in M BS BSP P
892/ 892/00 0007 078 8
Conn Connec ecto torr 1 in F x 1 in in F BS BSP P
1604 1604/0 /000 008 8
Adap Adapte terr 1 in M x 1 in in M BS BSP P
1604 1604/0 /000 008 8
Adap Adapte terr 1 in in M x 3/4 3/4 in in M BSP BSP
816/ 816/20 2001 013 3
Adap Adapte terr 3/4 3/4 in F x 1 in M BSP BSP
892/00201
Replacement Gauge 0-20 bar (0-300 lbf/in2)
892/00202
Replacement Gauge 0-40 bar (0-600 lbf/in2)
892/00203
Replacement Gauge 0-400 bar (0-6000 lbf/in2)
892/ 892/00 0025 254 4
Repl Replac acem emen entt Hose Hose
993/69 993/69800 800
Seal Seal Kit Kit for for 892/ 892/002 00254 54 (can (can also also be used used with with probe 892/00706)
892/00706
Test Pr Probe
892/ 892/00 0034 347 7
Conne Connect ctor or - Hose Hose to gaug gauge e
Fig 32. 892/ 892/ 00253 00253 Hydraulic Cir cuit Pressure Test Test Kit
1-24
9803/9350-3
1-24
Secti Secti on 1 - Gene General ral Infor mation Service Tools Tool Detail Reference 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
892/00280
Pressure Gauge 0-600 bar (0-9000 lbf/in2)
892/00223
Hand Pump
892/ 892/00 0013 137 7
Micr Microo-bo bore re Hos Hose e 1/4 1/4 in BSP BSP x 3 metr metres es
892/00 892/00274 274
Adapter Adapter 1/4 in M BSP x 3/8 3/8 in M BSP BSP Taper aper
892/00 892/00262 262
1/4 in M BSP x 1/4 1/4 in F BSP BSP x Test Test Point Point
892/00706
Test Pr Probe
892/00278
Gauge 0 - 40 bar (0 - 600 lbf/in2)
892/00279
Gauge 0 - 400 bar (0 - 6000 lbf/in2)
Fig 33. Hydraulic Circui t Test Test Gauges Gauges and Connections
Fig 34. 34. Hand Hand Pump Equipment
Fig 35. 35. Spool Spool Clamps 892/00039
Spool Cl Clamp
992/ 992/10 1010 100 0
Spool pool Cla Clamp mp - Dia Diame mete terr 19mm 19mm (3/ (3/4 4 in) in)
992/0 92/028 2800 00
ARV Ext Extract ractor or
Fig 36. 331/31 331/31069 069 - Test Bl ock f or A .R.V. .R.V.
Fig 37. 331/22 331/22966 966 Pump Drive Ali gnment Tool
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Secti Secti on 1 - Gene General ral Infor mation Service Tools Tool Detail Reference
Section K - Engine
Fig 38. 892/ 892/000 00041 41 - De-glaz De-glazing ing Tool for Cylinder Bores To To assist bedding-in of new piston rings. For details of other engine service tools refer to: – Publication No. 9806/2100 English – Publication No. 9806/2101 French – Publication No. 9806/2102 German – Publication No. 9806/2103 Spanish Spanish – Publication No. 9806/2104 Italian
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Secti Secti on 1 - Gene General ral Infor mation Servi Servi ce Consumables Sealing and Retaining Compounds
Servic rv ice e Cons Consum uma able bl es Sealing Sealing and Retainin Retainin g Compo unds T11-001_3
Table 1. Ty p e
Des c r i p t i o n
JCB Multi-Gasket
A medium strength sealant suitable for all sizes of 4102/1212 gasket flanges, and for hydraulic fittings of 25-65 mm diameter.
50 ml
JCB High High Streng Strength th Threadlo Threadlocker cker
A high strength strength locking locking fluid fluid for for use use with with threaded threaded 4102/0551 components. Gasketing for all sizes of flange where the strength of the joint is important.
50 ml
JCB Retainer (High Strength)
For all retaining parts which are unlikely to be dismantled.
4101/0651
50 ml
JCB JCB Thre Thread adloc locke kerr and and Seal Sealer er
A medi medium um str stren engt gth h lock lockin ing g flui fluid d for for seal sealin ing g and 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
A high strength locking fluid for sealing and retaining retaining 4101/0550 nuts, bolts, and screws up to 50 mm diameter, and 4101/0552 for hydraulic fittings up to 25 mm diameter.
10 ml
JCB Threadlocker and Sealer (High Strength)
Par t No .
Qu an t i t y
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/ 104/02 025 51
200 200 ml ml (A (Aeros erosol ol))
4104/ 104/02 0253 53
1 ltr ltr (Bot Bottle) tle)
JCB Cleaner/Degreaser
For degreasing ing componen nents prior to use of anaerobic adhesives and sealants.
4104/ 104/15 155 57
400 400 ml ml (A (Aeros erosol ol))
Direct Glazing Kit
For one pane of glass; comprises of:
993/55700
– 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. Ultra Fast Adhesive
For direct glazing.
4103/2109
310 ml
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
Active Wipe 205
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Secti Secti on 1 - Gene General ral Infor mation Servi Servi ce Consumables Sealing and Retaining Compounds
Page Page left intention ally blank
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Secti Secti on 1 - Gene General ral Infor mation
Terms rm s and Defi Defini niti tion ons s Colour Coding Hydraulic Schematic Colour Codes T11-006
The following colour coding, used on illu strations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications.
Red
Full Pressure: Pressure Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and MRV operating pressure.
Pi n k
Pr es s u r e: Pressure that is above neutral circuit pressure but lower than that denoted by Red.
Or an g e
B lu e
Gr een
L ig ig ht ht Gr Gr ee een
Yel l o w
1-29
Ser v o : Oil pressure used in controlling a device (servo).
Neu r al : Neutral circuit pressure.
Ex h au s t
Cavi ta tat io io n: n: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).
L o c k Up : Oil trapped within a chamber or line, preventing movement of components (lock up).
9803/9350-3
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Secti Secti on 1 - Gene General ral Infor mation Terms and Defin Defin iti ons Colour Coding
Page Page left intention ally blank
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Secti on 2 Care and Safety Section 1 - General General Inform ation Section 2 - Care Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Gearboxes Section J - Track Track and Runn ing Gea Gear r Section Se ction K - Engine
717260
Publication No.
9803/9350-3
World Class Customer Support 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400
Sect Sectio ion n 2 - Care and and Safety Safety
Notes:
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Sect Sectio ion n 2 - Care Care and and Safety Safety Contents
Page No.
Safety Safety Notices Important Information ....................................................................... ......... 2-1 The Operator Manual ........................................................ .................... 2-1 Safety Warnings ....................................................................................2-1 Safety Check List ....................................................................................... 2-2 Safety - Yours and Others .................................................... ................. 2-2 General Safety .................................. .................................................... 2-2 Operating Safety ...................................................................................2-4 Maintenance Safety ...............................................................................2-7 Safety Decals ......................................................... ................................. 2-12 Introduction ..........................................................................................2-12 Safety Decal Recognition ....................................................................2-13
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Sect Sectio ion n 2 - Care Care and and Safety Safety Contents
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Page No.
2- i i
Sect Sectio ion n 2 - Care and and Safety Safety
Safety Notic ot ice es Important Important Information T1-015
The Operator Manual
!
Safety Safety Warnings
WARNING
Study the Operator Manual before starting the machine. You must understand and follow the instructions in the Operator Manual. You must observe all relevant laws and regulations. If you are unsure about anything, ask your JCB dealer or employer. employer. Do not guess, you or others could be killed or seriously injured. INT-1-1-1_2
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 i nform other operators. 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.
Do not operate the machine without an Operator Manual. 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.
!
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 hazard exists. If proper precautio ns 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
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Sect Sectio ion n 2 - Care and and Safety Safety Safety Safety Notices Safety Check List
Safety Safety Check Li st Safety - Yours and Others
General Safety INT-1-3-1_3
All machinery 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
T1-007_3
!
WARNING
Operator Manual You and others can be injured if you operate or maintain the machine without first studying the Operator Manual. Read the safety instructions before operating the machine. If you do not understand anything, ask your employer or JCB dealer to explain it. Keep the Operator Manual clean and in good condition. Do not operate the machine without an Operator Manual in the cab, or if there is anything on the machine you do not understand. understand. INT-1-3-2_2
!
WARNING
Care and and Al ertness Al l th e ti me yo u are work wo rk in g wi th or on th e m achin ach in e, take care and stay alert. Always be careful. Always b e alert for hazards. INT-1-3-5
!
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, earprotectors and i ndustrial gl oves. Keep Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and personal jew ell ery. INT-1-3-6_2
!
WARNING
Al coho co ho l an d Dr ug s 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 whil e operating the machine or attachments. Be aware aware of medicines which can cause drowsiness. INT-1-3-9_2
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Sect Sectio ion n 2 - Care and and Safety Safety Safety Safety Notices Safety Check List
!
!
WARNING
Feeling 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.
DANGER
Lightning Lightning can kill you. Do not use the machine machine if there is lightni ng in your area. 5-1-1-2
8-1-2-4
!
!
WARNING
Mobile Phones Switch off your mobile phone before entering an area area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious inj ury.
WARNING
Machine Modifications This machine is manufactured in compliance with legislative and other requirements. It should not be altered altered in any way which could affect affect or invalidate any any of these requirements. For advice consult your JCB Distributor. INT-1-3-10_2
Switch off and do not use your mobile phone when refuelling the machine. INT-3-3-9
!
WARNING
Lifting Equipment You can be injured if you use faulty liftin g equipment. Make Make sure that that lifting equipment is in good condi tion. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough fo r the job. INT-1-3-7
!
WARNING
Raised Equipment Never Never walk or wo rk 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 (even with t he engine stopped). 13-2-3-7_2
!
WARNING
Raised Machin Machin e 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 and suffer serious injury o r be killed. INT-3-3-7_1
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Sect Sectio ion n 2 - Care and and Safety Safety Safety Safety Notices Safety Check List
Operatin Operatin g Safety Safety
!
! WARNING
Machine Machine Condition A def ectiv ect iv e mach m achin in e can c an in ju re you yo u or ot her s. Do no t operate a machine machine which is defective or has missi ng parts. Make sure the maintenance procedures in this manual are completed before using the machine. INT-2-1-2_2
WARNING
You could be killed or seriously inju red if you operate a machine w ith a damaged or missi ng ROPS/FOP ROPS/FOPS. S. 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 may be dangerous and wil l in validate the ROPS/F ROPS/FOP OPS S certific ation. INT-2-1-9_6
!
WARNING
Machine Limits Operating the machine beyond its design limits can damage the machine, it can also be dangerous . Do Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications. INT-2-1-4
!
WARNING
INT-2-1-5
WARNING
The engine has exposed rotating parts. Switch OFF the engine before working i n the engine compartment. Do not use the machine with the engine cover open.
Work Sites Work sites can be hazardous. Inspect the site before working on it. Look for p otholes, weak weak ground, hidden rocks etc. Check for utilities such as electric cables (overhead and undergro und), 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-2-2-3
! WARNING
Exhaust Gases Gases Breathing the machine exhaust gases can harm and possibly kil l you. Do not op erate erate the machine in closed spaces 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
WARNING
Communications Bad communications can cause accidents. Keep people around around you in formed of what you will be doing. If you will be working with other people, make make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands.
5-2-6-5
!
WARNING
INT-2-2-1
Engine/Steering Failure If the engine or steering fails, stop the machine as quickly as possib le. Do Do not operate the machine machine until the fault has been corrected.
!
!
WARNING
Parking An in corr co rr ect ly park ed machi mac hi ne can move mo ve wi th ou t an operator. Follow the instructions in the Operator Manual to park the machine correctl y. INT-2-2-4_2
!
WARNING
Banks and Trenches Banked material and trenches can collapse. Do not work or dri ve too close to banks and trenches where there is danger of collapse. INT-2-2-5
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