jcb 3CX Service manual

Service Manual

Backhoe Loader

9803/3280 3CX, 4CX 930001 to 960000

214e, 214, 215, 217 903000 Onwards

Publication No.

S2-eng

Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publ ication may be reproduced, stored in a retrie val system, or transmitted in any form or by any other means,

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel [phone] Fax [phone]

electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

World Class

Customer Support

General Information

1

Service

Manual

3CX, 4CX,

Care & Safety

2

Routine Maintenance

3

Attachments

A

Body & Framework

B

Electrics

C

Controls

D

214e, 214, 215, 217

& VARIANTS

Backhoe

Loader

From M/c No. 930000 Onwards

From M/c No. 903000 Onwards (USA)

PUBLISHED BY THE

TECHNICAL PUBLICATIONS DEPARTMENT

OF JCB SERVICE; © WORLD PARTS CENTRE,

WATERLOO PARK, UTTOXETER, ST14 5PA

ENGLAND

Tel. ROCESTER [phone]

PRINTED IN ENGLAND

Publication No. 9803/3280 Issue 9

Hydraulics

Transmission

Brakes

Steering

Engine

Servo Controls

(Precision Controls)

E

F

G

H

K

L

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, 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 = General Information - includes torque settings and service tools.
2 = Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine Maintenance - includes service schedules and recommended lubricants for all the

machine.

The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for
example:

A = Attachments
B = 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.

Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each
alphabetically coded section.

All sections are listed on the front cover; tabbed divider cards align directly with individual 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.

With the exception of slewing operations 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing
forwards.

Machine Nomenclature

In this Service Manual, reference is made to machine models, e.g. 3CX, 4CX, these are European machine model names.
North American machine models have different names, the table below shows the European and the equivalent North
American nomenclature.

European North American

3CX = 214
4CX = 214S, 215S, 217S

9803/3280 Issue 1

Colour Coding

The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised
throughout JCB Service publications.

A390940

Red

Pink

Orange

Blue

Green

Light
Green

Yellow

Full Pressure

Pressure generated from operation of a service. Depending on application this may
be anything between neutral circuit pressure and M.R.V. operating pressure.

Pressure

Pressure that is above neutral circuit pressure but lower than that denoted by red.

Servo

Oil pressure used in controlling a device (servo).

Neutral

Neutral circuit pressure.

Exhaust

Cavitation

Oil subjected to a partial vacuum due to a drop in pressure (cavitation).

Lock Up

Oil trapped within a chamber or line, preventing movement of components (lock up).

9803/3280 Issue 1

Section 1 General Information

Section 1

i

i

Contents Page No.

Machine Identification Plate 1 - 1

Typical Vehicle Identification Number (VIN) 1 - 1

Typical Engine Identification Number 1 - 1

Serial Plates 1 - 2

Torque Settings 2 - 1

Service Tools Numerical List 3 - 1

Service Tools

- Body & Framework 4 - 1

- Electrics 4 - 4

- Hydraulics 4 - 6

- Transmission 4 - 10

- Engine 4 - 19*

Sealing and Retaining Compounds 5 - 1

9803/3280

Issue 2*

Section 1 General Information

Section 1

1 - 1

Machine Identification Plate

Your machine has an identification plate mounted on the
loader tower. The serial numbers of the machine and its
major units are stamped on the plate.

The serial number of each major unit is also stamped on the
unit itself. If a major unit is replaced by a new one, the serial
number on the identification plate will be wrong. Either
stamp the new number of the unit on the identification plate,
or simply stamp out the old number. This will prevent the
wrong unit number being quoted when replacement parts
are ordered.

The machine and engine serial numbers can help identify
exactly the type of equipment you have.

Typical Vehicle
Identification Number (VIN)

SLP 3CX T S V E 930000

C DD EE FF GG

AB

World Manufacturer Identification

A

Machine Model

B

Steer Type (T= 2WS, F=4WS)

C

Build Type (S=Sideshift, C=Centremount, L=Loader)

D

Year of Manufacture:

E

2 = 2002
3 = 2003
4 = 2004
5 = 2005
6 = 2006
7 = 2007
8 = 2008

C

1 - 1

U.K. and R.O.W.

S218131

Manufacturer Location (E = England)

F

Product Identification Number (PIN)

G

Typical Engine
Identification Number

AB 50262 U 500405 P

ABCDE

A Engine Type

AB = 4 cylinder turbo

B Build Number

C Country of Origin

D Engine Sequence Number

9803/3280

North America

E Year of Manufacture

A246740

Issue 1

Section 1 General Information

Section 1

1 - 2

Serial Plates

A Front Axle (2WS machine)
B Front Axle (4WS machine)
C Rear Axle (2WS machine)
D Rear Axle (4WS machine)
E Synchro Shuttle Transmission
F Powershift Transmission
G Engine

1 - 2

DD

S259110

BB

AA

EE

S257580

FF

S259100

A401030

9803/3280

CC

S156571

GG

S260120

Issue 1

Section 1 General Information

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 'S' Bolts

Bolt Size Hexagon (A/F) Torque Settings
in (mm) in Nm kgf m lbf ft

1/4 (6.3) 7/16 14 1.4 10
5/16 (7.9) 1/2 28 2.8 20
3/8 (9.5) 9/16 49 5.0 36
7/16 (11.1) 5/8 78 8.0 58
1/2 (12.7) 3/4 117 12.0 87
9/16 (14.3) 13/16 170 17.3 125
5/8 (15.9) 15/16 238 24.3 175
3/4 (19.0) 11/8 407 41.5 300
7/8 (22.2) 15/16 650 66.3 480
1 (25.4) 11/2 970 99.0 715
11/4 (31.7) 17/8 1940 198.0 1430
11/2 (38.1) 21/4 3390 345.0 2500

Metric Grade 8.8 Bolts

Bolt Size Hexagon (A/F) Torque Settings

(mm) mm Nm kgf m lbf ft

M5 (5) 8 7 0.7 5
M6 (6) 10 12 1.2 9
M8 (8) 13 28 3.0 21
M10 (10) 17 56 5.7 42
M12 (12) 19 98 10 72
M16 (16) 24 244 25 180
M20 (20) 30 476 48 352
M24 (24) 36 822 84 607
M30 (30) 46 1633 166 1205
M36 (36) 55 2854 291 2105

Rivet Nut Bolts/Screws

Bolt Size Torque Settings (for steel rivet nuts)

(mm) Nm kgf m lbf ft

M3 (3) 1.2 0.12 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

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

9803/3280

Issue 1

Section 1 General Information

Section 1

3 - 1

Service Tools Numerical List

Page No. Page No.

460/15708 Flow Test Adapter 4 - 13
460/15707 Banjo Bolt 4 - 13
1406/0011 Bonded Washer 4 - 7
1406/0014 Bonded Washer 4 - 7
1406/0018 Bonded Washer 4 - 7, 13
1406/0021 Bonded Washer 4 - 6, 4 - 7
1406/0029 Bonded Washer 4 - 7
1604/0003 Male Adapter 4 - 7
1604/0004 Male Adapter 4 - 7, 13
1604/0006 Male Adapter 4 - 6, 4 - 7
1604/0008 Adapter 4 - 6
1606/0003 Male Adapter 4 - 7
1606/0004 Male Adapter 4 - 7
1606/0007 Male Adapter 4 - 7
1606/0008 Male Adapter 4 - 7
1606/0009 Male Adapter 4 - 7
1606/0012 Male Adapter 4 - 6, 4 - 7
1606/0014 Male Adapter 4 - 7
1606/0015 Male Adapter 4 - 6, 4 - 7
1606/0017 Male Adapter 4 - 7
1612/0006 Adapter 4 - 6
2401/0222 O-ring 4 - 13
2403/0110 O-ring 4 - 13
2403/0108 O-ring 4 - 13
4101/0651 Retainer (High Strength) 5 - 1
4101/0250 Threadlocker and Sealer (10 ml) 5 - 1
4101/0251 Threadlocker and Sealer (50 ml) 5 - 1
4101/0451 Threadlocker 5 - 1
4102/0502 High Strength Gasketing 5 - 1
4102/0551 High Strength Threadlocker 5 - 1
4102/0933 Clear Silicone Sealant 5 - 1
4102/1212 Multi-Gasket 5 - 1
4102/1951 Threadseal 5 - 1
4102/2309 Black Polyurethane Sealant 5 - 1
4103/2109 Ultra Fast Adhesive (310ml) 5 - 1
4104/0251 Activator (Aersol) 5 - 1
4104/0253 Activator (Bottle) 5 - 1
4104/1203 Active Wipe 205 (250g) 5 - 1
4104/1206 Active Wipe 205 (30 ml) 5 - 1
4104/1310 Hand Cleaner 4 - 1
4104/1538 JCB Cleaner & Degreaser 5 - 1
4104/1557 Cleaner/Degreaser (400 ml) 5 - 1
4201/4906 Black Primer 206J (30ml) 5 - 1
721/10885 Interconnecting cable 4 - 18

*

816/00017 Adapter 4 - 8
816/00189 Blanking Cap 4 - 8
816/00190 Blanking Cap 4 - 8
816/00193 Blanking Cap 4 - 8
816/00196 Blanking Cap 4 - 8
816/00197 Blanking Cap 4 - 8
816/00294 Blanking Cap 4 - 8
816/00439 Male Adapter 4 - 7
816/00440 Male Adapter 4 - 7
816/15007 Male Adapter 4 - 7
816/15008 Male Adapter 4 - 7
816/15118 Pressure Test Adapter 4 - 6
816/20008 Adapter 4 - 6
816/20013 Adapter 4 - 6
816/50005 Adapter 4 - 8
816/50043 Adapter 4 - 8
816/55038 Pressure Test 'T' Adapter 4 - 6

(G/box ECU to Data Link Adaptor)

816/55040 Pressure Test 'T' Adapter 4 - 6
816/60096 Adapter 4 - 8
823/10420 Shim Kit - Powershift gearbox,

layshaft clutch 4 - 17
825/00410 Crowfoot Wrench 4 - 4
825/99833 Adapter for 825/00410 4 - 4
826/01099 Rivet Nut 4 - 1
826/01101 Rivet Nut 4 - 1
826/01102 Rivet Nut 4 - 1
826/01103 Rivet Nut 4 - 1
826/01104 Rivet Nut 4 - 1
826/01105 Rivet Nut 4 - 1
892/00011 Spool Clamp 4 - 8
892/00041 De-glazing Tool 4 - 21
892/00047 Adapter 4 - 8
892/00048 Adapter 4 - 8
892/00049 Adapter 4 - 8
892/00051 Adapter 4 - 8
892/00055 Blanking Plug 4 - 8
892/00056 Blanking Plug 4 - 8
892/00057 Blanking Plug 4 - 8
892/00058 Blanking Plug 4 - 8
892/00059 Blanking Plug 4 - 8
892/00060 Blanking Plug 4 - 8
892/00071 Male Adapter 4 - 7
892/00074 Female Connector 4 - 8
892/00075 Female Connector 4 - 8
892/00076 Female Connector 4 - 8
892/00077 Female Connector 4 - 8
892/00078 Connector 4 - 6
892/01054 Adaptor for Compression Testing 4 - 21

*

892/00137 Micro-Bore Hose 1/4in. BSP, 3 Metres 4 - 7
892/00167 Ram Seal Protection Sleeve 90 mm 4 - 9
892/00174 Measuring Cup 4 - 11
892/00179 Bearing Press 4 - 10
892/00180 Seal Fitting Tool 4 - 20
892/00181 Replacement Plastic Boss 4 - 20
892/00182 Bearing Pad Driver 4 - 12
892/00223 Hand Pump 4 - 7
892/00224 Impulse Extractor 4 - 11
892/00225 Adapter for Extractor 4 - 11
892/00252 Test Block for Loader Valve A.R.V 4 - 9

(214e Machines Only)
892/00253 Pressure Test Kit 4 - 6
892/00255 Pressure Test Adapter 4 - 6
892/00256 Pressure Test Adapter 4 - 6
892/00257 Pressure Test Adapter 4 - 6
892/00258 Pressure Test Adapter 4 - 6
892/00259 Pressure Test Adapter 4 - 6
892/00260 Pressure Test Adapter 4 - 6
892/00261 Pressure Test Adapter 4 - 6
892/00262 Pressure Test 'T' Adapter 4 - 6, 4 - 7
892/00263 Pressure Test 'T' Adapter 4 - 6
892/00264 Pressure Test 'T' Adapter 4 - 6
892/00265 Pressure Test 'T' Adapter 4 - 6
892/00268 Flow Monitoring Unit 4 - 6
892/00269 Sensor Head 4 - 6
892/00270 Load Valve 4 - 6
892/00271 Adapter 4 - 6
892/00272 Adapter 4 - 6
892/00273 Sensor Head 4 - 6
892/00274 Adapter 4 - 7

3 - 1

9803/3280

Issue 4*

Section 1 General Information

Section 1

3 - 2

Service Tools Numerical List

Page No. Page No.

892/00275 Adapter 4 - 6

*

892/00276 Adapter 4 - 6

*

892/00277 Adapter 4 - 6
892/00278 Gauge 4 - 7
892/00279 Gauge 4 - 7
892/00282 Shunt 4 - 4
892/00283 Tool Kit Case 4 - 4
892/00284 Tachometer 4 - 4
892/00285 Hydraulic Oil Temperature Probe 4 - 4
892/00286 Surface Temperature Probe 4 - 4
892/00293 Connector Pipe 4 - 6
892/00294 Connector Pipe 4 - 6
892/00298 Fluke Meter 4 - 4
892/00301 Flow Test Adapter 4 - 10
892/00302 Flow Test Adapter 4 - 10
892/00309 ARV Test Kit 4 - 7
892/00333 Heavy Duty Socket 4 - 11
892/00334 Ram Seal Fitting Tool 4 - 9
892/00335 ARV Cartridge Removal Tool 4 - 7
892/00347 Connector - Hose to gauge 4 - 6
892/00706 Test Probe 4 - 6, 4 - 7
892/00812 Drive Coupling Spanner 4 - 10
892/00817 Heavy Duty Socket 4 - 11
892/00818 Heavy Duty Socket 4 - 11
892/00819 Heavy Duty Socket 4 - 11
892/00822 Splined Bolt Socket 4 - 11
892/00836 Lifting Wire Assembly 4 - 21
892/00842 Glass Lifter 4 - 2
892/00843 Folding Stand 4 - 1
892/00844 Long Knife 4 - 3
892/00845 Cartridge Gun 4 - 1
892/00846 Glass Extractor (Handles) 4 - 2
892/00847 Nylon Spatula 4 - 3
892/00848 Wire Starter 4 - 2
892/00849 Braided Cutting Wire 4 - 3
892/00881 Spool Seal Fitting Tool 4 - 7
892/00882 Alternator Pulley Socket 4 - 5
892/00891 Wheel Hub Seal - Fitting Tool 4 - 19
892/00918 Setting Tool Kit 4 - 16
892/00920 Flow Test Adapter 4 - 10
892/00948 Charging Kit 4 - 9
892/00949 Pressure Gauge 4 - 9
892/00956 Timing Pin 4 - 21
892/00964 Test Point (1/8BSP) 4 - 12
892/00965 Test Point (3/8BSP) 4 - 12
892/00966 Test Point (1/4BSP 4 - 12
892/01016 Ram Seal Protection Sleeve 25 mm 4 - 9
892/01017 Ram Seal Protection Sleeve 30 mm 4 - 9
892/01018 Ram Seal Protection Sleeve 40 mm 4 - 9
892/01019 Ram Seal Protection Sleeve 50 mm 4 - 9
892/01020 Ram Seal Protection Sleeve 50 mm 4 - 9

(slew ram)
892/01021 Ram Seal Protection Sleeve 60 mm 4 - 9
892/01022 Ram Seal Protection Sleeve 60 mm 4 - 9

(slew ram)
892/01023 Ram Seal Protection Sleeve 65 mm 4 - 9
892/01024 Ram Seal Protection Sleeve 70 mm 4 - 9
892/01025 Ram Seal Protection Sleeve 75 mm 4 - 9
892/01026 Ram Seal Protection Sleeve 80 mm 4 - 9
892/01027 Piston Seal Assembly Tool 4 - 9
892/01033 Electronic Service Tool Kit 4 - 18

3 - 2

892/01079 Ring Socket Spanner

Mainshaft setting ring 4 - 13

892/01080 Ring Socket Spanner

Layshaft setting ring 4 - 13

892/01077 Synchro Shuttle Gearbox Selector

Shaft Lock Screw 4 - 13

892/01078 Synchro Shuttle Gearbox

Mainshaft Adjuster 4 - 13

892/01076 Synchro Shuttle Support Plate

Transfer gear end float setting 4 - 13
892/01082 Powershift - Assembly Cradle 4 - 17
892/01083 Powershift - Assembly tool,

transfer gear 4 - 17
892/01084 Powershift - Transfer gear, bearing

assembly 4 - 17
892/01085 Powershift - Seal fitting tool 4 - 17
892/01092 Wheel Hub Service Kit 4 - 19
892/01096 Speed Sensor Test Harness 4 - 17
892/01110 Torque Converter Alignment Tool 4 - 18
926/15500 Rubber Spacer Blocks 4 - 3
992/04000 Torque Multiplier 4 - 12
992/04800 Flange Spanner 4 - 12
992/07608 Bearing Adapter 4 - 10
992/07609 Bearing Adapter 4 - 10
992/07610 Bearing Adapter 4 - 10
992/07611 Bearing Adapter 4 - 10
992/07612 Bearing Adapter 4 - 10
992/07613 Bearing Adapter 4 - 10
992/09100 Spool Clamp 4 - 8
992/09200 Charging Tool 4 - 1
992/09300 Ram Spanner 4 - 8
992/09400 Ram Spanner 4 - 8
992/09500 Ram Spanner 4 - 8
992/09600 Ram Spanner 4 - 8
992/09700 Ram Spanner 4 - 8
992/09900 Ram Spanner 4 - 8
992/10000 Ram Spanner 4 - 8
992/12300 12V Mobile Oven 4 - 1
992/12400 Static Oven - 2 Cartridge 4 - 2
992/12600 Static Oven - 6 Cartridge 4 - 2
992/12800 Cut-Out Knife 4 - 2
992/12801 "L" Blades 4 - 2
993/55700 Direct Glazing Kit 5 - 1
993/59500 Impulse Extractor Adapter 4 - 11
993/68100 Slide Hammer Kit 4 - 3
993/69800 Seal Kit 4 - 6
993/70111 Breakback Torque Wrench 4 - 15
993/85700 Battery Tester 4 - 4
998/10650 Powershift Torque Converter

- Pressure Test Kit 4 - 12
998/10738 Powershift Clutch - Adapter Spanner 4 - 13
7210/0001 Dummy Plug 4 - 5
7210/0002 Wire Seal (1.4 - 2.2 mm dia.) 4 - 5
7210/0003 Wire Seal (2.2 - 2.9 mm dia.) 4 - 5
7212/0001 2 Way Socket Connector 4 - 5
7212/0002 2 Way Pin Housing 4 - 5
7212/0003 2 Way Socket Retainer 4 - 5
7212/0004 2 Way Pin Retainer 4 - 5
7213/0001 3 Way Socket Connector 4 - 5
7213/0002 3 Way Pin Housing 4 - 5
7213/0003 3 Way Socket Retainer 4 - 5
7213/0004 3 Way Pin Retainer 4 - 5

9803/3280

Issue 6*

Section 1 General Information

Section 1

3 - 3

Service Tools Numerical List

Page No.

7213/0005 3 Way Socket Connector (DT) 4 - 5

*

7213/0006 3 Way Pin Housing (DT) 4 - 5

*

7213/0007 3 Way Socket Retainer (DT) 4 - 5
7213/0008 3 Way Pin Retainer (DT) 4 - 5
7214/0001 4 Way Socket Connector 4 - 5
7214/0002 4 Way Pin Housing 4 - 5
7214/0003 4 Way Socket Retainer 4 - 5
7214/0004 4 Way Pin Retainer 4 - 5
7216/0001 6 Way Socket Connector 4 - 5
7216/0002 6 Way Pin Housing 4 - 5
7216/0003 6 Way Socket Retainer 4 - 5
7216/0004 6 Way Pin Retainer 4 - 5
7218/0001 8 Way Socket Connector 4 - 5
7218/0002 8 Way Pin Housing 4 - 5
7218/0003 8 Way Socket Retainer 4 - 5
7218/0004 8 Way Pin Retainer 4 - 5
7219/0001 10 Way Socket Connector 4 - 5
7219/0002 10 Way Pin Housing 4 - 5
7219/0003 10 Way Socket Retainer 4 - 5
7219/0004 10 Way Pin Retainer 4 - 5
7219/0005 14 Way Socket Connector 4 - 5
7219/0006 14 Way Pin Housing 4 - 5
7219/0007 14 Way Socket Retainer 4 - 5
7219/0008 14 Way Pin Retainer 4 - 5

3 - 3

The following parts are replacement items for kits and would
normally be included in the kit numbers quoted on pages
1/3-1 and 1/3-2.

Service Tools Numerical List Page No.

Replacement item for kit no. 892/00180
892/00181 4 - 9

Replacement items for kit no. 892/00253
892/00201 Replacement Gauge 4 - 6
892/00202 Replacement Gauge 4 - 6
892/00203 Replacement Gauge 4 - 6
892/00254 Replacement Hose 4 - 6

Replacement items for kit no. 892/00309
892/00340 Test Block Body 4 - 7
892/00341 Setting Body 4 - 7
892/00343 Spanner 4 - 7
892/00345 Anti-Cavitation Lock Out Bung 4 - 7
993/68300 Adjusting Pin 4 - 7

Replacement items for kit no. 993/68100
993/68101 Slide Hammer 4 - 3
993/68102 End Stops 4 - 3
993/68103 Adaptor - M20 x 5/8" UNF 4 - 3
993/68104 Adaptor - M20 x 1" UNF 4 - 3
993/68105 Adaptor - M20 x M20 4 - 3
993/68106 Adaptor - M20 x M24 4 - 3
993/68107 Bar - M20 x M20 X 800MM 4 - 3
993/68108 Adaptor - M20 x 7/8" UNF 4 - 3
993/68109 Adaptor - M20 x M12 4 - 3
993/68110 Adaptor - M20 x 5/8" UNF (Shoulder) 4 - 3
993/68111 Adaptor - M20 x 1/2" UNF 4 - 3

9803/3280

Issue 5*

Section 1 General Information

Section 1

4 - 1

Service Tools (cont'd)

Section B - Body & Framework

826/01099 M6 x 16mm Rivet Nut
826/01101 M6 x 19mm Rivet Nut
826/01103 M8 x 18mm Rivet Nut
826/01102 M8 x 21mm Rivet Nut
826/01104 M10 x 23mm Rivet Nut
826/01105 M10 x 26mm Rivet Nut

Installation Tool Available from:
Bollhoff Fastenings Ltd.
Midacre
The Willenhall Estate
Rose Hill
Willenhall
West Midlands, WV13 2JW

4 - 1

S261210

Hand Cleaner - special blend for the removal of

polyurethane adhesives.

JCB part number - 4104/1310
(454g; 1 lb tub)

S186240

Cartridge Gun - hand operated - essential for the

application of sealants, polyurethane materials etc.

JCB part number - 892/00845

S186270

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

9803/3280

S186250

JCB part number ­892/00843

S186280

Issue 1

Section 1 General Information

Section 1

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.

JCB part number:
992/12400 - 2 Cartridge x 240V
992/12600 - 6 Cartridge x 240V

S186260

4 - 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.

JCB part number - 892/00842

S186300

Wire Starter - used to

access braided cutting wire
(below) through original
polyurethane seal.

JCB part number - 892/00848

S186310

Cut-Out Knife - used to

remove broken glass.

JCB part number - 992/12800

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

9803/3280

S186350

Issue 1

Section 1 General Information

Section 1

4 - 3

Service Tools (cont'd)

Section B - Body & Framework

Braided Cutting Wire - consumable heavy duty cut-out

wire used with the glass extraction tool (above).

JCB part number - 892/00849
(approx 25 m length)

S186330

4 - 3

Long Knife - used to give extended reach for normally

inaccessible areas.

JCB part number - 892/00844

S186360

Rubber Spacer Blocks - used to provide the correct

set clearance between glass edge
and cab frame.

JCB part number - 926/15500

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 6 :993/68106 Adaptor - M20 x M24
2 :993/68102 End Stops 7 :993/68107 Bar - M20 x M20 X 800MM
3 :993/68103 Adaptor - M20 x 5/ 8" UNF 8 :993/68108 Adaptor - M20 x 7/8" UNF
4 :993/68104 Adaptor - M20 x 1" UNF 9 :993/68109 Adaptor - M20 x M12
5 :993/68105 Adaptor - M20 x M20 10 :993/68110 Adaptor - M20 x 5/8" UNF (Shoulder)

11 :993/68111 Adaptor - M20 x 1/2" UNF

11

1

2

9

(unit quantity = 500 off)

S186550

2

6

2

5

4

8

3

10

9803/3280

7

S196910

Issue 1

Section 1 General Information

Section 1

4 - 4

Service Tools (cont'd)

Section C - Electrics

4 - 4

AVO Test Kit

1 892/00283 Tool Kit Case

2 892/00298 Fluke Meter 85

3 892/00286 Surface Temperature Probe

4 892/00284 Venture Microtach Digital Tachometer

5 892/00282 100 amp Shunt - open type

6 892/00285 Hydraulic Temperature Probe

S188231

825/00410 15 mm Crowfoot Wrench
825/99833 Adapter

S239510

892/00882 Socket for Alternator Pulley Nut993/85700 Battery Tester

S216770

9803/3280

S216200

Issue 1

Section 1 General Information

Section 1

4 - 5

Service Tools (cont'd)

Section C - Electrics

1 Electrical Repair Kit
2A :7212/0002 2 Way Pin Housing
2B :7212/0004 2 Way Pin Retainer
2C :7212/0003 2 Way Socket Retainer
2D :7212/0001 2 Way Socket Connector
3A :7213/0002 3 Way Pin Housing
3B :7213/0004 3 Way Pin Retainer
3C :7213/0003 3 Way Socket Retainer
3D :7213/0001 3 Way Socket Connector
4A :7213/0006 3 Way Pin Housing (DT)
4B :7213/0008 3 Way Pin Retainer (DT)
4C :7213/0007 3 Way Socket Retainer (DT)
4D :7213/0005 3 Way Socket Connector (DT)
5A :7214/0002 4 Way Pin Housing
5B :7214/0004 4 Way Pin Retainer
5C :7214/0003 4 Way Socket Retainer
5D :7214/0001 4 Way Socket Connector

4 - 5

6A :7216/0002 6 Way Pin Housing
6B :7216/0004 6 Way Pin Retainer
6C :7216/0003 6 Way Socket Retainer
6D :7216/0001 6 Way Socket Connector
7A :7218/0002 8 Way Pin Housing
7B :7218/0004 8 Way Pin Retainer
7C :7218/0003 8 Way Socket Retainer
7D :7218/0001 8 Way Socket Connector
8A :7219/0002 10 Way Pin Housing
8B :7219/0004 10 Way Pin Retainer
8C :7219/0003 10 Way Socket Retainer
8D :7219/0001 10 Way Socket Connector
9A :7219/0006 14 Way Pin Housing
9B :7219/0008 14 Way Pin Retainer
9C :7219/0007 14 Way Socket Retainer
9D :7219/0005 14 Way Socket Connector
10 :7210/0001 Dummy Plug
11 :7210/0002 Wire Seal (1.4 - 2.2 mm dia.)
12 :7210/0003 Wire Seal (2.2 - 2.9 mm dia.)

11

9803/3280

S188380

Issue 1

Section 1 General Information

Section 1

4-6

Service Tools (cont'd)

Section E - Hydraulics

S267300

S188131

Hydraulic Circuit Pressure Test Kit

892/00253 Pressure Test Kit
: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)
:892/00254 Replacement Hose
993/69800 Seal Kit for 892/00254 (can also be used with

probe 892/00706)
892/00706 Test Probe
892/00347 Connector - Hose to gauge

*

S188121

4-6

Pressure Test 'T' Adapters

892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point
816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point
892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point
892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point
892/00265 1 in M BSPx1inFBSPxTest Point

Flow Test Equipment

892/00268 Flow Monitoring Unit
892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)
892/00293 Connector Pipe
892/00270 Load Valve
1406/0021 Bonded Washer
1604/0006 Adapter 3/4 inMx3/4inMBSP
1612/0006 Adapter 3/4 in F x 3/4 in M BSP
892/00271 Adapter 3/4 in F x 5/8 in M BSP
892/00272 Adapter 5/8 in F x 3/4 in M BSP
816/20008 Adapter 3/4 in F x 1/2 in M BSP
892/00275 Adapter 1/2 in F x 3/4 in M BSP
892/00276 Adapter 3/4 in F x 3/8 in M BSP
892/00277 Adapter 3/8 in F x 3/4 in M BSP
892/00273 Sensor Head 0 - 380 l/min
892/00294 Connector Pipe
1606/0015 Adapter 1.1/4 in M BSPx1inMBSP
892/00078 Connector 1 inFx1inFBSP
1604/0008 Adapter 1 inMx1inMBSP
1606/0012 Adapter 1 inMx3/4inMBSP
816/20013 Adapter 3/4 inFx1inMBSP

Pressure Test Adapters

892/00255 1/4 in BSP x Test Point
892/00256 3/8 in BSP x Test Point
892/00257 1/2 in BSP x Test Point
892/00258 5/8 in BSP x Test Point
816/15118 3/4 in BSP x Test Point
892/00259 1 in BSP x Test Point
892/00260 1.1/4 in BSP x Test Point
892/00261 5/8 in UNF x Test Point

S200141

S188151

9803/3280

Issue 2*

Section 1 General Information

Section 1

4-7

Service Tools (cont'd)

Section E - Hydraulics

892/00881 Valve Spool

Seal Fitting Tool

S261220

Components for Valve Block A.R.V. Testing

For 4CX Variable Flow machines use 25/201103

892/00309 A.R.V. Pressure Test Kit
1 : 892/00340 Test Block Body
2 : 892/00341 Setting Body
3 : 993/68300 Adjusting Pin
4 : 892/00343 Spanner
5 : 892/00345 Anti-cavitation Lock Out Bung
6 892/00335 A.R.V. Cartridge Removal Tool

6

4

1

4-7

2

Hand Pump Equipment

892/00223 Hand Pump
892/00137 Micro-bore Hose 1/4 in BSP x 3 metres
892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
892/00706 Test Probe
892/00278 Gauge0-40bar(0-600 lbf/in2)
892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in2)

S193850

Male Adapters - BSP x NPT (USA only)

816/00439 3/8 in. x 1/4 in.
816/00440 1/2 in. x 1/4 in.
816/15007 3/8 in. x 3/8 in.
816/15008 1/2 in. x 3/8 in.

S193860

Bonded Washers

1406/0011 1/4 in. BSP
1406/0018 1/2 in. BSP
1406/0014 5/8 in. BSP
1406/0021 3/4 in. BSP
1406/0029 1.1/4 in. BSP

Male Adapters - BSP x BSP

1606/0003 3/8 in. x 1/4 in.
1604/0003 3/8 in. x 3/8 in.
892/00071 3/8 in. x 3/8 in. taper
1606/0004 1/2 in. x 1/4 in.
1606/0007 1/2 in. x 3/8 in.
1604/0004 1/2 in. x 1/2 in.
1606/0017 5/8 in. x 1/2 in.
1606/0008 3/4 in. x 3/8 in.
1606/0009 3/4 in. x 1/2 in.
1604/0006 3/4 in. x 3/4 in.
1606/0012 3/4 in.x1in.
1606/0014 3/4 in. x 1.1/4 in.
1606/0015 1 in. x 1.1/4 in.

3

5

S196700

S188140

9803/3280

Issue 1

Section 1 General Information

Section 1

4-8

Service Tools (cont'd)

Section E - Hydraulics

Female Cone Blanking Plug
892/00055 1/4 in. BSP
892/00056 3/8 in. BSP
892/00057 1/2 in. BSP
892/00058 5/8 in. BSP
892/00059 3/4 in. BSP
892/00060 1 in. BSP

S193870

Male Cone Blanking Cap
816/00294 1/4 in. BSP
816/00189 3/8 in. BSP
816/00190 1/2 in. BSP
816/00197 5/8 in. BSP
816/00196 3/4 in. BSP
816/00193 1 in. BSP

4-8

S193880

892/00047 3/8 in. BSP (A) x 1/4 in. BSP (B)
892/00048 1/2 in. BSP (A) x 1/4 in. BSP (B)
892/00049 5/8 in. BSP (A) x 1/4 in. BSP (B)
816/50043 3/4 in. BSP (A) x 1/4 in. BSP (B)
892/00051 1 in. BSP (A) x 1/4 in. BSP (B)
816/50005 1/2 in. BSP (A) x 1/2 in. BSP (B)
816/60096 3/4 in. BSP (A) x 3/4 in. BSP (B)
816/00017 1 in. BSP (A) x 1 in. BSP (B)

992/09100 Excavator Spool Clamp
892/00011 Spool Clamp

S193890

S193900

Female Connectors

892/00074 3/8 in. BSP x 3/8 in. BSP
892/00075 1/2 in. BSP x 1/2 in. BSP
892/00076 5/8 in. BSP x 5/8 in. BSP
892/00077 3/4 in. BSP x 3/4 in. BSP

Hexagon Spanners for Ram Pistons and End Caps
992/09300 55mm A/F
992/09400 65mm A/F
992/09500 75mm A/F
992/09600 85mm A/F
992/09700 95mm A/F
992/09900 115mm A/F
992/10000 125mm A/F

9803/3280

S216210 S193930

Issue 1

Section 1 General Information

110mm

175mm

R 1.4mm

3

o

R3m

m

7mm

11

o

10mm

20mm

5mm

Section 1

4-9

Service Tools (cont'd)

Section E - Hydraulics

892/00252 Test Block for Loader Valve A.R.V.

(214e Machines Only)

4-9

S220840

892/00334 Ram Seal Fitting Tool

892/00948 Charging Kit (without gauge)
892/00949 Gauge

S216250

S308271

892/01027 Piston Seal Assembly Tool

338500

S338410

Ram Seal Protection Sleeves

892/01016 For 25 mm Rod Diameter
892/01017 For 30 mm Rod Diameter
892/01018 For 40 mm Rod Diameter
892/01019 For 50 mm Rod Diameter
892/01020 For 50 mm Rod Diameter (slew ram)
892/01021 For 60 mm Rod Diameter
892/01022 For 60 mm Rod Diameter (slew ram)
892/01023 For 65 mm Rod Diameter
892/01024 For 70 mm Rod Diameter
892/01025 For 75 mm Rod Diameter
892/01026 For 80 mm Rod Diameter
892/00167 For 90 mm Rod Diameter

9803/3280

Issue 2*

Section 1 General Information

Section 1

4-10

Service Tools (cont'd)

SectionF-Transmission

892/00812 Drive Coupling Spanner for front

axle and gearbox yoke
couplings

892/00179 Bearing Press (use with

appropriate adapters)

S196720

A 892/00920 Flow Test Adapter
B 892/00301 Flow Test Adapter
C 892/00302 Flow Test Adapter

S266880

A

B

4-10

C

S188200

992/07608 Bearing Adapter
992/07609 Bearing Adapter
992/07610 Bearing Adapter
992/07611 Bearing Adapter
992/07612 Bearing Adapter
992/07613 Bearing Adapter

S188160

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.

9803/3280

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).

Issue 3*

Section 1 General Information

Section 1

4-11

Service Tools (cont'd)

Section F - Transmission

892/00224

Impulse Extractor Set for Hub Bearing Seals

4-11

S216290

892/00817 17 mm A/F x 3/4in. square drive
892/00818 22 mm A/F x 3/4in. square drive
892/00819 15 mm A/F x 1/2in. square drive
892/00333 19 mm A/F x 3/4in. square drive

S197070

892/00225 Adapter - Impulse Extractor

Small 17mm to 25mm
Medium 25mm to 45mm
Large 45mm to 80mm

993/59500 Adapter - Impulse Extractor (syncro

shuttle and powershift transmission)

892/00174

Measuring Cup - Pinion Head Bearing

S190770

892/00822

Splined Bolt Socket for
driveshafts

S197060

9803/3280

Issue 1

Section 1 General Information

A463020

Section 1

4-12

Service Tools (cont'd)

Section F - Transmission

992/04800

Flange Spanner - for locking pinion

flange while pinion nut is slackened or

torque set

4-12

S216310

892/00182 Bearing Pad Driver

S197040

998/10650 Powershift Torque Converter

*

- Pressure Test Kit

2

Comprises of:
1Pipe
2 Adaptor
3 Adaptor
4 Test point adaptor
5 Sealing washer

3

1

992/04000

Torque Multiplier (use in conjunction with a torque wrench to give a
5:1 multiplication when tightening pinion nuts)

S197030

S316250

Test Point

1 892/00964 Test point (1/8 BSP) Powershift

2 892/00965 Test point (3/8 BSP) Powershift

3 892/00966 Test point (1/4 BSP) Syncro Shuttle

These test points can be left in position after testing.

5

9803/3280

4

Issue 2*

Section 1 General Information

A395350

A396590

A396600

A396510

A410370

Section 1

4-13

Service Tools (cont'd)

Section F - Transmission

892/01077 Synchro Shuttle Gearbox - Selector

Shaft Lock Screw

Powershift Gearbox Flow Test Adaptor

1 460/15708 Flow Test Adapter
2 460/15707 Banjo Bolt
3 2401/0222 O-ring
4 2403/0110 O-ring
5 2403/0108 O-ring
6 1604/0004 Adapter
7 1406/0018 Sealing Washer

4-13

892/01078 Synchro Shuttle Gearbox - Mainshaft

Adjuster

Synchro Shuttle Gearbox - Setting ring socket
spanners

892/01079
(Mainshaft setting ring)

2

7

6

5

4

1

3

A313250

892/01080
(Layshaft setting ring)

998/10738 Adaptor Spanner

*

- Powershift 2/4WD Clutch (Germany)

9803/3280

Issue 2*

Section 1 General Information

Section 1

4 - 14

Service Tools (cont'd)

Section F - Transmission

S267300

Hydraulic Circuit Pressure Test Kit (also used for main hydraulic
system tests)

892/00253 Pressure Test Kit
: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)
:892/00254 Replacement Hose
993/69800 Seal Kit for 892/00254 (can also be used with

probe 892/00706)
892/00706 Test Probe
892/00347 Connector - Hose to gauge

*

S188121

4 - 14

Flow Test Equipment (also used for main hydraulic system
tests)

892/00268 Flow Monitoring Unit
892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)
892/00293 Connector Pipe
892/00270 Load Valve
1406/0021 Bonded Washer
1604/0006 Adapter 3/4 in M x 3/4 in M BSP
1612/0006 Adapter 3/4 in F x 3/4 in M BSP
892/00271 Adapter 3/4 in F x 5/8 in M BSP
892/00272 Adapter 5/8 in F x 3/4 in M BSP
816/20008 Adapter 3/4 in F x 1/2 in M BSP
892/00275 Adapter 1/2 in F x 3/4 in M BSP
892/00276 Adapter 3/4 in F x 3/8 in M BSP
892/00277 Adapter 3/8 in F x 3/4 in M BSP
892/00273 Sensor Head 0 - 380 l/min
892/00294 Connector Pipe
1606/0015 Adapter 1.1/4 in M BSP x 1 in M BSP
892/00078 Connector 1 in F x 1 in F BSP
1604/0008 Adapter 1 in M x 1 in M BSP
1606/0012 Adapter 1 in M x 3/4 in M BSP
816/20013 Adapter 3/4 in F x 1 in M BSP

S188151

9803/3280

Issue 2*

Section 1 General Information

A396950

A396580

A396930

A396960

A396940

Section 1

4 - 15

Service Tools (cont'd)

Section F - Transmission

4 - 15

1a

1b

1

1c

5

6

2

3

7

4

9803/3280

8, 9

Issue 3*

Section 1 General Information

Section 1

4 - 16

Service Tools (cont'd)

Section F - Transmission

Solid Spacer Setting Kit

Synchro Shuttle Gearbox, SD70, SD80
Axles, Powershift 2004 Gearbox

1 892/00918 Setting Tool Kit
1a 892/01164 Adaptor (2004 Gearboxes)

*

1b 892/01165 Sleeve (2004 Gearboxes)

*

1c 892/01163 Support Bracket (2004 Gearboxes)

*

2 921/52627 Spacer 14.20 Service use
3 993/70111 Breakback Torque Wrench
4 892/01076 Support Bracket -

Synchro Shuttle Gearbox

5 892/01075 Support Bracket

PD70, SD80 Rear Axles

6 997/11000 Support Bracket

SD55, SD70 Front Axles

7 998/10567 SD80 Pinion Shaft Adaptor

8 921/53300 Spacer Kit - SD55 Axles

*

Comprises of:

Spacer

thickness

mm
921/53322 13.550
921/53323 13.575
921/53324 13.600
921/53325 13.625
921/53301 13.650
921/53302 13.675
921/53303 13.700
921/53304 13.725
921/53305 13.750
921/53306 13.775
921/53307 13.800
921/53308 13.825
921/53309 13.850

9 823/10547 Spacer Kit - Powershift 2004 Gearbox

*

921/53310 13.875
921/53311 13.900
921/53312 13.925
921/53313 13.950
921/53314 13.975
921/53315 14.000
921/53316 14.025
921/53317 14.050
921/53318 14.075
921/53319 14.100
921/53320 14.125
921/53321 14.150

Spacer

thickness

mm

*

10 921/53400 Spacer Kit - Sychro Shuttle Gearbox,

SD70, SD80 Axles

Comprises of:

Spacer

thickness

mm
921/52628 12.600
829/30405 12.625
921/52629 12.650
829/30406 12.675
921/52630 12.700
829/30407 12.725
921/52601 12.750
829/30408 12.775
921/52602 12.800
829/30409 12.825
921/52603 12.850
829/30410 12.875
921/52604 12.900
829/30411 12.925
921/52605 12.950
829/30412 12.975
921/52606 13.000
829/30413 13.025
921/52607 13.050
829/30414 13.075
921/52608 13.100
829/30415 13.125
921/52609 13.150
829/30416 13.175
921/52610 13.200
829/30417 13.225
921/52611 13.250
921/53424 13.275

Note: After using a spacer, obtain a replacement to keep
the set complete.

921/53425 13.300
921/53426 13.325
921/53427 13.350
921/53428 13.375
921/53401 13.400
921/53402 13.425
921/53403 13.450
921/53404 13.475
921/53405 13.500
921/53406 13.525
921/53407 13.550
921/53408 13.575
921/53409 13.600
921/53410 13.625
921/53411 13.650
921/53412 13.675
921/53413 13.700
921/53414 13.725
921/53415 13.750
921/53416 13.775
921/53417 13.800

921/53418 13.825
921/53419 13.850
921/53420 13.875
921/53421 13.900
921/53422 13.925
921/53423 13.950
921/52626 14.000

Spacer

thickness

mm

4 - 16

Comprises of:

Spacer

thickness

mm
829/30946 13.850
829/30947 13.825
829/30948 13.800
829/30949 13.775
829/30950 13.750
829/30951 13.725
829/30952 13.700

9803/3280

Spacer

thickness

mm
829/30953 13.675
829/30954 13.650
829/30955 13.625
829/30956 13.600
829/30957 13.575
829/30958 13.550

Issue 2*

Section 1 General Information

A402680

711300

Section 1

4 - 17

Service Tools (cont'd)

Section F - Transmission

892/01094 Transmission Jack

When removing the Powershift gearbox use of a special
transmission jack is strongly recommended. This jack
can also be used when removing Synchro Shuttle
gearboxes.
Note that the jack must be used with special support
plates, see below.

4 - 17

Powershift - Support plates, for use with transmission jack,
Manufacture locally, for details see Section F, Service

Tools.

892/01082 - Powershift - Assembly Cradle, for details see

Section F, Service Tools.

Powershift - Gearbox hydraulic pump removal tools, allow
pump to be removed with torque converter housing fitted to
gearbox. Manufacture locally, for details see Section F,

Service Tools.

892/01083 Powershift - Assembly tool, transfer gear.

892/01084 Powershift - Transfer gear, bearing assembly.

892/01085 Powershift - Seal fitting tool

*

823/10420 Thrust Washer Kit - Powershift

gearbox - Layshaft clutch

Comprises of:

Washer thickness mm
823/10421 4.3
823/10422 4.4
823/10423 4.5
823/10424 4.6
823/10425 4.7
823/10426 4.8

892/01096 Speed Sensor Test Harness -

Powershift Gearbox

9803/3280

Issue 4*

Section 1 General Information

A406130

D

F

A

B

C

H

J

E

G

A

A

SECTION A-A

30.2

30.1

43.4

43.3

57.0

REF

2 DOWELS

8.0

12.0

10.0

TYP10.0

TYP10.0

x 45 TYP1.0

65.0

171.0

185.0

342.0

370.0

0.3 X

2 DOWELS

8 x 32 LONG

PRESS FIT

0.3 X

5

3 x 35(25)

X

Section 1

4 - 18

Service Tools (cont'd)

Section F - Transmission

Powershift Gearbox - 6 Speed (ShiftMaster)
Electronic Service Tool Kit

1 721/10885 - Interconnecting cable (Data Link Adaptor to

*

machine ECU diagnostics socket). Note that this cable
must be ordered separately in addition to the kit below.

892/01033 - Service Tool Kit comprises:

1A Data Link Adaptor (DLA), enables data exchange

between the machine ECU (Electronic Control Unit) and
a laptop PC loaded with the applicable ShiftMaster
diagnostics software.

2A Interconnecting cable, DLA to laptop PC. Several cables

are included to enable compatibility with different PC
port types.

3A Kit carrying case.

4 - 18

1

1A

3A

2A

892/01110 Torque Converter Alignment Tool

(for 12” and W300 torque converters)

9803/3280

A436700

Issue 5*

Section 1 General Information

Section 1

4 - 19

Service Tools (cont’d)

Section F - Transmission

Wheel Hub Service Tool -

A Bearing Puller
B Bearing Press
C Hub Seal Dolly

Item Description Part No. Qty
A, B & C Hub Service Kit 892/01092 1

comprises of:

1 Puller Beam 998/10623 1
2 Inner Bearing Plate 998/10607 1
3 Bolt M16x220 1315/3731Z 2
4 Nut M16 1370/0601Z 2
5 Reaction Tube 998/10614 1
6 ModifiedWheel Stud 998/10624 2
7 Wheel Bearing Carrier

Puller 998/10615 2

8 Nut M20 1370/0701Z 4
9 Washer M20 1420/0012Z 2
10 Puller Rod 998/10610 2
11 Nut M12 1370/0401Z 2
12 Washer M12 1420/0009Z 2
13 Bearing Centre Puller 998/10608 1
14 Bolt M10x60 1315/3414Z 1
15 Nut M10 1370/0301Z 1
16 Bearing Fitting Tube 998/10606 1
17 Puller Handle Nut 998/10616 1
18 Bolt M20x300 1315/3835Z 2
19 Washer 445/12303 2
20 Bearing 917/02800 1
21 Seal Dolly 892/00891 1

A

1

2

4

4 - 19

5

6

8,9

7

10

11,12

3

B

C

15

21

14

13

18

16

19, 20

8

17

A439160

9803/3280

Issue 2*

Section 1 General Information

Section 1

4 - 20

Service Tools (cont'd)

Section H - Steering

S216230

892/00180 Seal Fitting Tool for fitting 'O' ring and

kin ring to Hydraulic Steer Unit

892/00181 Replacement Plastic Boss

4 - 20

9803/3280

Issue 1

Section 1 General Information

A314530

Section 1

4 - 21

Service Tools (cont'd)

Section K - Engine

892/00836
Lifting Wire Assembly (for
engine removal)

S219080

4 - 21

S192390

892/00041 De-glazing Tool for Cylinder Bores (to

assist bedding-in of new piston rings)

892/00936 Timing pin for fuel injection pump

(AK, AR)

892/01054 Adaptor for compression testing

*

For details of other engine service tools refer to the Engine

*

Service Manual (publication no. 9806/2140) for low emission
engines.

(AK, AR)

9803/3280

Issue 2*

Section 1 General Information

Section 1

5 - 1

Sealing and Retaining Compounds

JCB Multi-Gasket A medium strength sealant suitable for all

sizes of gasket flanges, and for hydraulic fittings

of 25-65mm diameter. 4102/1212 50ml

JCB High Strength Threadlocker A high strength locking fluid for use with threaded

components. Gasketing for all sizes of flange where
the strength of the joint is important. 4102/0551 50ml

JCB Retainer (High Strength) For all retaining parts which are unlikely to be

dismantled. 4101/0651 50ml

JCB Threadlocker and Sealer A high strength locking fluid for sealing 4101/0250 10ml

and retaining nuts, bolts, and screws up to 4101/ 0251 50ml
50mm diameter, and for hydraulic fittings up
to 25mm diameter.

Threadseal A medium strength thread sealing compound. 4102/1951 50ml

Threadlocker A locking fluid for use on threads larger than

50mm dia. 4101/0451 50ml

Activator A cleaning primer which speeds the curing rate 4104/ 0251 (1ltr)

of anaerobic products. 4104/0253 Bottle (200ml)

5 - 1

Cleaner / Degreaser For degreasing components prior to use of

anaerobic adhesives and sealants. 4104/1557 400ml

Direct Glazing Kit 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 30 ml

4104/1203 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

9803/3280

Issue 1

Section 2 Care & Safety

Section 2

i

i

Contents Page No.

Safety Notices 1 - 1

General Safety 2 - 1

Operating Safety 3 - 1

Maintenance Safety 4 - 1

9803/3280

Issue 1

Section 2 Care & Safety

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

1 - 1

!

!

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

9803/3280

Issue 1

Section 2 Care & Safety

Section 2

2 - 1

All construction and agricultural equipment 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

2 - 1

!

!

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.

INT-1-3- 4

!

!

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.

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, ear-protectors and industrial gloves. Keep
cuffs fastened. Do not wear a necktie or scarf. Keep long
hair restrained.

INT-1-3- 6

!!

WARNING

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- 7

!

!

WARNING

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- 8

9803/3280

Issue 1

Section 2 Care & Safety

Section 2

3 - 1

Operating Safety

!

!

WARNING

Machine Condition

A defective machine can injure you or others. Do not operate
a machine which is defective or has missing parts. Make
sure the maintenance procedures in this handbook are
completed before using the machine.

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- 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.

INT-2-1- 4

!

!

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.

INT-2-1- 5

3 - 1

!!

WARNING

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- 9/3

!

!

WARNING

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

!

!

WARNING

Ramps and Trailers

Water, mud, ice, grease and oil on ramps or trailers can
cause serious accidents. Make sure ramps and trailers are
clean before driving onto them. Use extreme caution when
driving onto ramps and trailers.

INT-2-2- 6

!

!

WARNING

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.

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

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

!

!

DANGER

Sparks

Explosions and fire can be caused by sparks from the
exhaust or the electrical system. Do not use the machine in
closed areas where there is flammable material, vapour or
dust.

INT-2-2- 10

!

!

WARNING

Powershift Transmission

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

9803/3280

Issue 1

Section 2 Care & Safety

Section 2

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

Modifications and Welding

Non-approved modifications can cause injury and damage.
Parts of the machine are made from 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

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

4 - 1

!!

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

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

Battery Terminals

The machine is negatively earthed. Always connect the
negative pole of the battery to earth.

!

!

WARNING

Electrical Circuits

Understand the electrical circuit before connecting or
disconnecting an electrical component. A wrong connection
can cause injury and/or damage.

INT-3-1- 4

!

!

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.

INT-3-1- 6

When connecting the battery, connect the earth (-) lead last.

When disconnecting the battery, disconnect the earth (-)
lead first.

INT-3-1- 9

!

!

WARNING

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 face 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

9803/3280

Issue 1

Section 2 Care & Safety

Section 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.

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.

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

!

!

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

Always wear safety glasses when dismantling assemblies
containing components under pressure from springs. This
will protect against eye injury from components accidently
flying out.

GEN 6-2

4 - 2

!!

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

!

!

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 or paint thinners near 'O' rings and seals.

INT-3-2- 12

!

!

WARNING

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

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

9803/3280

Issue 1

Section 2 Care & Safety

Section 2

4 - 3

Maintenance Safety (cont'd)

!

!

WARNING

Hydraulic Hoses

Damaged hoses can cause fatal accidents. Inspect the
hoses regularly for:

- Damaged end fittings

- Chafed outer covers

- Ballooned outer covers

- Kinked or crushed hoses

- Embedded armouring in outer covers

- Displaced end fittings.

INT-3-3- 2

!

!

WARNING

Safety Strut

Raised loader arms can drop suddenly and cause serious
injury. Before working under raised loader arms, fit the
loader arm safety strut.

2-1-1-6

!

!

WARNING

A raised and badly supported machine can fall 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.

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

!

!

WARNING

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.

Disconnect the battery, to prevent the engine being started
while you are beneath the machine.

GEN-1-2

4 - 3

!!

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

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.

2-1-1-8

!

!

WARNING

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 that components have cooled then remove and

place material into plastic bags.

2 Thoroughly wash contaminated area with 10% calcium

hydroxide or other suitable alkali solution, if necessary
use wire wool to remove burnt remains.

3 Thoroughly wash contaminated area with detergent

and water.

4 Contain all removed material, gloves etc. used in this

operation in sealed plastic bags and dispose of in
accordance with Local Authority Regulations.

DO NOT BURN FLUOROELASTOMERIC MATERIALS.

9803/3280

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

Issue 1

Section 3 Routine Maintenance

Section 3

i

i

Contents Page No.

Checking for Damage 1 - 1

Cleaning the Machine 1 - 2

Seat Belt

Checking the Seat Belt Condition and Security 1 - 3

Fire Extinguisher (when fitted)

Checking the Fire Extinguisher 1 - 3

ROPS/FOPS Structure

Checking the ROPS/FOPS Structure 1 - 4

Tyres and Wheels

Tyre Inflation 1 - 5
Checking the Wheel Nut Torques 1 - 5

Lubricants - Health and Safety

Hygiene 1 - 6
Storage 1 - 6
Waste Disposal 1 - 6
Handling 1 - 6
First Aid - Oil 1 - 6
Spillage 1 - 6
Fires 1 - 6

Service Schedules 2 - 1

Loader Arm Safety Strut

Installing and Removing 2 - 4

Engine Panels

Opening and Closing the Bonnet 2 - 5
Removing and Fitting a Side Panel 2 - 6
Removing and Fitting the Front Grille 2 - 6

Greasing

General 3 - 1
Loader Arms 3 - 1
Backhoe & Quickhitch 3 - 2
Front Axle (2 Wheel Drive Machines) 3 - 3
Front Axle (4 Wheel Drive Machines) 3 - 3
Front Axle (All Wheel Steer Machines) 3 - 4
Rear Axle (All Wheel Steer Machines) 3 - 4
Extending Dipper 3 - 5
Driveshafts 3 - 5
6 - in - 1 Clamshovel 3 - 6
Stabilisers (Centremount Machines) 3 - 6
Loader Quickhitch 3 - 6
Power Sideshift 3 - 7
Kingpost 3 - 7
Knuckle (if fitted) 3 - 8
Backhoe Quickhitch (Hydraulic) 3 - 8

9803/3280

Issue 2*

Section 3 Section 3

Routine Maintenance

ii

ii

Contents Page No.

Engine Air Filter

Cleaning the pre-cleaner (if fitted) 3 - 9
Changing the Elements 3 - 10

Engine Oil and Filter

Checking the Oil Level 3 - 11
Changing the Oil and Filter 3 - 12

Engine Cooling System

Checking the Coolant 3 - 13
Changing the Coolant 3 - 14
Adjusting the Fan Belt 3 - 16
Cleaning the Cab Heater Filter 3 - 16

Fuel System

Types of Fuel 3 - 17
Fuel Standards 3 - 17
Low Temperature Fuels 3 - 17
Fatty Acid Methyl Ester Fuels 3 - 17
Petrol 3 - 17
Advice 3 - 17
Filling the Tank 3 - 18
Draining the Filter 3 - 19
Changing the Filter Element 3 - 20
Draining the Sediment Bowl 3 - 22
Cleaning the Fuel Lift Pump Strainer 3 - 24
(AK and AR Build Engines Only)
Bleed the System 3 - 25
Fuel Pipes - Removal and Replacement 3 - 26
(RE and RG Build Engines Only)

Synchro Shuttle Gearbox

Checking the Oil Level 3 - 27
Changing the Oil and Filter 3 - 28

Powershift Gearbox

Checking the Oil Level 3 - 29
Changing the Oil and Filter 3 - 30

Front and Rear Axle (All Wheel Steer Machines)

Checking the Differential Oil Level 3 - 32
Changing the Differential Oil 3 - 32
Checking the Hub Oil Levels 3 - 33
Changing the Hub Oil 3 - 33

Front and Rear Axle (Two Wheel Steer Machines)

Checking the Oil Level 3 - 34
Changing the Oil 3 - 34

Brakes

Parking Brake Adjustment 3 - 35
Checking the Foot Brake Fluid Level 3 - 35

9803/3280

Issue 3*

Section 3 Routine Maintenance

Section 3

iii

iii

Contents Page No.

Hydraulic System

Checking the Fluid Level 3 - 37
Hydraulic Tank Cap 3 - 37
Changing the Filter Element 3 - 38
Changing the Suction Strainer 3 - 39

Hydraulic Oil Cooler

Cleaning the Tubes/Fins 3 - 40

Windscreen Washer 3 - 41

Electrical System

Fuses & Relays 4 - 1

Battery

Warning Symbols 4 - 2
First Aid - Electrolyte 4 - 3
Checking the Electrolyte Level 4 - 3
Battery Isolator (if fitted) 4 - 4

Stabiliser Legs (Sideshift Machines Only)

Wear Pads 5 - 1
Wear Pad Adjustment 5 - 1

Extending Dipper Wear Pads

Inspecting the Top Wear Pads 5 - 2
Adjusting the Bottom Wear Pads 5 - 2

Air Conditioning (if fitted)

Adjusting the Compressor Drive Belt 5 - 3

Hose Burst Protection Valve (if fitted)

Checking Hose Burst Protection Valve 5 - 4
Lowering a Load - In a Failure Condition 5 - 4

Service Capacities and Lubricants 6 - 1

Coolant Mixtures 6 - 2

9803/3280

Issue 2*

Section 3 Routine Maintenance

Section 3

1 - 1

Inspect steelwork for damage. Note damaged paintwork for
future repair.

Make sure all pivot pins are correctly in place and secured
by their locking devices.

Ensure that the steps and handrails are undamaged and
secure.

Check for broken or cracked window glass. Replace
damaged items.

Check all bucket teeth for damage and security.

Check all lamp lenses for damage.

Inspect the tyres for damage and penetration by sharp
objects.

Check that all safety decals are in place and undamaged. Fit
new decals where necessary.

Checking for Damage

1 - 1

9803/3280

Issue 1

Section 3 Routine Maintenance

Section 3

1 - 2

Park the machine on firm level ground, engage the parking
brake and set the transmission to neutral. Lower the
attachments to the ground and stop the engine.

Clean the machine using water and/or steam. Do not allow
mud, debris etc to build upon the machine, pay particular
attention to the following areas:

1 Backhoe hoses passing through mainframe.
2 Around twin slew rams.
3 Twin ram slew recess in chassis (centremount).
4 Kingpost slide rails (sideshift).
5 Kingpost hose tray and bottom ‘shelf’ (sideshift).
6 Recess between slew ram and kingpost casting

(sideshift).

Stabiliser cavities can become clogged when operating in
soft/wet ground conditions. Remove and clean away all
debris that may have built up.

Do not allow mud to build up on the engine and
transmission. Make sure the radiator grille is not clogged up.

Cleaning the Machine

! WARNING

Airborne particles of light combustible material such as
straw, grass, wood shavings, etc. must not be allowed to
accumulate within the engine compartment or in the
propshaft guards (when fitted). Please inspect these
areas frequently and clean at the beginning of each work
shift or more often if required. Before opening the engine
cover, ensure that the top is clear of debris.

5-3-1-12/2

1 - 2

S272900

S272880

Avoid using neat detergent - always dilute detergents as per
the manufacturer's recommendations, otherwise damage to
the paint finish may occur.

It is important to note that excessive power washing can
cause damage to the seals or bearings. Take care during
routine machine washing not to direct high power water jets
directly at oil seals or universal joints.

Note: The machine must always be greased after pressure
washing or steam cleaning.

Always adhere to local regulations regarding the disposal of
debris created from machine cleaning.

The illustrations show some of the areas that must be
thoroughly cleaned as required.

S272890

9803/3280

Issue 1

Section 3 Routine Maintenance

Section 3

1 - 3

Seat Belt

Checking the Seat Belt Condition and
Security

! WARNING

When a seat belt is fitted to your machine replace it with
a new one if it is damaged, if the fabric is worn, or if the
machine has been in an accident. Fit a new seat belt
every three years.

2-3-1-7/1

Inspect the seat belt for signs of fraying and stretching.
Check that the stitching is not loose or damaged. Check that
the buckle assembly is undamaged and works correctly.

Check that the belt mounting bolts are undamaged, correctly
fitted and tightened.

1 - 3

Fire Extinguisher

(when fitted)

Checking the Fire Extinguisher

Check the fire extinguisher for damage, security and signs of
leaking.

Check that the gauge B indicates that the extinguisher is
charged ie. the needle is in the GREEN segment.

Note: If the needle is in or very near the RED segment at
either end of the gauge, the extinguisher must be serviced or
replaced.

Make sure the safety pin is fitted and secure.

The extinguisher should be serviced every 12 months by a
suitably qualified person.

B

S170520

9803/3280

Issue 1

Section 3 Routine Maintenance

Section 3

1 - 4

ROPS/FOPS Structure

Checking the ROPS/FOPS Structure

The procedure for checking the ROPS/FOPS structure is
described in the Body & Framework section. Refer to

Section B Body & Framework, Service Procedures, Cab
ROPS/FOPS Structure - Checks.

1 - 4

9803/3280

Issue 1

Section 3 Routine Maintenance

Section 3

1 - 5

Tyres and Wheels

Tyre Inflation

These instructions are for adding air to a tyre which is
already inflated. If the tyre has lost all its air pressure, call in
a qualified tyre mechanic. The tyre mechanic should use a
tyre inflation cage and the correct equipment to do the job.

! WARNING

An exploding tyre can kill, inflated tyres can explode if
overheated. Do not cut or weld the rims. Use a
tyre/wheel specialist for all repair work.

2-3-2-7

1 Prepare the Wheel

Before you add air to the tyre, make sure it is correctly
fitted on the machine or installed in a tyre inflation cage.

2 Prepare the Equipment

Use only an air supply system which includes a
pressure regulator. Set the regulator no higher than

1.38 bar (20 psi) above the recommended tyre
pressure. See Section F, Technical Data for
recommended tyres and pressures for your machine.

1 - 5

Checking the Wheel Nut Torques

On new machines, and whenever a wheel has been
removed, check the wheel nut torques every two hours until
they stay correct.

Every day, before starting work, check that the wheel nuts
are tight.

The correct torques are shown in the table below.

Front - Nm lbf ft

680 500

Rear - Nm lbf ft

680 500

! WARNING

If, for whatever reason, a wheel stud is renewed, all the
studs for that wheel must be changed as a set, since the
remaining studs may have been damaged.

2-3-2-8

Use an air hose fitted with a self-locking air chuck and
remote shut-off valve.

3 Add the Air

Make sure that the air hose is correctly connected to
the tyre valve. Clear other people from the area. Stand
behind the tread of the tyre while adding the air.

Inflate the tyre to the recommended pressure. Do not
over-inflate.

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Issue 1

Section 3 Routine Maintenance

Section 3

1 - 6

It is most important that you read and understand this
information and the publications referred to. Make sure
all your colleagues who are concerned with lubricants
read it too.

Lubricants - Health and Safety

Hygiene

JCB lubricants are not a health risk when used properly for
their intended purposes.

However, excessive or prolonged skin contact can remove
the natural fats from your skin, causing dryness and
irritation.

Low viscosity oils are more likely to do this, so take special
care when handling used oils, which might be diluted with
fuel contamination.

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.

1 - 6

2 Apply a barrier cream to the skin before handling used

oil.

3 Note the following when removing engine oil from skin:

a Wash your skin thoroughly with soap and water.

b Using a nail brush will help.

c Use special hand cleansers to help clean dirty

hands.

d Never use petrol, diesel fuel, or paraffin for washing.

4 Avoid skin contact with oil 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

Storage

Always keep lubricants out of the reach of children.

Never store lubricants in open or unlabelled containers.

Waste Disposal

All waste products should be disposed of in accordance
with all the relevant regulations.

The collection and disposal of used oil should be in
accordance with any local regulations. Never pour used
engine oil into sewers, drains or on the ground.

Handling

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.

Eyes.

In the case of eye contact, flush with water for 15 minutes. If
irritation persists, get medical attention.

Swallowing.

If oil is swallowed do not induce vomiting. Get medical
advice.

Skin.

In the case of excessive skin contact, wash with soap and
water.

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 engine oil:

1 Avoid prolonged, excessive or repeated skin contact

with used oil.

9803/3280

Issue 1

Section 3 Routine Maintenance

Section 3

2 - 1

A badly maintained machine is a danger to the operator and
the people working around him. Make sure that the regular
maintenance and lubrication jobs listed in the service
schedules are done to keep the machine in a safe and
efficient working condition.

Service Schedules

Apart from the daily jobs, the schedules are based on
machine running hours. Keep a regular check on the
hourmeter readings to correctly gauge service intervals. Do
not use a machine which is due for a service. Make sure
any defects found during the regular maintenance checks
are rectified immediately.

! WARNING

Maintenance
Maintenance must be done by suitably qualified
personnel. Before attempting any maintenance work,
make sure the machine is safe. Park on level ground. If it
is necessary to work with the loader arms raised, then
the loader arm safety strut must be fitted as shown in
Loader Arm Safety Strut in MAINTENANCE section.

2-3-1-1

Pre-start Cold Checks Operation 10 50 †100 500 1000 2000
Service Points and Fluid Levels Hr Hr Hr Hr Hr Hr
ENGINE

Oil level - Check
Oil and Filter (AK and AR Build)  - Change
Oil and Filter (RE and RG Build)  - Change
Air Cleaner Outer Element  - Change
Air Cleaner Inner Element - Change
Fuel Filter (AK and AR Build) - Change
Fuel Filter (RE and RG Build) - Change
Fuel Filter - Drain
Lift Pump Strainer (AK and AR Build Only) - Clean
Coolant Quality/Level - Check
Fuel Sedimenter - Drain and Clean
Fan Belt Tension/Condition - Check
Valve Clearances and Clean Breather Gauze (if fitted)  - Check and Adjust
Engine Mounting Bolts for Tightness  - Check
Radiator - Clean
All Hoses - Condition - Check

Calendar equivalents:

10 Hours = Daily
50 Hours = Weekly

500 Hours = Six Months
1000 Hours = Yearly
2000 Hours = 2 Years

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TRANSMISSION, AXLES AND STEERING

Transmission Oil Level - Check
Transmission Oil  - Change
Transmission Filter - Change
Axle Oil Level (incl. Hubs when applicable)  - Check
Axle Oil (incl. Hubs when applicable)  - Change
Axle Oil - Limited Slip Differential - Change
Tyre Pressures/Condition - Check
Front Hub Bearings  - Check
Transmission Strainer - Clean
Drive Shafts - Security/Grease
Steer Axle Movement/Shimming  - Check
Steer Axle Pivots and Linkages  - Grease
Front Axle Main Pivot - Grease

HYDRAULICS

Oil Level  - Check
Oil  - Sample/Change
Oil Filter - Change
Rams - Chrome Condition - Check

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Issue 2*