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JCB HOSE AND COUPLING CATALOGUE. ISSUE 2 NOVEMBER 1997

INDEX How to use the catalogue Hose identification Hose Assembly Cutting the hydraulic hose Skiving the hose Electric skiving machine Manual skiving tool Hose Crimping for two piece coupling Fitting the coupling to the hose Polyurethane sleeving Wire guard Hose clamp ferrules Phase angle setting Identification tags JCB specification bulk hose identification Hose rating Hose diameter

Hose specification Hose DIN 20022 ISN Hose SAE 100R1 T Hose proprietary exceeds DIN 20022 2SN/SAE 100R2 AT Hose proprietary meets or exceeds DIN 20023 4SP/SAE 100R12 Hose proprietary exceeds 100R12/SAE 100R9R meets or exceeds 100R13 Hose thick cover exceeds DIN 20022 2ST Hose length JCB hose identification JCB specification bulk hose identification JCB Loadall (boom) hose identification Coupling identification Termination type Diameter Coupling specification Coupling style

INDEX (CONTINUED) JCB BSP coupling identification JCB Mini – excavator / Fastrac Mk1 coupling JCB Loadall (boom) coupling identification JCB BSP male coupling identification Sundry item identification Hose assembly identification Hose specification tables (See Hose Database)

HOW TO USE THE CATALOGUE 1. Identify the JCB hose assembly you require by the JCB part number (which in most cases should be stamped on the couplings of the old hose assembly) and refer to the contents page for the correct section. 2. If this is not possible, the hose assembly part number may be able to be identified using either the CD-ROM or Microfiche. 3. Alternatively, establish the bore size of the hose and refer to the contents page for the correct section.

THE RANGE This catalogue covers JCB low, medium, high and extra high pressure hydraulic hose assemblies. Sizes from 1/4” through to 11/2” bore hose.

Note: There are certain hoses which are used in safety critical applications and have not been included in this catalogue. JCB Dealers must not attempt to make these hoses.

HOSE IDENTIFICATION JCB hose assembly size is designated by the first 3 digits of the part number: 209/----- = 3⁄4 ” BSP high pressure hose assy 477/----- = various sizes and specifications of high 478/----- } pressure hose assy (Fastrac MK2) 607/----- = 3⁄4 ” BSP medium pressure hose assy 608/----- = 1” BSP medium pressure hose assy 611/----- = 1⁄4 ” BSP high pressure hose assy 612/----- = 3⁄8 ” BSP high pressure hose assy 613/----- = 1⁄2 ” BSP high pressure hose assy 614/----- = 5⁄8 ” BSP high pressure hose assy 615/----- = 3⁄4 ” BSP high pressure hose assy 616/----- = hose assy with split flange 617/----- = 1” BSP high pressure hose assy 618/----- = 11⁄4 ” BSP high pressure hose assy 620/----- = 3⁄4 ” BSP high pressure hose assy 621/----- = 3⁄4 ” BSP high pressure hose assy 622/----- = 1” BSP high pressure hose assy 629/----- = various sizes and specifications of high or low pressure hose assy (specials) 631/----- = 1⁄4 ” BSP low pressure hose assy 632/----- = 3⁄8 ” BSP low pressure hose assy

633/----- = 634/----- = 635/----- = 637/----- = 638/----- = 639/----- = 741/----- = 742/----- = 743/----- = 744/----- = 745/----- = 749/----- = 751/----- = 752/----- = 754/----- = 755/----- = 756/----- = 759/----- = 774/----}= 778/-----

⁄2 ” BSP low pressure hose assy ⁄8 ” BSP low pressure hose assy 3 ⁄4 ” BSP low pressure hose assy 1” BSP low pressure hose assy 11⁄4 ” BSP low pressure hose assy 11⁄2 ” BSP low pressure hose assy 1 ⁄4 ” BSP ORFS* high pressure hose assy 3 ⁄8 ” BSP ORFS* high pressure hose assy 1 ⁄2 ” BSP ORFS* high pressure hose assy 5 ⁄8 ” BSP ORFS* high pressure hose assy 3 ⁄4 ” BSP ORFS* high pressure hose assy 3 ⁄8 ” BSP ORFS* high pressure hose assy 1 ⁄4 ” BSP ORFS* low pressure hose assy 3 ⁄8 ” BSP ORFS* low pressure hose assy 5 ⁄8 ” BSP ORFS* low pressure hose assy 3 ⁄4 ” BSP ORFS* low pressure hose assy 1” BSP ORFS* low pressure hose assy 1 ⁄4 ” BSP ORFS* low pressure hose assy 1 5

⁄4 ” BSP ORFS* low pressure hose assy

3

* ORFS = ‘O’ RING FACE SEAL (BSP FLAT FACE)

HOSE ASSEMBLY The following outlines the procedures for assembling a hydraulic hose to approved JCB standards. If you are in any doubt as to the exact method of making a hose refer to the full instructions in your equipment manuals.

5.

Fit the second coupling to the hose and set the Phase Angle if required.

6.

Crimp the coupling onto the hose.

7.

Pressure test the hose to the specified test pressure if necessary.

1.

Select the correct hose bore diameter, measure and cut the hose to the required length.

8.

Engrave the Part Number and distributor identification onto hose tag and attach to the completed hose assembly.

2.

If required, skive both ends of the hose, ensuring that the correct size Mandrel is used to obtain required skive length.

9.

Fit end caps to the hose assembly.

3.

Fit and crimp one coupling ensuring that the correct Die Sets are used and that crimp dimensions are accurately set.

4.

If required fit Polyurethane sleeving, wire guard etc. over hose.

The hose is now ready

HYDRAULIC HOSE ASSEMBLY In order to make a JCB Quality Approved hose assembly the following procedure should be followed:

CUTTING THE HYDRAULIC HOSE Ensure that the machine is firmly mounted on a flat surface using 12mm bolts through holes (A) in base plate (Fig 1)

The Hose Cut Off Machine is designed specifically to cut JCB rubber hose and should NOT be used for any other purpose. The machine should NEVER be used without ALL the guards being in position. Keep hands and loose clothing away from the blade at all times. 1. Refer to this catalogue to determine the correct diameter and pressure rating for the hose assembly you are making. 2. Accurately measure the cut hose length required for the hose assembly being produced.

A

Fig 1

A

3. The two pins (B) in the hinged table (C) at the front of the machine, should be inserted into the symmetrically opposite pair of holes which hold the hose to be cut firmly, without causing excessive bend. 4. Position the hose with the cut mark opposite the blade. (fig 2) 5. Switch the machine on by rotating button (D). 1 = ON. 2 = OFF 6. Push the hose onto the blade using ONLY the handle (E), maintaining a firm even pressure without generating excessive heat. KEEP HANDS AWAY FROM THE BLADE 7. Continue pushing until the hose is fully cut through. 8. Smoke will be produced by the cutting blade when the blade is becoming blunt and requires sharpening or replacing. 9. When the cut is completed allow table (C) to return to its start position and switch off the machine. 10. When not in use the machine should be switched off and the handle secured with the hook on the blade guard. To replace blade refer to the Operating Instructions

C Fig 2

E B L D B

C

Fig 3

SKIVING THE HOSE Some hose assemblies made by JCB Dealers will use “Skived” hose. Skiving the hose means removing the outer layer of rubber from the ends of the hose. This is done on some hose sizes where the application involves high impulse loads, requiring the coupling to grip the wire directly. The following JCB Specification hoses should never be skived: ⁄4” (606/00120 series), 1⁄2” (606/20320 series) 3 ⁄8” (606/00220 series), 5⁄8” (606/20420 series) 1

To determine whether or not other hoses need skiving before attaching the couplings, refer to the Crimp Data for the appropriate hose and coupling combination.

The Skiving tool is designed to cleanly remove the rubber outer cover and expose the reinforcing wire for a range of hoses. To enable the tool to be set accurately, a number of setting collars are included, with the skiving machine which when used with the appropriate sized mandrel will ensure a swift clean skive. If the hose is being correctly skived, the wire reinforcement in the hose should become clearly visible but should not have been damaged by the tool. If the wire is not visible, then the skive is not deep enough.

ELECTRIC SKIVING MACHINE Unscrew the thumb screw and remove the cylinder guard.

Select the correct size mandrel for the hose to be skived. The hose size is stamped on the mandrel eg. 12 = 3⁄4” bore size.

N.B. When skiving 24 size hose (11⁄2” bore), the socket head cap screw locating the cam follower (see spares list) into the groove on the back of the knurled back plate should be relocated in the alternative threaded hole. To do this first unscrew the assembly from the Cutting Head Rotator.

Screw the mandrel into the threaded hole “finger tight”.

Select the appropriate setting collar (refer to the chart in the crimp information).

Slide the collar onto the mandrel until the outside diameter is immediately under the cutting edge of the blade. NB. The collar is only a guide.

Rotate the knurled back plate relative to the body, until the blade just comes into contact with the setting collar.

Insert the tommy bar into the top of the mandrel and tighten. Check that the cutting edge is just touching the outer diameter of the setting collar.

Remove the tommy bar and setting collar

Replace the outer guard together with the thumbscrew. N.B. When skiving 11⁄2 ” bore hose, use the larger of the two guards provided.

Push the bore of the hose onto the mandrel until the stop is reached, using a slight anti-clockwise movement, then gripping the hose lightly press the foot control pedal. The cutting head will rotate in an anti-clockwise direction. Slowly pull back the hose applying even backward pressure and so skiving the rubber of the hose. This operation may be repeated as necessary to ensure a clean skive. When a clean skive has been established, remove the hose from the cutting head and release the foot control pedal, thereby stopping the rotating head. The skiving operation is now complete.

Blade Adjustment, Replacement and Spares List Refer to instructions supplied with the skiving tool.

MANUAL SKIVING TOOL Unscrew the thumb screw and remove the cylinder guard (A). Select the correct size mandrel for the hose to be skived. The hose size is stamped on the mandrel eg. 12 = 3⁄4” bore size. N.B. When skiving 24 size hose (11⁄2” bore) the socket head capscrew, locating the cam follower into the groove on the back of the knurled back plate, should be re-located in the alternative threaded hole. Screw the mandrel (B) into the threaded hole “finger tight”. Select the appropriate setting collar (C) and slide it onto the mandrel until the diameter marked with the hose to be skived is immediately under the cutting edge of the blade. N.B. The collar is only a guide.

A

B

C

B

C

Rotate the knurled back plate relative to the body, until the blade just comes into contact with the setting collar.. Insert the tommy bar into the top of the mandrel and tighten. Check that the cutting edge is just touching the outer diameter of the setting collar. Remove the tommy bar and setting collar, and replace the outer guard together with the thumbscrew. Note When skiving 24 (11⁄2” bore) hose, the guard should not be refitted.The whole body should now be screwed onto the brace, and the tool is ready for use as follows:Hold the hose in a vice with approximately 5” projecting at a convenient angle.

Push the mandrel into the bore of the hose, turning the handle of the brace, maintaining a light forward pressure. When the tool cannot be pushed any further into the hose, it should be retracted whilst continuing to rotate the brace. The rubber cover should be removed cleanly down to the wire braid beneath. There should be no rubber left on the wire braid. The wire braid should not be damaged. The operation is now complete. Blade Adjustment, Replacement and Spares List Refer to instructions supplied with the skiving tool

HOSE CRIMPING FOR TWO PIECE COUPLING Refer to the Operating Instructions supplied with the Crimping Machine. Follow the Operating Instructions (supplied with the crimping equipment) for the setting up of the equipment and setting the crimp data. When crimping two piece couplings always use Die Sets which have a straight crimp face as opposed to the Die Sets which have a chamfer at both ends of the crimp face which must be used for crimping one piece couplings.

FITTING THE COUPLING TO THE HOSE . The Coupling comprises two parts:A) The Shell

B) The Insert

Insert the hose and coupling through the bottom of the Die set and position the coupling so that the whole length of the shell is covered by the Dies. Follow the rest of the procedures as shown in Operation Instructions supplied with the Crimping Machine.

First, push the shell onto the hose as far as it will go. Then push the insert into the bore of the hose until the first shoulder is against the end of the hose. Position the Shell so that when it has been crimped it sits between the first and second shoulders on the insert.

Before attaching the second coupling to the hose, check whether or not the hose requires the fitting of any additional protection or a Phase Angle setting. If the hose assembly requires any of these items, the following procedures should be followed:

POLYURETHANE SLEEVING Select the size of sleeving required for the size of hose being assembled (See list of sundries) and cut to the length stated for the hose assembly.

Cut off excess length of the tie so that it is flush with the end of the clip. Attach the second coupling to the other end of the hose.

Slide the sleeving onto the hose and over the coupling shell, so that the shell is fully covered by the sleeving. Select the appropriate sized Sleeving Tie. Tie it around the end of the Polyurethane Sleeving, so that the sleeving is tightly held between the coupling shell and the tie.

WIRE GUARD Select the size of wire guard required for the size of hose being assembled (See list of sundries) and carefully cut to the required length. Slide the guard onto the hose. Except where otherwise stated, all wire guard is the full length of the hose. When assembling hoses of 5⁄8” bore or smaller, where the two piece coupling is used, the wire guard should be long enough to cover the shell of both couplings when the hose has been assembled.

When assembling hoses of 3⁄4” bore or larger, where a one piece coupling is used, the wire guard should not cover the coupling shell.

HOSE CLAMP FERRULES If the hose assembly requires the fitting of a “Hose Clamp Ferrule” it should be fitted as follows: Slide the Hose Clamp Ferrule onto the hose to the required position (The position measurement is taken from the centre of the ferrule). Insert the hose between the die sets of the crimping machine (use the same die set as used for crimping the couplings). Remarks: Ferrule 877mm from end Position the ferrule so that the top of it is level with the top of the dies. Carefully crimp the ferrule. It is only necessary to crimp the ferrule tight enough so that it cannot be slid along the hose. Do not crimp the hose to the point where the gauge pin is level with the top of the gauge (11⁄4” Manual Crimper) or the limit switch stops the machine (11⁄4” & 2” Electric Crimpers).

PHASE ANGLE SETTING The Phase Angle of a hose assembly refers to the positions of the Couplings relative to each other. It is measured in the anti-clockwise direction from the centreline of the first coupling when it is held at the 3 o’clock position looking along the assembly from the first coupling towards the second coupling. To set the phase angle, crimp the first coupling onto the hose. Then push the second coupling onto the hose and rotate it to the required position before crimping it.

90° Phase Angle

IDENTIFICATION TAGS Having assembled a replacement hose for a JCB machine it is necessary to attach an identification tag to it in order that:A) should it ever need replacing again it can easily be identified by a JCB distributor, and also B) in the unlikely event that the hose fails due to faulty materials or incorrect assembly, it is possible to identify which JCB Distributor assembled the hose. The hose should be identified with an alloy tag onto which should be engraved (either scribed or stamped): A) the hose assembly Part Number eg. “613/46600”, and B) the initials of the JCB distributor or other suitable mark to uniquely identify which distributor has produced the hose assembly.

Once the hose assembly is complete, the ends of the hose must be fitted with plastic End Caps to prevent the hose becoming contaminated.

JCB SPECIFICATION BULK HOSE IDENTIFICATION 606/----- = bulk hose supplied by JCB Service

HOSE RATING

When producing hose assemblies for JCB machines (or any other machine requiring BSP termination hoses) the following specification hose must be used.

606/X - - - - X = Hose rating i.e. JCB standard relating to the hose assembly and testing. 606/0 - - - JCB Production Specification 606/2 - - - JCB 1000/09000 series 606/3 - - - JCB Loadall Boom Hose DIN 20022ST Specification

For non BSP termination hoses refer to ‘Hose and Coupling Catalogue - Non JCB Products”.

HOSE DIAMETER The following hose sizes are available from JCB Service. 606/606/606/606/606/606/606/606/606/-

0X - 01 - 02 - 03 - 04 - 05 - 06 - 07 - 08 - -

X = Hose diameter i.e. 1 ⁄4” 3 ⁄8” 1 ⁄2” 5 ⁄8” 3 ⁄4” 1” 11⁄4” 11⁄2”

HOSE SPECIFICATION JCB Hose is manufactured to the JCB standards that exceed the relevant international S.A.E. OR D.I.N. specifications. The 5 specifications available from JCB Service will satisfy almost all JCB hose requirements.

606/- 0 - X - X = Hose specification (pressure rating) i.e. 606/- 0 - 0 - Exceeds SAE 100RI / DIN 20022 ISN 606/- 0 - 2 - Exceeds SAE 100R2AT / DIN 20022 2SN 606/- 0 - 3 - Exceeds SAE 100R2A 606/- 0 - 4-

Exceeds SAE 100R12

606/- 0 - 5 - Exceeds SAE 100R9R

JCB specification hose will be identified with the JCB Service Standards Number. This number relates to the hose diameter and its pressure rating eg. 606/00700 = 11⁄4” diameter, SAE 100RI pressure rating.

HOSE SPECIFICATION (continued)

HOSE

SPECIFICATION DIN 20022 1SN (ISTT) SAE 100R1

CONSTRUCTION

GENUINE JCB PART 606/

Tube : NBR Reinforcement : One Wire Braid Cover : NBR/CR

TEMPERATURE RANGE

DIN 20022 1SN

- 40°C to +100°C

Hose Bore

Hose O.D.

Min. Burst Pressure

Max. Working Pressure

Min. Bend Radius

Weight Kgs

R Kg

mm

ins

-size

ins

mm

PSI

bar

PSI

bar

mm

JCB SERIES NO.

100m

19.05

3

⁄4

-12

1.10

28

6090

420

1522

105

240

60

606/00500

25.40

1

-16

1.42

36

5075

350

1276

88

300

76

606/00600

HOSE SPECIFICATION (continued)

HOSE

SPECIFICATION SAE 100R1 AT + HI-TEMP. CONSTRUCTION

GENUINE JCB PART 606/

Tube : NBR Reinforcement : One Braid High Tensile Steel Wire

SAE 100R1 T

Cover : CSM

TEMPERATURE RANGE

- 40°C to +135°C

Hose Bore

Hose O.D.

Min. Burst Pressure

Max. Working Pressure

Min. Bend Radius

Weight Kgs

R Kg

mm

ins

-size

ins

mm

PSI

bar

PSI

bar

mm

100m

31.75 38.10

11⁄4 11⁄2

-20 -24

1.72 1.99

44 50

2500 2000

172 138

625 500

43 34

406 508

130 153

JCB SERIES NO. 606/00700 606/00800

HOSE SPECIFICATION (continued)

HOSE

SPECIFICATION JCB PROPRIETARY HOSE EXCEEDS DIN 20022 2SN/SAE 100R2 AT

CONSTRUCTION

GENUINE JCB PART 606/

Tube : NBR Reinforcement : Two Wire Braids Cover : SBR/CR

TEMPERATURE RANGE

PROPRIETARY

- 40°C to +120°C

Hose Bore

Hose O.D.

Min. Burst Pressure

Max. Working Pressure

Min. Bend Radius

Weight Kgs

R Kg

mm

JCB SERIES NO.

ins

-size

ins

mm

PSI

bar

PSI

bar

mm

100m

⁄4

-4

.59

15

23200

1600

5800

400

70

31

606/00120

⁄8

-6

.71

18

19140

1320

4785

330

90

44

606/00220

⁄2

-8

.83

21

15950

1100

3987

275

126

52

606/20320

6.35

1

9.52

3

12.70

1

15.87

5

⁄8

-10

1.02

26

14500

1000

3625

250

140

71

606/20420

19.05

3

⁄4

-12

1.14

29

12325

850

3117

215

240

92

606/80520

25.40

1

-16

1.50

38

9425

650

2392

165

300

129

606/80620

31.75

1 ⁄4

-20

1.90

48

6500

448

1625

112

419

208

606/80720

1

HOSE SPECIFICATION (continued)

HOSE

SPECIFICATION JCB PROPRIETARY HOSE MEETS OR EXCEEDS DIN 20023 4SP/SAE 100R12

CONSTRUCTION

GENUINE JCB PART 606/

Tube : CR Reinforcement : Four layers Spiral Wire

PROPRIETARY

Cover : CR

TEMPERATURE RANGE

- 40°C to +120°C

Hose Bore

Hose O.D.

Min. Burst Pressure

Max. Working Pressure

Min. Bend Radius

Weight Kgs

R Kg

mm

19.05

ins

-size

ins

mm

PSI

bar

PSI

bar

mm

100m

⁄4

-12

1.22

31

20,300

1400

5075

350

298

122

3

JCB SERIES NO. 606/00540

HOSE SPECIFICATION (continued)

HOSE

SPECIFICATION JCB PROPRIETARY HOSE EXCEEDS SAE 100R12/SAE 100R9R MEETS OR EXCEEDS SAE 100R13

CONSTRUCTION Tube : CR Reinforcement : -12 &-16 Four Spiral Wire -20, Six Spiral Wire

GENUINE JCB PART 606/

Cover : CR

TEMPERATURE RANGE

PROPRIETARY - 40°C to 120°C

Hose Bore

Hose O.D.

Min. Burst Pressure

Max. Working Pressure

Min. Bend Radius

Weight Kgs

R Kg

mm

ins

-size

ins

mm

PSI

bar

PSI

bar

25.40

1

-16

1.53

39

20,000

1380

6000

414

330

220

606/00650

31.75

1 ⁄4

-20

1.97

50

20,000

1380

5000

345

419

373

606/00750

1

mm

JCB SERIES NO.

100m

HOSE SPECIFICATION (continued)

HOSE

SPECIFICATION JCB PROPRIETARY HOSE EXCEEDS DIN 20022 2ST

CONSTRUCTION

GENUINE JCB PART 606/

Tube : NBR Reinforcement : Two Wire Braids Cover : SBR/CR

TEMPERATURE RANGE

THICK COVER

- 40°C to +120°C

Hose Bore

Hose O.D.

Min. Burst Pressure

Max. Working Pressure

Min. Bend Radius

Weight Kgs

R Kg

mm

ins

-size

ins

mm

⁄2

-8

0.97

⁄8

-10

1.09

12.70

1

15.87

5

JCB SERIES NO.

PSI

bar

PSI

bar

mm

100m

24.6

15950

1100

3987

275

180

75

606/30330

27.8

14500

1000

3625

250

200

89

606/30430

HOSE LENGTH JCB Service supply bulk hose in a range of lengths from 10m to 50m in order to suit needs of all sizes of Dealer. When ordering bulk hose, substitute the last character of the Standard number for 1, 2 or 5 depending upon the length of hose required eg. 606/- - - - 0

= Series Number

606/- - - - 1

10m length of hose

606/- - - - 2

20m length of hose

606/- - - - 5

50m length of hose

606/- - - - 9

Approx. 100m in assorted lengths of less than 10m (this is only available for 1⁄2” and 5⁄8” sizes of JCB specification of hose).

JCB SPECIFICATION BULK HOSE IDENTIFICATION Hose Bore 1 ⁄4” 1 ⁄4” 1 ⁄4”

Specification SAE 100 R2AT / DIN 20022 2SN SAE 100 R2AT / DIN 20022 2SN SAE 100 R2AT / DIN 20022 2SN

Length (m) 10 20 50

Part Number 606/00121 606/00122 606/00125

3

⁄8” ⁄8” 3 ⁄8”

SAE 100 R2AT / DIN 20022 2SN SAE 100 R2AT / DIN 20022 2SN SAE 100 R2AT / DIN 20022 2SN

10 20 50

606/00221 606/00222 606/00225

⁄2” ⁄2” 1 ⁄2” 1 ⁄2”

SAE SAE SAE SAE

100 100 100 100

R2AT R2AT R2AT R2AT

/ / / /

DIN DIN DIN DIN

20022 20022 20022 20022

2SN 2SN 2SN 2SN

10 20 50 100

606/20321 606/20322 606/20325 606/20329

⁄8” ⁄8” 5 ⁄8” 5 ⁄8”

SAE SAE SAE SAE

100 100 100 100

R2AT R2AT R2AT R2AT

/ / / /

DIN DIN DIN DIN

20022 20022 20022 20022

2SN 2SN 2SN 2SN

10 20 50 100

606/20421 606/20422 606/20425 606/20429

3

⁄4” ⁄4” 3 ⁄4”

SAE 100R1 / DIN 20022 1SN SAE 100R1 / DIN 20022 1SN SAE 100R12 / SAE 100R9R

10 20 18

606/00501 606/00502 606/00542

1” 1” 1”

SAE 100R1 / DIN 20022 1SN SAE 100R1 / DIN 20022 1SN SAE 100R12 / SAE 100R9R

10 20 18

606/00601 606/00602 606/00652

11⁄4” 11⁄4”

SAE 100R1AT SAE 100R9R

18 18

606/00702 606/00752

11⁄2”

SAE 100R1AT

18

606/00802

3

1 1

5 5

3

JCB LOADALL (BOOM) HOSE IDENTIFICATION Diameter

Specification

Length (m)

Part Number

⁄2”

DIN 20022 2ST

20

606/30332

⁄2”

DIN 20022 2ST

50

606/30335

⁄8”

DIN 20022 2ST

20

606/30432

⁄8”

DIN 20022 2ST

50

606/30435

1

1

5

5

All Loadall boom hose is two wire braid high pressure specification with a thick cover.

COUPLING IDENTIFICATION

COUPLING SPECIFICATION

In order to ensure that the correct specification of coupling is attached to a length of hose, the same numbering procedure is adopted for both bulk hose and couplings 893/9_ _ _ _ = coupling for JCB hose assembly

Coupling and collars may vary with hose specification for the same diameter of hose. It is therefore essential to use the correct specification of coupling and collar. 893/9 - - C - C = Hose specification (pressure rating) i.e. 893/9 - - 0 - SAE 100R1 / DIN 20022 ISN 893/9 - - 2 - SAE 100R2AT / DIN 20022 2SN 893/9 - - 3 - SAE 100R2A 893/9 - - 4 - SAE 100R12 893/9 - - 5 - SAE 100R9R

TERMINATION TYPE 893/9A - - 893/90 - - 893/91 - - 893/92 - - -

A = Termination type i.e. JCB O - Ring B.S.P. JCB 801/803/ Fastrac Coupling JCB Loadall Boom Coupling

DIAMETER This refers to the bore diameter of hose that End Fitting is designed to fit. 893/9BB - BB = Hose diameter i.e. 1 893/901 - ⁄4” 3 893/902 - ⁄8” 1 893/903 - ⁄2” 5 893/904 - ⁄8” 3 893/905 - ⁄4” 893/906 - 1” 893/907 - 11⁄4” 893/908 - 11⁄2”

COUPLING STYLE 893/9 893/9 893/9 893/9 893/9 893/9 893/9 893/9 893/9 893/9

-

-

-

-

D 0 1 2 3 4 5 6 7 8

D = Coupling Style i.e. Straight 90 deg. Forged/Block/Compact Elbow 90 deg. Swept Elbow 90 deg. Swivel Compact Elbow 135 deg. Forged/Compact Elbow 135 deg. Swept Elbow Male Straight Hose Clamp Ferrule Extended Male Straight

JCB BSP COUPLING IDENTIFICATION Hose Diameter 1 ⁄4” 1 ⁄4” 1 ⁄4” 1 ⁄4” 1 ⁄4”

Coupling Style Straight 90 deg Compact Elbow 90 deg Swept Elbow 90 deg Swivel Compact Elbow 135 deg Swept Elbow

Hose Preparation Non - Skive Non - Skive Non - Skive Non - Skive Non - Skive

Part No. 893/90120 893/90121 893/90122 893/90123 893/90125

⁄8” ⁄8” 3 ⁄8” 3 ⁄8” 3 ⁄8”

Straight 90 deg Compact Elbow 90 deg Swept Elbow 135 deg Compact Elbow 135 deg Swept Elbow

Non Non Non Non Non

-

Skive Skive Skive Skive Skive

893/90220A 893/90221 893/90222A 893/90224 893/90225A

⁄2” ⁄2” 1 ⁄2” 1 ⁄2”

Straight 90 deg Compact Elbow 90 deg Swept Elbow 135 deg Swept Elbow

Non Non Non Non

-

Skive Skive Skive Skive

893/90320 893/90321 893/90322 893/90325

⁄8” ⁄8” 5 ⁄8” 5 ⁄8”

Straight 90 deg Compact Elbow 90 deg Swept Elbow 135 deg Swept Elbow

Non Non Non Non

-

Skive Skive Skive Skive

893/90420 893/90421 893/90422 893/90425

3 3

1 1

5 5

JCB BSP COUPLING IDENTIFICATION (cont’d) Hose Diameter 3 ⁄4” 3 ⁄4” 3 ⁄4” 3 ⁄4”

Coupling Style HP & LP Straight HP & LP 90 deg Compact Elbow HP & LP 90 deg Swept Elbow HP & LP 135 deg Swept Elbow

Hose Preparation HP = skive, LP = Non-Skive HP = skive, LP = Non-Skive HP = skive, LP = Non-Skive HP = skive, LP = Non-Skive

Part No. 893/90540 893/90541 893/90542 893/90545

1” 1” 1” 1”

LP LP LP LP

Straight 90 deg Compact Elbow 90 deg Swept Elbow 135 deg Swept Elbow

Non-Skive Non-Skive Non-Skive Non-Skive

893/90600 893/90601 893/90602 893/90605

1” 1” 1” 1”

HP HP HP HP

Straight 90 deg Compact Elbow 90 deg Swept Elbow 135 deg Swept Elbow

Skive Skive Skive Skive

893/90650 893/90651 893/90652 893/90655

11⁄4” 11⁄4”

LP Straight LP 90 deg Swept Elbow

Skive Skive

893/90700 893/90702

11⁄4” 11⁄4”

HP Straight HP 90 deg Swept Elbow

Skive Skive

893/90750 893/90752

11⁄2” 11⁄2”

LP Straight LP 90 deg Swept Elbow

Skive Skive

893/90800 893/90802

LP = Coupling Fitted to Low Pressure Hose

HP = Coupling Fitted to High Pressure Hose

JCB MINI - EXCAVATOR / FASTRAC MK1 COUPLING IDENTIFICATION Hose Diameter 1 ⁄4” 1 ⁄4” 1 ⁄4”

Coupling Style Straight 90 deg Swept Elbow 135 deg Swept Elbow

Hose Preparation Non - Skive Non - Skive Non - Skive

Part No. 893/91120 893/91122 893/91125

3

⁄8” ⁄8” 3 ⁄8”

Straight 90 deg Swept Elbow 135 deg Swept Elbow

Non - Skive Non - Skive Non - Skive

893/91220 893/91222 893/91225

1

⁄2” ⁄2” 1 ⁄2”

Straight 90 deg Swept Elbow 135 deg Swept Elbow

Non - Skive Non - Skive Non - Skive

893/91320 893/91322 893/91325

5

⁄8” ⁄8” 5 ⁄8”

Straight 90 deg Swept Elbow 135 deg Swept Elbow

Non - Skive Non - Skive Non - Skive

893/91420 893/91422 893/91425

3

⁄4” ⁄4” 3 ⁄4”

HP & LP Straight HP & LP 90 deg Swept Elbow HP & LP 135 deg Swept Elbow

HP = Skive, LP = Non-Skive HP = Skive, LP = Non-Skive HP = Skive, LP = Non-Skive

893/31023 893/31035 893/31029

1”

LP 90 deg Swept Elbow

Non-Skive

893/30037

3

1

5

3

LP = Coupling Fitted to Low Pressure Hose

HP = Coupling Fitted to High Pressure Hose

JCB LOADALL (BOOM) COUPLING IDENTIFICATION Hose Diameter 1 ⁄2”

Coupling Style Straight

Hose Preparation Non - Skive

Part No. 893/92330

⁄2”

90 deg Swept Elbow

Non - Skive

893/92331

⁄8”

Straight

Non - Skive

893/92430

⁄8”

90 deg Swept Elbow

Non - Skive

893/92431

Hose Preparation Non - Skive

Part No. 893/90326

1

5

5

JCB BSP MALE COUPLING IDENTIFICATION Hose Diameter 1 ⁄2”

Coupling Style Straight male

⁄2”

Straight extended male

Non - Skive

893/90328

⁄8”

Straight extended male

Non - Skive

893/90428

1

5

SUNDRY ITEM IDENTIFICATION Hose Diameter 3 ⁄8”

Description ⁄8” Poly Sleeve

U.O.I. (m) 10

Part No. 647/05201

⁄2” Poly Sleeve

10

647/05301

⁄8” Poly Sleeve

10

647/05401

3

⁄2”

1

⁄8”

5

3

⁄4”

3

⁄4” Poly Sleeve

10

647/05801

1”

1” Poly Sleeve

10

647/05901

Description ⁄4” HP Wire Guard

U.O.I. (m) 10

Part No. 814/00331

⁄8” HP Wire Guard

10

814/00332

⁄2” HP Wire Guard

10

814/00333

⁄8” HP Wire Guard

10

814/00334

⁄4” HP Wire Guard

10

814/00335

1”

1” LP Wire Guard

10

814/00336

1”

1” HP Wire Guard

10

814/00337

1

1 ⁄4”

1 ⁄4” LP Wire Guard

10

814/00338

1 ⁄4”

1 ⁄4” HP Wire Guard

10

814/00339

1 5

Hose Diameter 1 ⁄4”

1

⁄8”

3

⁄2”

1

⁄8”

5

⁄4”

3

3 1 5 3

1

1

1

SUNDRY ITEM IDENTIFICATION (cont’d) Hose Diameter 1 ⁄4” 3 ⁄8” 1 ⁄2” 5 ⁄8” 3 ⁄4” 1” 11⁄4” 11⁄2”

Description ⁄4” Hose End Cap 3 ⁄8” Hose End Cap 1 ⁄2” Hose End Cap 5 ⁄8” Hose End Cap 3 ⁄4” Hose End Cap 1” Hose End Cap 11⁄4” Hose End Cap 11⁄2” Hose End Cap

U.O.I. 200 200 100 100 100 100 100 100

Part No. 835/00083 835/00084 835/00085 835/00086 835/00087 835/00088 835/00089 835/00093

Hose Diameter 1 ⁄4” 3 ⁄8” 1 ⁄2” 5 ⁄8” 3 ⁄4” 1”

Description ⁄4” Hose Clamp Ferrule 3 ⁄8” Hose Clamp Ferrule 1 ⁄2” Hose Clamp Ferrule 5 ⁄8” Hose Clamp Ferrule 3 ⁄4” Hose Clamp Ferrule 1” LP Hose Clamp Ferrule

U.O.I. 10 10 10 10 10 10

Part No. 893/90127 893/90227 893/90427 893/90547 893/90607 893/90707

Hose Diameter All

Description Sleeving Tie

U.O.I. 100

Part No. 993/99350

Hose Diameter All

Description Identification Tag

U.O.I. 100

Part No. 993/99194

1

1

HOSE ASSEMBLY IDENTIFICATION JCB Hoses are of three main types with the fourth digit of the part number referring to the coupling style fitted to either end of the hose. In most instances the hoses fall into one of the three categories shown opposite.

Length

1. Two straight end fittings identified with a 0 or 1 eg 611/0----

Length

2. One straight and one elbow end fitting identified with a 2 or 3 eg 611/2Length

3. Two elbow end fittings identified with a 4 or 5 eg 611/4----