JCB 540, 550, 535 Side Engine Loadalls Service Manual

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Page 1

Service Manual

Open front screen

Side Engine Loadalls

Section 1 - General Information

Section 2 - Care and Safety

Section 3 - Routine Maintenance

Section B - Body and Framework

Section M - Electronic Data Systems

Section C - Electrics

Section E - Hydraulics

Section F - Transmission

Section G - Brakes

Section H - Steering

Section K - Engine

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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

Publication No.

9803/3750-05

World Class

Customer Support

Page 2

Notes:

Section 0 - Service Manual

0-0 0-0

9803/3750-05

Page 3

Section 1

Open front screen

General Information

Service Manual - Side Engine Loadalls

Section 1

Section 2 - Care and Safety

Section 3 - Routine Maintenance

Section B - Body and Framework

Section M - Electronic Data Systems

- General Information

Section C - Electrics

Section E - Hydraulics

Section F - Transmission

Section G - Brakes

Section H - Steering

Section K - Engine

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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

Publication No.

9803/3750-05

World Class

Customer Support

Page 4

Notes:

Section 1 - General Information

1-0 1-0

9803/3750-05

Page 5

Section 1 - General Information

Page No.Contents

Applications

Introduction ...................................... ....................................................... 1-1-1

Tables ..................................................................................................... 1-1-2

Use

Introduction ...................................... ....................................................... 1-2-1

Scope ..................................................................................................... 1-2-2

Format .................................................................................................... 1-2-3

Left and Right Sides ............................................................................... 1-2-4

Hydraulic Schematic Codes ................ ................................................... 1-2-5

Electrical Device Codes .......................................................................... 1-2-6

Machine Identification

Introduction ...................................... ....................................................... 1-3-1

Related Topics ........................................................................................ 1-3-2

Machine Identification Plate .................................................................... 1-3-3

Component Identification Plates ............................................................. 1-3-5

Torque Settings

Introduction ...................................... ....................................................... 1-4-1

Zinc Plated Fasteners and Dacromet Fasteners .................................... 1-4-2

Hydraulic Connections ............................... ... .... ... ... ... .... ... ... ... ... .... ... ... ... 1-4-6

`Positional Type' Hydraulic Adaptors .................................................... 1-4-10

Service Tools

Introduction ...................................... ....................................................... 1-5-1

Numerical List ......................................................................................... 1-5-2

Tool Detail Reference ............................................................................. 1-5-5

Rivet Nuts ............................................................................................. 1-5-23

Slide Hammer Kit ....................................... ... .... ... ... ... .... ....................... 1-5-25

Service Consumables

Introduction ...................................... ....................................................... 1-6-1

Sealing and Retaining Compounds ........................................................ 1-6-2

Fuel

Introduction ...................................... ....................................................... 1-7-1

Related Topics ........................................................................................ 1-7-2

Acceptable and Unacceptable Fuels ...................................................... 1-7-3

Stall Speed Combinations

Introduction ...................................... ....................................................... 1-8-1

Related Topics ........................................................................................ 1-8-2

Specifications ......................................................................................... 1-8-3

1-i 1-i

Page 6

Section 1 - General Information

Page No.Contents

1-ii 1-ii

Page 7

Section 1-1 - General Information

Applications

Introduction

This manual contains topics that relate to some or all JCB Loadall machines in the 5A group. There are several machine model codes in the family.

Machine variants: There are different machine variants within the same model name. This happens because o f market requirements, or when the machine specification changes after a period of time. Information relating specifically to different variants of the same model is given in the applications tables and i n the Topics throughout the manual where applicable.

Use the applications tables to see which topics relate to which machine models and variants.

Important: The machine model names are NOT referred to in the topics. You must refer to the applications tables for the applicable machine models.

Tables ( T 1-1-2)

K Section 1 - General Information ( T 1-1-2) K Section 2 - Care and Safety ( T 1-1-3) K Section 3 - Routine Maintenance ( T 1-1-4) K Section B - Body and Framework ( T 1-1-5) K Section C - Electrics ( T 1-1-6)

K Section E - Hydraulics ( T 1-1-7) K Section F - Transmission ( T 1-1-8) K Section G - Brakes ( T 1-1-9) K Section H - Steering ( T 1-1-10) K Section K - Engine ( T 1-1-11) K Section M - Electronic Data Systems ( T 1-1-12)

Machine Group Model Code Model Name

5A F 540-170 5A G 550-140 5A L 540-140 5A M 550-170 5A N 535-125 Hi Viz 5A P 535-140 Hi Viz

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Section 1-1 - General Information

Tables

Section 1 - General Information

Machine models

Topic Ref

1-2 Use All Machines 1-3 Machine Identification All Machines 1-4 Torque Settings All Machines 1-5 Service Tools All Machines 1-6 Service Consumables All Machines 1-7 Fuel All Machines 1-8 Stall Speed Combinations All Machines

Title Variant 540-170

5AF

550-140

5AG

540-140

5AL

550-170

5AM

Applications

Tables

535-125

HiViz

5AN

535-140

HiViz

5AP

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Section 1-1 - General Information

Section 2 - Care and Safety

Machine models

Topic Ref

2-1 Safety Notices All Machines 2-2 General Procedures All Machines

Title Variant 540-170

5AF

550-140

5AG

540-140

5AL

550-170

5AM

Applications

Tables

535-125

HiViz

5AN

535-140

HiViz

5AP

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Section 1-1 - General Information

Section 3 - Routine Maintenance

Topic Ref

3-1 Introduction All Machines 3-2 Service Schedules - Machines

3-3 Service Schedules - Machines

3-4 Fluids, Lubricants and

3-5 Cleaning the Machines All Machines 3-6 Inspection All Machines 3-7 Seat Belts All Machines 3-8 ROPS/FOPS (and OECD)

3-9 Greasing All Machines 3-10 Heater and Air Conditioning All Machines 3-1 1 Brakes All Machines 3-12 Electrical System All Machines 3-13 Engine All Machines 3-14 Engine Air FIlter All Machines 3-15 Fuel System All Machines 3-16 Hydrauli c Sys t e m All Machines 3-17 Transmission All Machines 3-18 Tyres and Wheels All Machines

3-19 Wear Pads All Machines 3-20 Windscreen Washer All Machines 3-21 Access Panels All Machines 3-22 Fire Extingui sher All Machines

Title Variant 540-170

5AF

with SD and SF Engines

with SE Engines

Capacities

Structure

Mechanical F.I. engines

Electronic F.I. engines

z zzzzz

z zzz

550-140

5AG

Machine models 540-140

5AL

All Machines

550-170

5AM

Applications

Tables

535-125

HiViz

5AN

535-140

HiViz

5AP

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Section B - Body and Framework

Topic Ref

B1 Fork Carriage B2 Cab Heating and Ven tila tion

B3 Cab Air Conditioning SYSTEM B4 Load Moment Indicator (LMI)

B6 Cab B7 Air Conditioning Condensor -

B8 Air Conditioning Condensor -

B9 Cab HV and HVAC Unit B10 Air Conditioning Binary Switch B11 Heater Valve B12 Fuel T ank B13 Chassis Panels B14 Boom 3 Stage

B15 LMI Axl e Transducer

B16 Stabilisers

Title Variant 540-170

SYSTEM

Cooling Pack Mounted

Roof Mounted

4 Stage

Section 1-1 - General Information

Applications

Tables

Machine models

550-140

5AF

5AG

zzzzzz

zz zz

zzzzzz

540-140

5AL

550-170

5AM

535-125

HiViz

5AN

535-140

HiViz

5AP

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Section C - Electrics

Topic Ref

C1 Fuses and Relays C2 Schematics C3 Electrical Harness SYSTEM C4 Battery Charging SYSTEM C5 Alternator C6 Battery

Title Variant 540-170

Section 1-1 - General Information

Applications

Tables

Machine models

550-140

5AF

5AG

zzzzzz

540-140

5AL

550-170

5AM

535-125

HiViz

5AN

535-140

HiViz

5AP

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Section E - Hydraulics

Topic Ref

E1 Systems and Schematics E2 Parallel Hydraulic SYSTEM E3 Parallel Servo Hydraulic

E4 Hydraulic Interlock SYSTEM E5 Parallel Control Valve - 6

E6 Parallel Control Valve - 5

E7 Parallel Control Valve - 2

E8 Servo Control Va lv e s E9 Servo Solenoid Diverter Valve

E10 Stabiliser Isolation Valve E11 Sway/Fan Selector Valve E12 Main Pump 110 l/min

E13 Cooling Fan Motor

Title Variant 540-170

SYSTEM

Section

Block

E14 Extension Ram E15 Lift Rams E16 Tilt Ram E17 Displacement Ram E18 Sway Ram E19 Stabiliser Rams E20 Ram Maintenance

170 l/min

Section 1-1 - General Information

Applications

Tables

Machine models

550-140

5AF

5AG

zzzzzz

zz zz

January

2009 From

January

2009

zzzzzz

zz zz

zzzzzz

540-140

5AL

550-170

5AM

January

2009 From

January

2009

535-125

HiViz

5AN

535-140

HiViz

5AP

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Section F - Transmission

Topic Ref

F1 CONFIGURATION F2 Wheels and Tyres F3 Front Axles SD80 Pivot

F4 Rear Axles SD80 Pivot

F5 PS750 Gearbox SYSTEM F6 PS750 Mk IV Gearbox

F7 PS764 Gearbox SYSTEM F8 PS750 Gearbox F9 PS750 Mk IV Gearbox F10 PS760 Gearbox F11 Bevel Gearbox F12 Torque Converter F13 Transmission Oil Cooler -

F14 Transmission Oil Cooler -

F15 Propshafts F16 Speed Sensors F17 Speedometer

Title Variant 540-170

SYSTEM

Air Blast

Liquid to Liquid

sway SD80 Trunnion

sway

sway SD80 Trunnion

sway

Intercooled engines

Non intercooled engines

Section 1-1 - General Information

Applications

Tables

Machine models

550-140

5AF

5AG

zzzzzz

zzzz

zzzzzz

zzzz

zzzzzz

zzzz

zzzzzz

540-140

5AL

550-170

5AM

535-125

HiViz

5AN

535-140

HiViz

5AP

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Section G - Brakes

Topic Ref

G1 Twin Axle Service Brakes SYSTEM

G2 Twin Axle Service Brakes SYSTEM

G3 External Park Brake SYSTEM PS750

G4 Internal Park Brake SYSTEM PS760

G5 Park Brake Calliper PS750

G6 Park Brake Disc PS750

G7 Park Brake Switch G8 Servo Exhauster Unit G9 Servo Unit - Twin Axle Brakes G10 Master Cylinder G11 Fluid Reservoir

Title Variant 540-170

(S1)

(S2)

gearbox

Section 1-1 - General Information

Applications

Tables

Machine models

550-140

5AF

5AG

zzzz

zzzzzz

zzzz

zzzzzz

540-140

5AL

550-170

5AM

535-125

HiViz

5AN

535-140

HiViz

5AP

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Section H - Steering

Topic Ref

H1 Steering SYSTEM H2 Manual Steer Mode SYSTEM H3 Auto Steer Mode SYSTEM H4 Hydraulic Steering Unit H5 Priority Valve H6 Power Track Rods H7 Steer Ram s H8 Steering Column H9 Manual Steer Mode Valve H10 Auto Steer Mode Valve

Title Variant 540-170

Section 1-1 - General Information

Applications

Tables

Machine models

550-140

5AF

5AG

zzzzzz

zzzz

zzzzzz

540-140

5AL

550-170

5AM

535-125

HiViz

5AN

535-140

HiViz

5AP

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Section K - Engine

Topic Ref

K1 Stop and Start SYSTEM

K2 Stop and Start SYSTEM

K3 Cold Start Heater SYSTEM Mechani

K4 Starter Motor K5 Cooling Pack - (Non Intercooled) K6 Cooling Pack - (Intercooled

K7 Cooling Pack - (Electronic F .I.

K8 Coolant Expansion Tank K9 Air Filter Vacuum Switch K10 Throttle Pedal and Cable K11 Throttle Position Sensor (TPS) K12 Exhaust Silencer K13 JCB Dieselmax (Mechanical F .I.

K14 JCB Dieselmax (Electronic F.I.

Title Variant 540-170

(Mechanical F.I. Engines)

(Electronic F.I. Engines)

Mechanical F.I. Engines)

Engines)

cal F.I. Engines

Section 1-1 - General Information

Applications

Tables

Machine models

550-140

5AF

5AG

zzzzzz

zzzz

zzzzzz

zzzz

zzzzzz

zzzz

zzzzzz

zzzz

540-140

5AL

550-170

5AM

535-125

HiViz

5AN

535-140

HiViz

5AP

zzz

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Section M - Electronic Data Systems

Topic

Title Variant 540-170

Ref

M1 CANbus SYSTEM M2 Loadall Monitoring SYSTEM M3 Fault Code SYSTEM M4 Servicemaster SYSTEM M5 Servicemaster Tools M6 Electronic Control Unit Theory M7 Pulse Width Modulation Theory

Section 1-1 - General Information

Applications

Tables

Machine models

550-140

5AF

5AG

zzzzzz

540-140

5AL

550-170

5AM

535-125

HiViz

5AN

535-140

HiViz

5AP

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Section 1-2 - General Information

Use

Introduction

This topic contains information about the structure of the manual and how to use the manual.

Scope ( T 1-2-2)

K Personnel ( T 1-2-2) K Applications ( T 1-2-2)

K Newest Data ( T 1-2-2) K Format ( T 1-2-3) K Left and Right Sides ( T 1-2-4) K Hydraulic Schematic Codes ( T 1-2-5)

K Colour Codes ( T 1-2-5) K Electrical Device Codes ( T 1-2-6)

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Scope

Personnel

This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department.

These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Finally, please

remember above all else SAFETY MUST COME FIRST!

Applications

This manual contains data relevant to a range of machines. Make sure you reference the data for the correct machine. K

Applications ( T 1-1-1)

Section 1-2 - General Information

Use

Scope

Newest Data

From time to time new machines, systems or devices require the manual to be re-issued. Make sure you have the newest issue.

Always check the on-line JCB data system for relevant technical information.

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Format

The manual is compiled in sections, the first three are numbered and contain information as follows:

1 General Information - Use the Applications Tables

at the front of the section to see which topic in the manual is applicable to which machine model. The section also includes general information such as torque settings and service tools.

2 Care & Safety - includes warnings, cautions and

general procedures related to aspects of workshop procedures contained in the manual.

3 Routine Maintenanc e - 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:

Section 1-2 - General Information

Use

Format

AAttachments B Body and Framework...etc.

The sections contain topics. Each topic is a self contained set of data about a machine SYSTEM or Device.

Some topics are only applicable to some machine models. Use the Applications Tables in this section to see which topic is applicable to which machine model.

Each topic contains data such as specifications, descriptions, fault finding and test procedures. Device topics also contain removal, replacement, dismantle and

assemble procedures. Some topics contain procedures and specifications for

different variants. This happens because of market requirements, or when the machine specification changes after a period of time. Where applicable, a table in the introduction of each topic contains information to help you identify the correct specifications or procedures.

Each topic also contains a Related Topics table. This table lists all the topics that contain related data. For example a hydraulic SYSTEM contains devices such as valves and pumps. These devices have their own topics and they are listed in the SYSTEM related topics table.

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Left and Right Sides

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

Section 1-2 - General Information

Use

Left and Right Sides

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Hydraulic Schematic Codes

Colour Codes

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

Section 1-2 - General Information

Use

Hydraulic Schematic Codes

Red

Pink Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red.

Orange Pilot: Oil pressure used in controlling a device (Pilot).

Blue Neural: Neutral circuit pressure.

Green Exhaust:

Light Green Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).

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

Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure.

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Electrical Device Codes

This manual uses a code system to help you identify the electrical devices on the machine.

When the electrical system is designed at the factory codes are given to the electrical connectors on the electrical harnesses. The system allows the same code to be used for different connectors.

For this reason a different system is used in this manual. Each main category of devices is given a code type:

Code Type Category

-000 Earth points +000 Power (from battery or alternator) 1000 Switches 2000 Relays 3000 Valves/Coils 4000 ECU’s 5000 Sensors 6000 Indicators/Lamps 7000 Other devices 8000 Harness Interconnections 9000 Fuses

Section 1-2 - General Information

Use

Electrical Device Codes

Each device is given one code and the code is used throughout the manual. The same code is given to both the device and its electrical connector.

Important: The electrical schematics and the harness drawings in Section C are reproduced from the factory drawings. For this reason they retain the factory connector codes.

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Section 1-3 - General Information

Machine Identification

Introduction

This topic contains information about a machine identifica tion. On the machine and on the machine devices there are identification data plates.

K Related Topics ( T 1-3-2) K Machine Identification Plate ( T 1-3-3)

K Typical Product Identification Number (PIN) ( T 1-3-3) K Component Identification Plates ( T 1-3-5)

K Typical Engine Identification Number ( T 1-3-5)

K Transmission Identification Numbers ( T 1-3-6)

K ROPS/FOPS and OECD Certification Plates ( T 1-3-7)

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Section 1-3 - General Information

Machine Identification

Related Topics

Table 1. Related Topics in This Publication

The table lists other topics in the manual that contain information related to this topic. Refer to the applicable topics to complete your procedures. Where applicable the text in this section contains cross references to this page to help you find the correct information. Some machines have different systems and devices. Make sure you refer to the correct topic, refer to Section 1 - Applications.

Sections Topic Titles Sub Titles

1 K

Applications ( T 1-1-1) ALL

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Section 1-3 - General Information

Machine Identification Plate

Machine Identification

Machine Identification Plate

The machine has an identification plate mounted as shown. K Fig 1. ( T 1-3-3). The serial numbers of the machine and its major units are stamped on the plate.

Note: The machine model and build specification is indicated by the PIN.

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

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

Typical Product Identification Number (PIN)

Machines Built Before January 2010

T011100

1 World Manufacturer Identification (3 Digits) 2 Machine Model (3 Digits)

Standard Builds: 5AF = 540-170 5AM = 550-170 5AG = 550-140 5AN = 535-125 HiViz 5AL = 540-140 5AP = 535-140 HiViz 5AM = 550-170

3 Engine Ty pe (1 Di g i t)

JCB Dieselmax (Tier 3): R = Turbocharged and after-cooled, 97kW (130Hp) S = Turbocharged and after-cooled, 74.2kW

(100Hp) T = Turbocharged, 63kW (85Hp)

Fig 1.

4 Gearbox Model (1 Digit)

E = 3 Speed (PS750) G = 4 Speed (PS750) F = 3 Speed (PS760) H = 4 Speed (PS760)

420811

5 Randomly generated check letter (1 Digit) 6 Year of Manufacture (1 Digit)

7 = 2007 A = 2010 8 = 2008 B = 2011 9 = 2009 C = 2012

7 Machine Serial Number (7 Digits)

Each machine has a unique serial number.

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Machines Built After January 2010

1 World Manufacturer Identification (3 Digits) 2 Machine Model (3 Digits)

Standard Builds: 5AF = 540-170 5AM = 550-170 5AG = 550-140 5AN = 535-125 HiViz 5AL = 540-140 5AP = 535-140 HiViz 5AM = 550-170

3 Engine Type (1 Digit)

Section 1-3 - General Information

Machine Identification

Machine Identification Plate

T011100-C1

JCB Dieselmax (Tier 3): R = Turbocharged and after-cooled, 97kW (130Hp) S = Turbocharged and after-cooled, 74.2kW

(100Hp) T = Turbocharged, 63kW (85Hp)

4 Gearbox Model (1 Digit)

E = 3 Speed (PS750) G = 4 Speed (PS750) F = 3 Speed (PS760) H = 4 Speed (PS760)

5 Randomly generated check letter (1 Digit)

6 Machine Serial Number (8 Digits)

Each machine has a unique serial number.

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Component Identification Plates

Typical Engine Identification Number

Engine data labels 2A are located on the cylinder block at position 2C and ro cker cover 2D (if fitted). The data label contains important engine information and includes the engine identification number 2E.

A typical engine identification number is explained as follows:

Section 1-3 - General Information

Machine Identification

Component Identification Plates

SD 320/40001 U 00001 04

1 2 345

1 Engine Type

SD = turbocharged SE = electronic common rail fuel injection,

turbocharged and intercooled. SF = turbocharged and intercooled.

2 Engine part number 3 Country of manufacture

U = United Kingdom

4 Engine Serial Number 5 Year of Manufacture

The last three parts of the engine identification number are stamped on the cylinder block at position 2B.

U 00001 04

Fig 2. Engine

C007280-C2

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Transmission Identification Numbers

The transmission components have a serial number stamped on a data plate A as shown.

Section 1-3 - General Information

Machine Identification

Component Identification Plates

Fig 3. Front Axle

Fig 4. Rear Axle

Fig 5. PS750 Powershift Transmission

263370-C1

A710840-C1

A401030-C2

Fig 6. PS760 Powershift Transmission

A710830-C1

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ROPS/FOPS and OECD Certification Plates

Section 1-3 - General Information

Machine Identification

Component Identification Plates

Machines built to ROPS/FOPS standards have an identification label A fitted to the inside of the cab. Machines built to ROPS/FOPS and OECD standards have identification label B fitted to the inside of the cab.

Fig 7.

445911-5

Definition of terms:

ROPS Roll Over Protection Structure FOPS Falling Objects Protection Structure OECD Organisation for Economic Co-operation and

Development.

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Section 1-3 - General Information

Page left intentionally blank

Machine Identification

Component Identification Plates

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Section 1-4 - General Information

Torque Settings

Introduction

This topic contains information about torques. Torque values are given for types and sizes of bolts and hydraulic connectors and adapters.

Where a torque is given as a single figure it ma y be varied by plus or mi nus 3%. Torque figures are given for fasteners with different surface treatments. Make sure you use the correct torque figures.

Where torques are given in topics within the other sections always use these values.

Zinc Plated Fasteners and Dacromet Fasteners ( T 1-4-2)

K Introduction ( T 1-4-2)

K Bolts and Screws ( T 1-4-2) K Hydraulic Connections ( T 1-4-6)

K 'O' Ring Face Seal System ( T 1-4-6)

K 'Torque Stop' Hose System ( T 1-4-9) K `Positional Type' Hydraulic Adaptors ( T 1-4-10)

K Fitting Procedure ( T 1-4-10)

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Section 1-4 - General Information

Zinc Plated Fasteners and Dacromet Fasteners

T11-002

Torque Settings

Introduction

Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.

The two types of fasteners can be readily identified by colour and part number suffix. K

( T 1-4-2).

Table 1. Fastener T y pes Fastener Type

Zinc and Yellow

Dacromet Mottled silver finish 'D' (e.g. 1315/3712D)

Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener.

Note: A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt.

Colour Part No. Suffix

Golden finish 'Z' (e.g. 1315/3712Z)

Table 1. Fastener T ypes

Bolts and Screws

Use the following torque setting tables only where no torque setting is specified in the text.

Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate.

Torque settings are given for the following conditions:

Condition 1

– Un-lubricated fasteners – Zinc fasteners – Yellow plated fasteners

Condition 2

– Zinc flake (Dacromet) fasteners – Lubricated zinc and yellow plated fasteners – Where there is a natural lubrication. For example,

cast iron components

Verbus Ripp Bolts

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

Note: Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.

Fig 1.

Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

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Page 35

Bolt Size Hexagon (A/F) Condition 1 Condition 2

in. mm in. Nm kgf m lbf ft Nm kgf m lbf ft

1/4 6.3 7/16 11.2 1.1 8.3 10.0 1.0 7.4

5/16 7.9 1/2 22.3 2.3 16.4 20.0 2.0 14.7

3/8 9.5 9/16 40.0 4.1 29.5 36.0 3.7 26.5

7/16 11.1 5/8 64.0 6.5 47.2 57.0 5.8 42.0

1/2 12.7 3/4 98.00 10.0 72.3 88.0 9.0 64.9

9/16 14.3 13/16 140.0 14.3 103.2 126.0 12.8 92.9

5/8 15.9 15/16 196.0 20.0 144.6 177.0 18.0 130.5 3/4 19.0 1 1/8 343.0 35.0 253.0 309.0 31.5 227.9 7/8 22.2 1 15/16 547.0 55.8 403.4 492.0 50.2 362.9

1 25.4 1 1/2 814.0 83.0 600.4 732.0 74.6 539.9 1 1/8 31.7 1 7/8 1181.0 120.4 871.1 1063.0 108.4 784.0 1 1/4 38.1 2 1/4 1646.0 167.8 1214.0 1481.0 151.0 1092.3

Bolt Size Hexagon (A/F) Condition 1 Condition 2

ISO Metric

Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft

M5 5 8 5.8 0.6 4.3 5.2 0.5 3.8 M6 6 10 9.9 1.0 7.3 9.0 0.9 6.6

M8 8 13 24.0 2.4 17.7 22.0 2.2 16.2 M10 10 17 47.0 4.8 34.7 43.0 4.4 31.7 M12 12 19 83.0 8.5 61.2 74.0 7.5 54.6 M16 16 24 205.0 20.9 151.2 184.0 18.8 135.7 M20 20 30 400.0 40.8 295.0 360.0 36.7 265.5

M24 24 36 690.0 70.4 508.9 621.0 63.3 458.0 M30 30 46 1372.0 139.9 1011.9 1235.0 125.9 910.9 M36 36 55 2399.0 244.6 1769.4 2159.0 220.0 1592.4

Section 1-4 - General Information

Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

T able 2. Torque Settings - UNF Grade 'S' Fasteners

Table 3. Torque Settings - Metric Grade 8.8 Fasteners

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Bolt Size Hexagon (A/F) Condition 1 Condition 2

ISO Metric

Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft

M5 5 8 8.1 0.8 6.0 7.3 0.7 5.4

M6 6 10 13.9 1.4 10.2 12.5 1.3 9.2

M8 8 13 34.0 3.5 25.0 30.0 3.0 22.1 M10 10 17 67.0 6.8 49.4 60.0 6.1 44.2 M12 12 19 116.0 11.8 85.5 104.0 10.6 76.7 M16 16 24 288.0 29.4 212.4 259.0 26.4 191.0 M20 20 30 562.0 57.3 414.5 506.0 51.6 373.2 M24 24 36 971.0 99.0 716.9 874.0 89.1 644.6 M30 30 46 1930.0 196.8 1423.5 1737.0 177.1 1281.1 M36 36 55 3374.0 344.0 2488.5 3036.0 309.6 2239.2

Bolt Size Hexagon (A/F) Condition 1 Condition 2

ISO Metric

Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft

M5 5 8 9.8 1.0 7.2 8.8 0.9 6.5

M6 6 10 16.6 1.7 12.2 15.0 1.5 11.1

M8 8 13 40.0 4.1 29.5 36.0 3.7 26.5 M10 10 17 80.0 8.1 59.0 72.0 7.3 53.1 M12 12 19 139.0 14.2 102.5 125.0 12.7 92.2 M16 16 24 345.0 35.2 254.4 311.0 31.7 229.4 M20 20 30 674.0 68.7 497.1 607.0 61.9 447.7 M24 24 36 1165.0 118.8 859.2 1048.0 106.9 773.0 M30 30 46 2316.0 236.2 1708.2 2084.0 212.5 1537.1

M36 36 55 4049.0 412.9 2986.4 3644.0 371.6 2687.7

Section 1-4 - General Information

Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

Table 4. Metric Grade 10.9 Fasteners

Table 5. Metric Grade 12.9 Fasteners

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Page 37

Section 1-4 - General Information

Zinc Plated Fasteners and Dacromet Fasteners

Table 6. Torque Settings - Rivet Nut Bolts/Screws

Bolt Size

ISO Metric

Thread mm

M3 3 1.2 0.1 0.9 M4 4 3.0 0.3 2.0 M5 5 6.0 0.6 4.5 M6 6 10.0 1.0 7.5

M8 8 24.0 2.5 18.0 M10 10 48.0 4.9 35.5 M12 12 82.0 8.4 60.5

Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc)

Bolt Size

ISO Metric

Thread

M3 2.0 0.2 1.5 M4 6.0 0.6 4.5 M5 11.0 1.1 8.0 M6 19.0 1.9 14.0

M8 46.0 4.7 34.0 M10 91.0 9.3 67.0 M12 159.0 16.2 117.0 M16 395.0 40.0 292.0 M18 550.0 56.0 406.0 M20 770.0 79.0 568.0 M24 1332.0 136.0 983.0

Nm kgf m lbf ft

Torque Settings

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Hydraulic Connections

'O' Ring Face Seal System

Adaptors Screwed into Valve Blocks

Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.

Table 8. Torque Settings - BSP Adaptors

BSP Adaptor

Size

1/4 19.0 18.0 1.8 13.0 3/8 22.0 31.0 3.2 23.0 1/2 27.0 49.0 5.0 36.0 5/8 30.0 60.0 6.1 44.0 3/4 32.0 81.0 8.2 60.0

1 38.0 129.0 13.1 95.0

1 1/4 50.0 206.0 21.0 152.0

Hexagon (A/F)

Section 1-4 - General Information

Torque Settings

Hydraulic Connections

T11-003

Nm kgf m lbf ftin. mm

SAE Tube

Size

4 7/16 - 20 15.9 20.0 - 28.0 2.0 - 2.8 16.5 - 18.5 6 9/16 - 18 19.1 46.0 - 54.0 4.7 - 5.5 34.0 - 40.0 8 3/4 - 16 22.2 95.0 - 105.0 9.7 - 10.7 69.0 - 77.0

10 7/8 - 14 27.0 130.0 - 140.0 13.2 - 14.3 96.0 - 104.0

12 1 1/16 - 12 31.8 190.0 - 210.0 19.4 - 21.4 141.0 - 155.0 16 1 5/16 - 12 38.1 290.0 - 310.0 29.6 - 31.6 216.0 - 230.0 20 1 5/8 47.6 280.0 - 380.0 28.5 - 38.7 210.0 - 280.0

SAE Port

Thread Size

Table 9. Torque Settings - SAE Connections

Hexagon (A/F)

Nm kgf m lbf ftmm

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Page 39

Hoses Screwed into Adaptors

Section 1-4 - General Information

Torque Settings

Hydraulic Connections

Fig 2.

Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring 2-C which is compressed into a 45° seat machined into the

face of the adaptor port.

Table 10. BSP Hose - Torque Settings

BSP Hose Size Hexagon (A/F)

1/8 14.0 14.0 - 16.00 1.4 - 1.6 10.3 - 11.8 1/4 19.0 24.0 - 27.0 2.4 - 2.7 17.7 - 19.9 3/8 22.0 33.0 - 40.0 3.4 - 4.1 24.3 - 29.5 1/2 27.0 44.0 - 50.0 4.5 - 5.1 32.4 - 36.9 5/8 30.0 58.0 - 65.0 5.9 - 6.6 42.8 - 47.9

3/4 32.0 84.0 - 92.0 8.6 - 9.4 61.9 - 67.8

1 38.0 115.0 - 126.0 11.7 - 12.8 84.8 - 92.9 1 1/4 50.0 189.0 - 200.0 19.3 - 20.4 139.4 - 14 7.5 1 1/2 55.0 244.0 - 260.0 24.9 - 26.5 180.0 - 19 1.8

Note: Dimension 2-D will vary depending upon the torque applied.

Nm kgf m lbf ftin. mm

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Page 40

Section 1-4 - General Information

Adaptors into Component Connections with Bonded Washers

Table 11. BSP Adaptors with Bonded W a sh er s - Torque Settings

BSP Size

Nm kgf m lbf ftin.

1/8 20.0 2.1 15.0 1/4 34.0 3.4 25.0 3/8 75.0 7.6 55.0 1/2 102.0 10.3 75.0 5/8 122.0 12.4 90.0 3/4 183.0 18.7 135.0

1 203.0 20.7 150.0 1 1/4 305.0 31.0 225.0 1 1/2 305.0 31.0 225.0

Torque Settings

Hydraulic Connections

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Page 41

'Torque Stop' Hose System

Section 1-4 - General Information

Torque Settings

Hydraulic Connections

Fig 3.

`Torque Stop' Hoses 3-B screwed into adaptors 3-A seal onto an 'O' ring 3-C which is compressed into a 45° seat machined in the face of the adaptor port. To prevent the 'O' ring being damages as a result of over tightening, 'Torque

Table 12. BSP `Torque Stop' Hose - Torque Settings

BSP Hose Size Hexagon (A/F)

1/8 14.0 14.0 1.4 10.0 1/4 19.0 27.0 2.7 20.0 3/8 22.0 40.0 4.1 30.0 1/2 27.0 55.0 5.6 40.0 5/8 30.0 65.0 6.6 48.0

3/4 32.0 95.0 9.7 70.0

1 38.0 120.0 12.2 89.0 1 1/4 50.0 189.0 19.3 140.0 1 1/2 55.0 244.0 24.9 180.0

Stop' Hoses have an additional shoulder 3-D, which acts as a physical stop.

Note: Minimum dimension 3-E fixed by shoulder 3-D.

Nm kgf m lbf ftin. mm

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`Positional Type' Hydraulic Adaptors

Fitting Procedure

On a typical machine, some hydraulic components may utilise `Positional Type' SAE Hydraulic Adaptors. When fitting `Positional Type' Hydraulic Adaptors it is important to adopt the following procedure. If this procedure is not followed correctly, damage to the `O' ring seal 4-A can occur resulting in oil leaks.

1 Ensure the locknut 4-B is screwed back onto the body

of the adaptor as far as possible as shown.

2 Check the `O' ring backing washer 4-C is a tight fit on

the adaptor. Note that the washer should not move freely, if the washer is slack do not use the adaptor.

3 Check the `O' ring 4-A is fitted and that it is free from

damage or nicks. Before fitting the adaptor, smear the `O' ring with clean hydraulic fluid.

Section 1-4 - General Information

Torque Settings

`Positional Type' Hydraulic Adaptors

Fig 4.

Note: The dimensions and shore hardness of the `O' ring is critical. Should it become necessary to replace the `O' ring, ensure that only JCB Genuine Parts are used.

4 Screw the adaptor into the port of the hydraulic

component as far as possible, so that ALL the threads engage and the `O' ring is correctly seated against the sealing face.

5 Set the angular position of the adaptor as required,

then secure by tightening the locknut 4-B.

Note: When fitted correctly no more than one thread

should be visible at 5-Z as shown.

6 Torque tighten the locknut to 81 Nm (60 lbf ft).

Fig 5.

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Section 1-5 - General Information

Service Tools

Introduction

The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools are available from JCB Service or, in some instances, can be manufactured locally from the specifications given in this section.

Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.

Numerical List ( T 1-5-2)

K K Tool Detail Reference ( T 1-5-5) K Rivet Nuts ( T 1-5-23) K Slide Hammer Kit ( T 1-5-25)

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Page 44

Numerical List

Some tools are supplied as kits or sets. Cross references are given to tables showing the kit contents.

Section 1-5 - General Information

Service Tools

Numerical List

Part Number:

- Bonded Washers - see tool detail reference for content K

- Electrical Repair Kit - see tool detail reference for content K Fig 23. ( T 1-5-10)

- Female Cone Blanking Plugs - see tool detail reference for content K Fig 36. ( T 1-5-15)

- Female Connectors - see tool detail reference for content K Fig 38. ( T 1-5-15)

- Hydraulic Hand Pump Equipment - see tool detail reference for content K Fig 42. ( T 1-5-16)

- Male Adaptors BSP x BSP - see tool detail reference for content K Fig 32. ( T 1-5-14)

- Male Cone Blanking Caps - see tool detail reference for content K Fig 37. ( T 1-5-15)

- Pressure Test Point `T' Adaptors - see tool detail reference for content K Fig 34. ( T 1-5-14)

- Pressure Test Point Adaptors - see tool detail reference for content K Fig 33. ( T 1-5-14)

- Rivet Nut Tool - see tool detail reference for content K Fig 1. ( T 1-5-5) 320/20050 Engine Lifting Bracket Kit K Fig 63. ( T 1-5-22) 332/E7911 Exhaust fitting clamp K Fig 61. ( T 1-5-21) 4104/1310 Hand Cleaner K Fig 15. ( T 1-5-8) 460/15708 Flow Test Adaptor (Powershift) - Other components required, see tool detail K Fig 46. ( T 1-5-17) 718/20235 USB PC Cable K Fig 64. ( T 1-5-22) 718/20236 Serial PC Cable K Fig 64. ( T 1-5-22) 718/20237 Machine Cable K Fig 64. ( T 1-5-22) 728/26500 USB DLA K Fig 64. ( T 1-5-22) 892/00011 Spool Clamp K Fig 49. ( T 1-5-18)

892/00167 Ram Protection Sleeve for 90 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/00180 Seal Fitting Tool - Hydraulic Steer Unit K Fig 50. ( T 1-5-18) 892/00229 Flow Meter K Fig 44. ( T 1-5-16) 892/00253 Hydraulic Pressure Test Kit - see tool detail reference for content K Fig 29. ( T 1-5-13) 892/00268 Flow Monitoring Unit - Other components required, see tool detail K Fig 27. ( T 1-5-12) 892/00334 Ram Seal Fitting Tool K Fig 54. ( T 1-5-20) 892/00349 Crimp Tool K Fig 25. ( T 1-5-11) 892/00350 Butane Heater Assembly K Fig 24. ( T 1-5-10) 892/00351 Splice 0.5-1.5 mm (Red) K Fig 26. ( T 1-5-11) 892/00352 Splice 1.5-2.5 mm (Blue) K Fig 26. ( T 1-5-11) 892/00353 Splice 3.0 - 6. 0 mm (Yellow) K Fig 26. ( T 1-5-11) 892/00812 Drive Coupling Spanner K Fig 59. ( T 1-5-21)

Description: T ool Detail Reference:

Fig 39. ( T 1-5-15)

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Section 1-5 - General Information

Service Tools

Numerical List

Part Number:

892/00822 Splined Bolt Socket K Fig 58. ( T 1-5-21) 892/00842 Glass Lifter K Fig 3. ( T 1-5-6) 892/00843 Folding Stand for Holding Glass K Fig 4. ( T 1-5-6) 892/00844 Long Knife K Fig 17. ( T 1-5-8) 892/00845 Cartridge Gun K Fig 5. ( T 1-5-6) 892/00846 Glass Extractor (Handles) K Fig 6. ( T 1-5-6) 892/00847 Nylon Spatula K Fig 7. ( T 1-5-6) 892/00848 Wire Starter K Fig 8. ( T 1-5-6) 892/00849 Braided Cutting Wi re K Fig 9. ( T 1-5-7) 892/00881 Valve Spool Seal Fitting Tool K Fig 43. ( T 1-5-16) 892/00893 Torque Converter Alignment Tool K Fig 60. ( T 1-5-21) 892/00905 LMI Test Box K Fig 21. ( T 1-5-9) 892/00948 Nitrogen Charging Kit (without gauge) K Fig 48. ( T 1-5-17) 892/00949 Gauge K Fig 48. ( T 1-5-17) 892/00964 Te st Point 1/8 BSP (Powershift) K Fig 40. ( T 1-5-16) 892/00965 Te st Point 3/8 BSP (Powershift) K Fig 41. ( T 1-5-16) 892/01016 Ram Protection Sleeve for 25 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01017 Ram Protection Sleeve for 30 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01018 Ram Protection Sleeve for 40 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01019 Ram Protection Sleeve for 50 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01020 Ram Protection Sleeve for 50 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01021 Ram Protection Sleeve for 60 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01022 Ram Protection Sleeve for 60 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01023 Ram Protection Sleeve for 65 mm Rod Diameter K Fig 53. ( T 1-5-20)

892/01024 Ram Protection Sleeve for 70 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01025 Ram Protection Sleeve for 75 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01026 Ram Protection Sleeve for 80 mm Rod Diameter K Fig 53. ( T 1-5-20) 892/01027 Piston Seal Assembly Tool K Fig 56. ( T 1-5-20) 892/01174 Data Link Adaptor Kit K Fig 64. ( T 1-5-22) 892/01268 Digital Pressure Gauge 0-400 bar K Fig 45. ( T 1-5-16) 892/01271 Hose for Digital Pressure Gauge 892/01268 K Fig 45. ( T 1-5-16) 926/15500 Rubber Spacer Blocks K Fig 10. ( T 1-5-7) 992/01100 Glazing Tool K Fig 16. ( T 1-5-8) 992/04000 Torque Multiplier K Fig 57. ( T 1-5-21) 992/04800 Flange spanner K Fig 62. ( T 1-5-21) 992/09100 Spool Clamp K Fig 49. ( T 1-5-18) 992/09300 Hexagon Spanner 55 mm A/F K Fig 55. ( T 1-5-20)

Description: T ool Detail Reference:

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Page 46

Section 1-5 - General Information

Service Tools

Numerical List

Part Number:

992/09400 Hexagon Spanner 65 mm A/F K Fig 55. ( T 1-5-20) 992/09500 Hexagon Spanner 75 mm A/F K Fig 55. ( T 1-5-20) 992/09600 Hexagon Spanner 85 mm A/F K Fig 55. ( T 1-5-20) 992/09700 Hexagon Spanner 95 mm A/F K Fig 55. ( T 1-5-20) 992/09900 Hexagon Spanner 115 mm A/F K Fig 55. ( T 1-5-20) 992/10000 Hexagon Spanner 125 mm A/F K Fig 55. ( T 1-5-20) 992/12300 12V Mobile Oven K Fig 11. ( T 1-5-7) 992/12400 24V Static Oven (2 Cartridge) K Fig 12. ( T 1-5-7) 992/12800 Cut-Out Knife K Fig 13. ( T 1-5-7) 992/12801 `L' Blades K Fig 14. ( T 1-5-7) 993/68100 Slide Hammer Kit - see tool detail reference for content K Fig 2. ( T 1-5-5) 993/85700 Battery Tester K Fig 22. ( T 1-5-9)

Description: T ool Detail Reference:

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Page 47

Fig 1. Rivet Nut Tool

Section 1-5 - General Information

Service Tools

Tool Detail Reference

1 826/01099 M6 x 16 mm Rivet Nut

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

2 - Installation Tool available from: Bollhoff

Fastenings Ltd (www.bollhof.com)

1 993/68101 Slide Hammer 7 993/68107 Bar - M20 x M20 X 800 mm 2 993/68102 End Stops 8 993/68108 Adaptor - M20 x 7/8" UNF 3 993/68103 Adaptor - M20 x 5/8" UNF 9 993/68109 Adaptor - M20 x M12 4 993/68104 Adaptor - M20 x 1" UNF 10 993/68110 Adaptor - M20 x 5/8" UNF (Shoulder) 5 993/68105 Adaptor - M20 x M20 11 993/68111 Adaptor - M20 x 1/2" UNF 6 993/68106 Adaptor - M20 x M24

Fig 2. 993/68100 Slide Hammer Kit

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Page 48

Fig 3. 892/00842 Glass Lifter

Minimum 2 off - Essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.

Section 1-5 - General Information

Service Tools

Tool Detail Reference

Fig 6. 892/00846 Glass Extractor (Handles)

Used with braided cutting wire to cut out broken glass.

Fig 9. ( T 1-5-7).

Fig 4. 892/00843 Folding Stand

Essential for preparing new glass prior to installation.

Fig 5. 892/00845 Cartridge Gun

Hand operated. Essential for the application of sealants, polyurethane materials etc.

Fig 7. 892/00847 Nylon Spatula

General tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge.

Fig 8. 892/00848 Wire Starter

Used to access braided cutting wire through original polyurethane seal. K

Fig 9. ( T 1-5-7).

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Page 49

Section 1-5 - General Information

Service Tools

Tool Detail Reference

Fig 9. 892/00849 Braided Cutting Wire

Consumable heavy duty cut-out wire used with the glass extraction tool. K

Fig 10. 926/15500 Rubber Spacer Blocks

Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.

Fig 6. ( T 1-5-6). Approx 25 m length.

Fig 12. 992/12400 Static Oven 240V

Required to pre-heat adhesive prior to use. No plug supplied.

Note: 110V models available upon request - contact JCB Technical Service.

Fig 13. 992/12800 Cut-Out Knife

Used to remove broken glass.

Fig 11. 992/12300 Mobile Oven 12V

1 cartridge capacity. Required to pre-heat adhesive prior to use. It is fitted with a male plug (703/23201) which fits into a female socket (715/04300).

Fig 14. 992/12801 'L' Blades

25 mm (1 in.) cut. Replacement blades for cut-out knife.

Fig 13. ( T 1-5-7). Unit quantity = 5 off.

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Fig 15. 4104/1310 Hand Cleaner

Special blend for the removal of polyurethane adhesives (454g; 1 lb tub).

Section 1-5 - General Information

Service Tools

Tool Detail Reference

Fig 18. 892/00298 Fluke Meter

Fig 16. 992/01100

Glazing T ool, used to insert aperture seal expansion strip.

Fig 17. 892/00844 Long Knife

Used to give extended reach for normally inaccessible areas.

Fig 19. 892/00285 Hydraulic Temperature Probe

Fig 20. 892/00284 Venture Microtach Digital

Tachometer

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Page 51

Fig 21. 892/00905 LMI Test Box

For testing load moment indicator system

Section 1-5 - General Information

Service Tools

Tool Detail Reference

Fig 22. 993/85700 Battery Tester

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Page 52

Electrical Repair Kit ( T 1-5-10)

1 Electrical Repair Kit 2A 7212/0002 2 Way Pin Housing 2B 7212/0004 2 Way Pin Retainer 2C 7212/0003 2 Way Socket Retainer 2D 7212/0001 2 Way Socket Connector 3A 7213/0002 3 Way Pin Housing 3B 7213/0004 3 Way Pin Retainer 3C 7213/0003 3 Way Socket Retainer 3D 7213/0001 3 Way Socket Connector 4A 7213/0006 3 Way Pin Housing (DT) 4B 7213/0008 3 Way Pin Retainer (DT) 4C 7213/0007 3 Way Socket Retainer (DT) 4D 7213/0005 3 Way Socket Connector (DT) 5A 7214/0002 4 Way Pin Housing 5B 7214/0004 4 Way Pin Retainer 5C 7214/0003 4 Way Socket Retainer 5D 7214/0001 4 Way Socket Connector 6A 7216/0002 6 Way Pin Housing 6B 7216/0004 6 Way Pin Retainer 6C 7216/0003 6 Way Socket Retainer 6D 7216/0001 6 Way Socket Connector 7A 7218/0002 8 Way Pin Housing 7B 7218/0004 8 Way Pin Retainer 7C 7218/0003 8 Way Socket Retainer 7D 7218/0001 8 Way Socket Connector

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

Section 1-5 - General Information

Service Tools

Tool Detail Reference

Fig 23. Electrical Repair Kit

Fig 24. 892/00350 Butane Heater Assembly

1-5-10 1-5-10

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Fig 25. 892/00349 Crimp Tool

Fig 26. Splice

892/00351 Splice 0.5-1.5 mm (Red) 892/00352 Splice 1.5-2.5 mm (Blue) 892/00353 Splice 3.0-6.0 mm (Yellow)

Section 1-5 - General Information

Service Tools

Tool Detail Reference

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Section 1-5 - General Information

Service Tools

Tool Detail Reference

Note: No longer available, refer to 998/11046 JCB ServiceMaster Flow Test Kit. K

Fig 27. Flow Test Equipment

Fig 28. ( T 1-5-12).

892/00268 Flow Monitoring Unit

892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/min) 892/00273 Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min) 892/00293 Connector Pipe 892/00270 Load Valve 1406/0021 Bonded Washer 1604/0006A Adapter 3/4 in M x 3/4 in M BSP 1612/2054 Adapter 3/4 in F x 3/4 in M BSP 892/00271 Adapter 3/4 in F x 5/8 in M BSP 892/00272 Adapter 5/8 in F x 3/4 in M BSP 816/20008 Adapter 3/4 in F x 1/2 in M BSP 892/00275 Adapter 1/2 in F x 3/4 in M BSP 892/00276 Adapter 3/4 in F x 3/8 in M BSP 892/00277 Adapter 3/8 in F x 3/4 in M BSP 1606/0015 Adapter 1.1/4 in M BSP x 1 in M BSP 892/00078 Connector 1 in F x 1 in F BSP 1604/0008 Adapter 1 in M x 1 in M BSP 1606/0012 Adapter 1 in M x 3/4 in M BSP 816/20013 Adapter 3/4 in F x 1 in M BSP

Fig 28. 998/11046 JCB ServiceMaster Flow Test Kit

998/11047 600 LPM Flow Turbine with Loading Valve 998/11048 1-7/8" UNF x1 - 1/4" BSP Flow Block Adaptors

x2 998/11049 Carrying Case for Flow Test Kit 998/11050 Temperature Sensor (125°C Max)

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Section 1-5 - General Information

Service Tools

Tool Detail Reference

Note: No longer available, refer to 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit. K

Fig 30. ( T 1-5-13).

Fig 29. 892/ 00253 Hydraulic Circuit Pressure Test Kit

892/00201

892/00202 892/00203

Replacement Gauge 0-20 bar (0-300 lbf/in

Replacement Gauge 0-40 bar (0-600 lbf/in

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 T e st Probe 892/00347 Connector - Hose to gauge

998/11052 Hand Held 4-Channel ServiceMaster Unit 998/11053 SensoWin Software Kit and PC Cable 998/1 1054 Equiment Case SCC-750 998/1 1055 0-600 Bar Pressure Transduce x2 998/11056 0-100 Bar pressureTransducer x2 998/11057 RPM Tachometer (includes fixed cable, 2

meters) 998/11058 5 Meter Connecting Cable 998/11059 M16 Metric Adaptors for Test Points x4 998/11060

400mm Test Hose 90

HSP to M16 x2

998/11061 400mm Test Hose Straight HSP to M16 x2

Fig 30. 998/11051 JCB ServiceMaster Digital

Hydraulic Datalogger Pressure Test Kit

Fig 31. Hydraulic Circuit Test Gauges and

Connections

892/00280 892/00279 892/00346

Pressure Gauge 0-600 bar (0-9000 lbf/in

Pressure Gauge 0-400 bar (0-6000 lbf/in

Pressure Gauge 0-70 bar (0-1000 lbf/in2) 892/00347 Connector 892/00254 Hose

)

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Section 1-5 - General Information

Male Adapters - BSP x BSP 1606/2052 3/8 in. x 1/4 in. 1604/0003A 3/8 in. x 3/8 in . 892/00071 3/8 in. x 3/8 in. taper 1606/0004 1/2 in. x 1/4 in. 1606/0007A 1/2 in. x 3/8 in .

Fig 32. Male Adaptors

Male Adapters - BSP x NPT (USA only) 1606/0009 3/4 in. x 1/2 in. 816/00439 3/8 in. x 1/4 in. 1604/2055 3/4 in. x 3/4 in. 816/00440 1/2 in. x 1/4 in. 1606/0012 3/4 in. x 1 in. 816/15007A 3/8 in. x 3/8 in. 1606/0014 3/4 in. x 1.1/4 in. 816/15008 1/2 in. x 3/8 in. 1606/0015 1 in. x 1.1/4 in.

Fig 33. Pressure Test Adapters

1604/0004A 1/2 in. x 1/2 in . 1606/0017 5/8 in. x 1/2 in. 1606/0008 3/4 in. x 3/8 in.

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

Service Tools

Tool Detail Reference

Fig 34. Pressure Test 'T' Adapters

816/55045 1/4 in. M BSP x 1/4 in. F BSP x Test Point 816/55038 3/8 in. M BSP x 3/8 in. F BSP x Test Point 816/55040 1/2 in. M BSP x 1/2 in. F BSP x Test Point 892/00263 5/8 in. M BSP x 5/8 in. F BSP x Test Point 892/00264 3/4 in. M BSP x 3/4 in. F BSP x Test Point 892/00265 1 in. M BSP x 1 in. F BSP x Test Point 892/00266 1.1/4 in. M BSP x 1.1/4 in. F BSP x Test Point 892/00267 1.1/4 in. M BSP x 1.1/2 in. F BSP x Test Point

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Fig 35. 'T' Adapters

Fig 36. Female Blanking Caps

Section 1-5 - General Information

Service Tools

Tool Detail Reference

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)

892/00055A 1/4 in. BSP 892/00056A 3/8 in. BSP 892/00057 1/2 in. BSP 892/00058A 5/8 in. BSP 892/00059A 3/4 in. BSP 892/00060 1 in. BSP

Fig 37. Male Cone Blanking Caps

Fig 38. Female Connectors

Fig 39. Bonded Washers

816/90045 1/4 in. BSP 816/00189A 3/8 in. BSP 816/00190A 1/2 in. BSP 816/90022 5/8 in. BSP 816/90274 3/4 in. BSP 816/90205 1 in. BSP

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

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

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Section 1-5 - General Information

Service Tools

Tool Detail Reference

Fig 40. 892/00964 Test Point 1/8 BSP Fig 41. 892/00965 Test Point 3/8 BSP

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 T e st Probe 892/00278 892/00279

Gauge 0 - 40 bar (0 - 600 lbf/in Gauge 0 - 400 bar (0 - 6000 lbf/in2)

)

Fig 42. Hand Pump Equipment

Fig 43. 892/00881 Valve Spool Seal Fitting Tool

TBA

Fig 44. 892/00229 Flow Meter

C068360

Fig 45. 892/01268 Digital Pressure Gauge 0-400 bar

892/01271 Hose for pressure gauge

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Section 1-5 - General Information

Service Tools

Tool Detail Reference

Note: Components listed as follows also required:

Item Description 1 892/00920 Adaptor

2 892/00302 Adaptor

Fig 47. 892/00301 Flow Test Adaptor

Fig 46. 460/15708 Flow Test Adaptor

Note: Components listed below also required:

Item Description 1 460/15707 Banjo bolt 2 2401/0222 O-ring 3 2403/0110 O-ring 4 2403/0108 O-ring 5 1604/0004 Adaptor - 2 off 6 1406/0018 Sealing washer - 2 off

A313250-C1

Fig 48. Nitrogen Charging Kit

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

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Section 1-5 - General Information

Service Tools

Tool Detail Reference

Fig 49. Spool Clamps

992/09100 Spool Clamp 892/00011 Spool Clamp

Fig 51. Ram Piston Nut Removal/Fitting Spanner

JS07050

Fig 50. 892/00180 - Seal Fitting Tool

Seal Fitting Tool for fitting 'O' ring and back-up ring to Danfoss Orbitrol Unit.

892/00181 - Replacement Plastic Boss

993/99512 Spanner 55 mm A/F 993/99513 Spanner 60 mm A/F 993/99514 Spanner 65 mm A/F 993/99515 Spanner 70 mm A/F 993/99516 Spanner 75 mm A/F 993/99517 Spanner 85 mm A/F 993/99518 Spanner 90 mm A/F 993/99519 Spanner 100 mm A/F 993/99520 Spanner 110 mm A/F 993/99521 Spanner 115 mm A/F SSP0046 Spanner 80 mm A/F SSP0047 Spanner 95 mm A/F

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Fig 52. Ram Piston Nut Removal/Fitting Rig

Section 1-5 - General Information

Service Tools

Tool Detail Reference

993/99525 Rig Assembly (not including spanners and ram) 993/99522 Anchor Side Plate (supplied loose unwelded) 993/99523 Anchor Cross Member (supplied loose

unwelded) 993/99524 Ram Eye End Modification Plate Assembly 556/43400 Lift Ram 545/18000 Lynch Pin 811/50232 1.1/4in Pivot Pin

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Fig 53. Ram Protection Sleeves

Section 1-5 - General Information

Service Tools

Tool Detail Reference

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

7mm

Fig 54. 892/00334 Ram Seal Fitting Tool

Fig 55. Hexagon Spanners for Ram Pistons and End

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

Caps

0mm

10mm

5mm

R3m

110mm

175mm

R 1.4mm

Fig 56. 892/01027 Piston Seal Assembly Tool

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Fig 57. 992/04000 Torque Multiplier

Section 1-5 - General Information

Service Tools

Tool Detail Reference

Fig 60. 892/00893 Torque Converter Alignment Tool

For use with 11” torque converters

Fig 58. 892/00822 Splined Bolt Socket

Fig 59. 892/00812 Drive Coupling Spanner

Fig 61. 332/E7911 Exhaust Fitting Clamp

Fig 62. 992/04800 Flange Spanner

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Fig 63. 320/20050 Lifting Bracket Kit

Section 1-5 - General Information

Service Tools

Tool Detail Reference

Fig 64. 892/01174 Data Link Adaptor Kit

A USB PC Cable 718/20235 B Serial PC Cable 718/20236 C USB DLA 728/26500 D Machine Cable 718/20237

Kit 892/01174 (includes items A,B,C and D)

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Section 1-5 - General Information

Rivet Nuts

TB-001_2

Service Tools

Rivet Nuts

A 'Rivet Nut' is a one piece fastener installed 'blind' from one side of the machine body/framework. The rivet nut 65- A is compressed so that a section of its shank forms an 'upset' against the machine body/framework, leaving a durable thread 65-B.

Fig 65.

Rivet nuts are fitted to various parts of the machine body and framework. They are used in a number of applications, for instance, hose clamp and hydraulic valve retention etc.

Various sized rivet nuts are available. K

Specifications ( T 1-5-23) to determine the size of rivet

nut to be used for particular applications.

Tab le 1.

Table 1. Specifications Rivet Nut Thread

Diameter

M5 7 0.25 - 3.00 14.00 7.10

M6 9 0.50 - 3.00 16.00 9.10

M8 11 0.50 - 3.00 18.00 11.10

M10 13 1.00 - 3.50 23.00 13.10

Note: All dimensions in mm

Rivet Nut Outside Diameter

Material Thickness

3.00 - 5.50 17.00

3.00 - 5.50 19.00

3.00 - 5.50 21.00

3.50 - 6.00 26.00

Rivet Length (Total)

Drill Hole Dia.

If for any reason a new rivet nut requires fitting, then the correct installation procedure must be followed. K

Procedure ( T 1-5-24).

Note: In an emergency, and if no installation tool is

available, it is possible to fit a rivet nut by using a nut and bolt the same thread diameter as the rivet nut being installed. However, this is not the recommended method.

Fitting

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Section 1-5 - General Information

Service Tools

Rivet Nuts

Fitting Procedure

1 Drill a hole in the machine body/framework where the

rivet nut is to be fitted. De-burr hole edges.

2 Screw the rivet nut onto the mandrel of the installation

tool. The bottom of the ma ndre l sh oul d be in li ne wit h the bottom of the rivet nut 66-A.

Fig 66.

(smooth bulge) seating itself against the body/ framework 68-E.

Note: The thread of the rivet nut must not be stripped, take care when 'upsetting' the rivet nut.

Fig 68.

6 Remove the installation tool.

3 Wind the body of the installation tool down the

threaded mandrel until it touches the head of the rivet nut 67-B.

Fig 67.

4 Insert the rivet nut (assembled to the tool) into the

hole drilled in step 1.

5 Hold handle 68-C and at the same time draw the

mandrel into the installation tool by turning nut 68-D. The rivet nut will contract in length and form an 'upset'

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Section 1-5 - General Information

Slide Hammer Kit

TB-003

Service Tools

Slide Hammer Kit

The slide hammer kit is used to remove pivot pins that must be extracted, i.e. cannot be 'knocked through'. The purpose of this description is to explain how the kit and the various components are used to remove the pivot pins.

The adaptors 69-A that form part of the kit have a screwed thread at each end. One of the threads will always be M20 size, this is to accommodate the end stops, items 69-B and 69-C. The other end of the adaptor will have varying thread sizes to suit the different size of threads in the pivot pins.

Fitting Procedure

1 Prepare the pivot pin, for instance, if fitted, remove

the pivot pin retaining bolt.

2 Determine the thread size of the pivot pin and then fit

the appropriate adaptor 69-A as shown. Use the spanner flats 69-D to securely fit the adaptor.

Fig 69. Typical M/c. Installation

3 Fit an end stop 69-B onto the other end of the adaptor

(M20 thread size), make sure that the adaptor threads are fully engaged.

4 Fit the 'slide bar' 69-E into the end stop. Again make

sure that the threads are fully engaged.

5 Fit the 'slide hammer', item 69-F, onto the slide bar as

shown.

6 Finally, fit another end stop, item 69-C, at the en d of

the slide bar, as shown. The slide hammer kit is now ready to use.

7 To extract the pivot pin, slide the hammer along the

bar until it contacts end stop 69-C. Repeat this step until the pivot pin is released.

8 To remove the slide hammer kit, reverse steps 2 to 7.

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Section 1-5 - General Information

Page left intentionally blank

Service Tools

Slide Hammer Kit

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Section 1-6 - General Information

Service Consumables

Introduction

Consumables such as sealing and retaining compounds are necessary to complete some procedures. Before you start work make sure that the consumables show in the tables are available.

K Sealing and Retaining Compounds ( T 1-6-2)

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Page 70

Section 1-6 - General Information

Service Consumables

Sealing and Retaining Compounds

T11-001_4

Table 1.

Type Description Part No. Quantity

JCB Multi-Gasket A medium strength sealant suitable for all sizes of

gasket flanges, and for hydraulic fittings of 25-65 mm diameter.

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.

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

dismantled.

JCB Threadlocker and Sealer A medium stre ngth locking fluid for sealing and

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

JCB Threadlocker and Sealer (High Strength)

JCB Threadseal A medium strength thread sealing compound. 4102/1951 50 ml JCB Activator A cleaning primer which speeds the curing rate of

JCB Cleaner/Degreaser For degreasing components prior to use of

Direct Glazing Kit For one pane of glass; comprises of:

A high strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter.

anaerobic products.

anaerobic adhesives and sealants.

4102/1212 50 ml

4102/0551 50 ml

4101/0601 10 ml 4101/0651 50 ml 4101/0250 10 ml 4101/0251 50 ml

4101/0550 10 ml 4101/0552 200 ml

4104/0251 200 ml (Aerosol) 4104/0253 1 ltr (Bottle) 4104/1557 400 ml (Aerosol)

993/55700

Ultra Fast Adhesive For direct glazing. 4103/2109 310 ml Active Wipe 205 For direct glazing. 4104/1203 250 ml Black Primer 206J For direct glazing. 4201/4906 30 ml Clear Silicone Sealant To seal butt jointed glass. 4102/0901 Plastic to Metal Bonder To seal plastic to metal joints. 4103/0956 50 g Black Polyurethane Sealant To finish exposed edges of laminated glass. 4102/2309 310 ml

– 1 x Ultra Fast Adhesive (310 ml) – 1 x Active Wipe 205 (30 ml) – 1 x Black Primer 206J (30 ml) – plus applicator nozzle etc.

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Section 1-7 - General Information

Fuel

Introduction

This topic contains information fuel types and use with JCB Dieselmax engines. When investigating engine related faults find out what types and sources of fuel are used by the operator.

K Related Topics ( T 1-7-2) K Acceptable and Unacceptable Fuels ( T 1-7-3)

K Additives ( T 1-7-4) K Service Requirements for use of B20 Biodiesel ( T 1-7-4) K Fuel Types ( T 1-7-5) K Usage and Effects of Fuels ( T 1-7-6) K Sulphur Content ( T 1-7-7) K Effects of Fuel Contaminates ( T 1-7-8)

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Section 1-7 - General Information

Fuel

Related Topics

Table 1. Related Topics in This Publication

Sections Topic Titles Sub Titles

1 K 2 3 Service Schedules ALL

(1) You must obey all of the relevant care and safety procedures.

Machine Identification ( T 1-3-1)

ALL (Care and Safety)

(1)

ALL

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Section 1-8 - General Information

Specifications

Stall Speed Combinations

Specifications

Tests carried out at the factory record the correct engine r.p.m. (stall speed) when under maximum load from the transmission and hydraulic systems.

The figures relate to tests conducted at an ambient of 25

C and barometric pressure of 100 kPa (sea level). Note that changes in ambient temperature, pressure and humidity and fuel grade will affect engine power and hence the stall figures.

As an example, at 10,000 ft the power reduction of a naturally aspirated engine could be 29% and for a turbo engine 8%.

Engine Stall Speeds r.p.m.

Torque Converter Only 1820 2000 2000 2000

Hydraulics (M.R.V.) Only 2370 2350 2340 2340

Combined Converter + M.R.V.

Build Specification

Engine size:

85 h.p. (63 kW) Turbocharged

100 h.p (74 kW) Turbocharged and Intercooled

114 h.p. (85 kW) Turbocharged and Intercooled

130 h.p. (97 kW) Turbocharged and Intercooled

(1)

Note: The figures apply to `bedded-in' engines, i.e. engines that have done a minimum of 250 working hours, therefore they should not be used for pre-delivery inspection (PDI) checks.

All figures are recorded with the transmission oil at 60°C (140 °F) and the hydraulic oil at 55 °C (131 °F). Figures achieved should be within +/- 100 rpm from the figures given in the table.

Table 2.

Engine Build Code

SD SE SF SF

1300

(2)

1725

1760

(2)

1760

(2)

(1) Combined stall tests are performed with the crowd service operated until the relief valve is lifted. (2) Make sure that the hydraulic oil temperature is 60 degrees C.

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Section 1-8 - General Information

Page left intentionally blank

Stall Speed Combinations

Specifications

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Section 2

Care and Safety

Service Manual - Side Engine Loadalls

Section 1 - General Information

Section 2 - Care and Safety

Section 3 - Routine Maintenance

Section B - Body and Framework

Section C - Electrics

Section E - Hydraulics

Section F - Transmission

Section G - Brakes

Section H - Steering

Section K - Engine

Section M - Electronic Data Systems

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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

Publication No.

9803/3750-05

World Class

Customer Support

Page 84

Notes:

Section 2 - Care and Safety

2-0 2-0

9803/3750-05

Page 85

Section 2 - Care and Safety

Page No.Contents

Safety Notices

Introduction ............................................................................................2-1 - 1

Important Information ............................................................................2-1 - 2

Safety Check List ...................................................................................2-1 - 3

Safety Labels .......... ... ... ... .... ................................................................2-1 - 16

General Procedures

Introduction ............................................................................................2-2 - 1

Related Topics .......................................................................................2-2 - 2

Parking the Machine and Making it Safe ...............................................2-2 - 3

Boom Safety Strut .................................................................................2-2 - 4

Venting Hydraulic Pressure ...................................................................2-2 - 7

Connecting/Disconnecting Hydraulic Hoses ..........................................2-2 - 8

Quick Release Couplings ......................................................................2-2 - 9

Hydraulic Contamination ........... ... ... .... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ...2-2 - 11

Battery Disconnection/Connection ......................................................2-2 - 13

Removing and Replacing Components ......................................... ......2-2 - 14

Battery Charging System Precautions ....................... .... ... ... ... .............2-2 - 15

Hydraulic Rams ......................................... ... .... ... ................................2-2 - 16

2 - i 2 - i

Page 86

Safety Notices

Introduction

In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.

!MDANGER

Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured.

INT-1-2-1

!MWARNING

Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured.

INT-1-2-2

Section 2-1 - Care and Safety

!MCAUTION

Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine.

INT-1-2-3

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Section 2-1 - Care and Safety

Important Information

T1-042

Safety Notices

Important Information

The Operator Manual

!MWARNING

Y ou and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator Manual. You must understand and follow the instructions in the Operator Manual. If you do not understand anything, ask your employer or JCB dealer to explain it.

INT-1-4-2

Do not operate the machine without an Operator Manua l, or if there is anything on the machine you do not understand.

Treat the Operator Manual as part of the machine. Keep it clean and in good condition. Replace the Operator Manual immediately if it is lost, damaged or becomes unreadable.

Safety Warnings

This safety alert system identifies important safety messages in this manual. When you see this symbol, be alert, your safety is involved, carefuly read the message that follows, and inform other operators.

In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below.

!MDANGER

Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured.

INT-1-2-1

!MWARNING

Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured.

INT-1-2-2

!MCAUTION

Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine.

INT-1-2-3

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Safety Notices

Safety Check List

Safety - Yours and Others

INT-1-3-1_3

All machinary can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others.

In this manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB distributor to explain them.

But safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them.

Do not work with the machine until you are sure that you can control it.

Do not start any job until you are sure that you and those around you will be safe.

If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything.

For more information about cleanliness require ments and fuel types refer to Section 1 - General Information.

!MCAUTION

Do not allow dirt to enter the fuel system. Before disconnecting any part of the fuel system, thoroughly clean around the connection. When a component h as been disconnected, for example a fuel pipe, always fit protective caps and plugs to prevent dirt ingress.

Failure to follow these instruction will lead to dirt entering the fuel system. Dirt in the fuel system will seriously damage the fuel injection equipment and could be expensive to repair.

ENG-1-7

Remember

BE CAREFUL BE ALERT

BE SAFE

Common Rail (SE Engine) Specific

In addition to the general safety notices and general g ood workshop practices issued in this section and throughout the manual, there are specific points to note when completing maintenance on SE engine equipment:

Diesel Fuel Quality

Important: The potential for engine damage due to the use of incorrect or contaminated fuel is much greater with common rail injection technology than with mechanical injection systems.

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Safety Check List

Effects of Contamination

Once inside the system, fuel circuit contaminants greatly effect the performance and life of the fuel injection equipment. For example, contaminants in the fuel pump will develop internal wear to cause internal leakage and hence lower discharges. Use of poor quality fuels and poor maintenance could also lead to contaminants entering the fuel injectors. There is a possibility of catastrophic equipment failure if debris should prevent the injectors from fully closing. The main contaminants can be classified as follows: These contaminations can appear during manufacture. assembly and operation.

– Solid Particles - sand, fibres, metallic particles,

welding scale, sealing materials and wear particles etc.

– Liquid - usually water and incompatible oils and

gases.

– Gases - Air, sulphur dioxide etc. which can create

corrosive compounds if dissolved in the fluid.

It is critical that the machine is thoroughly cleaned prior to completing any maintenance work. The main filter is rated at 2 micron = 0.002 mm (0.0007874 in).

Listed are a few typical comparisons of micron size:

– Red Blood Cell = 8 microns (0.008 mm, 0.000315 in). – Human Hair = 70 microns (0.07 mm, 0.00275 in). – Grain of Salt = 100 microns (0.1 mm, 0.00394 in). – The smallest particle visible to the naked eye is 40

microns (0.00157 in) approximately.

Common Rail Safety Checklist

The following safety checklist is intended to help remind you of safety procedures and practices relating to a common rail SE engine.

SAFETY IS YOUR RESPONSIBILITY

– Do make sure the engine and surrounding area has

been thoroughly cleaned prior to completing any maintenance tasks. Refer to Section 1, Cleanliness Requirements.

– Do complete all work in accordance with the Service

Manual procedures.

– Do disconnect both the battery positive (+) and

battery negative (-) cables prior to completing any welding on the machine.

– Do use the recommended grade of fuel (EN590). The

fuel injection pump, injector or other parts of the fuel system can be damaged if you use a fuel or fuel additives not recommended by JCB. Refer to Section 1 - Acceptable and Unacceptable Fuels.

– Do make sure all the necessary new parts are

available before starting any maintenance work.

– Do not `crack' the injector high pressure fuel lines to

bleed the fuel system. The system operates at pressures in excess of 1200 bar (17400lbs/in

– Do not steam clean the electronic control unit (ECU)

or the ECU connectors.

– Do not touch the ECU connector pins, this will

eliminate the possibility of damage caused by electrostatic discharge.

– Do not leave any fuel connections `open' for any

extended period of time.

– Do not open any new parts packaging until the part is

ready to be fitted. Unnecessary exposure will increase the risk of contamination.

– Do not reuse high pressure fuel pipes. Reusing the

pipes will lead to potential fuel leaks.

– Do not attempt to remove and replace the rail

pressure sensor or high pressure valve. It is not possible to refit these components without the risk of fuel leaks. If the valve or sensor is diagnosed as faulty then a new common rail assembly must be fitted.

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General Safety

!MWARNING

To operate the machine safely you must know the machine and have the skill to use it. You must abide by all relevant laws, health and safety regulations that apply to the country you are operating in. The Operator Manual instructs you on the machine, its controls and its safe operation; it is not a training manual. If you are a new operator, get yourself trained in the skills of using a machine before trying to work with it. If you don't, you will not do your jo b well, and you will be a danger to yourself and others.

INT-1-4-1

!MWARNING

Care and Alertness All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards.

INT-1-3-5

!MWARNING

Clothing You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, earprotectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. Remove rings, watches and personal jewellery.

INT-1-3-6_2

!MWARNING

Alcohol and Drugs It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines which can cause drowsiness.

INT-1-3-9_2

T1-043

!MWARNING

Feeling Unwell Do not attempt to operate the machine if you are feeling unwell. By doing so you coul d be a danger to yourself and those you work with.

8-1-2-4

!MWARNING

Mobile Phones Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious injury.

Switch off and do not use your mobile phone when refuelling the machine.

INT-3-3-9

!MWARNING

Lifting Equipment Y ou can be injured if you use incorrect or faulty lifting equipment. Yo u must identify the weight of the item to be lifted then choose lifting equipment that is strong enough and suitable for the job. Make sure that lifting equipment is in good condition and complies with all local regulations.

INT-1-3-7_2

!MWARNING

Raised Equipment Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a hydraulic device can drop and injure you if the hydraulic system fails or if the control is operated (even with the engine stopped).

Make sure that no-one goes near the machine while you install or remove the mechanical device.

13-2-3-7_3

!MWARNING

Raised Machine NEVER position yourself or any part of your body under a raised machine which is not properly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed.

INT-3-3-7_1

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!MDANGER

Lightning Lightning can kill you. Do not use the machine if there is lightning in your area.

5-1-1-2

!MWARNING

Machine Modifications This machine is manufactured in compliance with legislative and other requirements. It should not be altered in any way which could affect or invalidate any of these requirements. For advice consult your JCB Distributor.

INT-1-3-10_2

Section 2-1 - Care and Safety

Safety Notices

Safety Check List

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Safety Check List

Operating Safety

!MWARNING

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

INT-2-1-2_2

!MWARNING

Machine Limits Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications.

INT-2-1-4

!MWARNING

Engine/Steering Failure If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected.

INT-2-1-5

!MWARNING

The engine has exposed rotating parts. Switch OFF the engine before working in the engine compartmen t. Do not use the machine with the engine cover open.

5-2-6-5

!MWARNING

Exhaust Gases Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, fit an exhaust extension. If you begin to feel drowsy, stop the machine at once and get into fresh air.

INT-2-1-10_2

!MWARNING

You could be kil led or s eriousl y injured if you ope rate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protection Structure (ROPS)/Falling Objects Protection Structure (FOPS) has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangero us and will invalidate the ROPS/FOPS certification.

INT-2-1-9_6

!MWARNING

Work Sites Work sites can be hazardous. Inspect the site before working on it. Look for potholes, weak ground, hidden rocks etc. Check for utilities such as electric cables (overhead and underground), gas and water pipes etc. Mark the positions of the underground cables and pipes. Make sure that you have enough clearance beneath overhead cables and structures.

INT-2-2-1

!MWARNING

Communications Bad communications can cause accidents. Keep people around you informed of what yo u will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands.

INT-2-2-3

!MWARNING

Parking An incorrectly parked machine can move without an operator. Follow the instructions in the Operator Manual to park the machine correctly.

INT-2-2-4_2

!MWARNING

Banks and Trenches Banked material and trenches can collapse. Do not work or drive too close to banks and trenches where there is danger of collapse.

INT-2-2-5

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Safety Check List

!MWARNING

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

INT-2-2-6

!MWARNING

Safety Barriers Unguarded machines in public places can be dangerous. In public places, or where your visibility is reduced, place barriers around the work area to keep people away.

INT-2-2-8

!MDANGER

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

INT-2-2-10

!MWARNING

Hazardous Atmospheres This machine is designed for use in n ormal out door atmospheric conditions. It should not be used in an enclosed area without adequate ventilation. Do not use the machine in a potentially explosive atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor.

INT-2-1-14

!MCAUTION

Regulations Obey all laws, work site and local regulations which affect you and your machine.

INT-1-3-3

!MWARNING

Practice You or others can be killed or seriousl y injured if you do unfamiliar operations without first practising them. Practise away from the work site on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely.

INT-2-1-1

!MWARNING

Reversing Reversing at high speeds can cause accidents. Do not reverse in a high gear with full th rottle. Always drive at a safe speed to suit working conditions.

INT-2-2-9_1

!MWARNING

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

5-3-1-12_3

!MWARNING

Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls. If that happens you could lose control of the ma c hi ne.

2-2-3-6

!MWARNING

Visibility Accidents can be caused by working in poor visibility. Use your lights to improve visibility. Keep the road lights, window s an d mirrors clean.

Do not operate the machine if you cannot see clearly.

5-1-4-7

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!MWARNING

Electrical Power Cables You could be electrocuted or badly burned if you get the machine or its attachments too close to electrical power cables.

You are strongly a dvised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near electric power lines.

Before you start using the machine, check with your electricity supplier if there are any buried power cables on the site.

There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier.

2-2-5-4

!MCAUTION

If you have an attachment which is not covered in the Operator Manual do not install it, use it or remove it until you have obtained, read and understood the pertinent information. Install attachments only on the machines for which they were designed.

5-5-1-1_2

!MWARNING

Use only the JCB approved attachments that are specified for your machine. Operating with nonspecified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yoursel f or others.

The use of non-approved attachments could invalidate your warranty.

2-4-5-2_1

!MWARNING

Controls You or others can be killed or seriously injured if you operate the control levers from outside the machine. Operate the control levers only when you are correctly seated.

0179_2

!MWARNING

Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the correct machine location until you need to use it.

Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use selfcontained breathing apparatus.

INT-3-2-7_2

!MWARNING

Should the machine start to roll over, you can be crushed if you try to leave the cab. If the machine starts to roll over, do not try and jump from the cab. Stay in the cab, with your seat belt fastened.

INT-2-1-12

!MCAUTION

Fork Spacing Loads can fall off incorrectly spaced forks. Always space the forks correctly for the load. Make sure the forks are completely under the load before lifting.

5-1-4-2

!MCAUTION

One-Fork Lifting A load lifted on one fork can slip off. Never lift a load with one fork.

5-1-4-3

!MCAUTION

Unloading Never unload the forks by stopping the machine suddenly. Follow the procedures in the Operator Manual for unloading.

5-1-4-4_2

!MCAUTION

Uneven Ground Loads stacked on uneven ground can topple. Never stack loads on uneven ground.

5-1-4-5

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!MWARNING

Scaffolding Overloaded scaffolding can collapse. Never load scaffolding beyond the regulation capacity.

5-1-4-6

!MCAUTION

Overhead Clearance A raised boom can strike overhead objects. Always check for overhead clearance before raising the boom.

5-1-5-1

!MWARNING

Boom/Travelling Operating the boom while travelling can cause accidents. You will not have total control of the machine. Never operate the boom while travelling.

5-1-5-2

!MDANGER

Forks/Working Platform Using the forks alone as a working platform is hazardous; you can fall off and be killed or injured. Never use the forks as a working platform.

5-1-5-3

!MWARNING

Controls You or others can be killed or seriousl y injured if you operate the control levers from outside the machine. Operate the control levers only when you are correctly seated in the machine.

0179

!MWARNING

Powershift Transmission Do not change from a high gear to a low gear (for instance, 4th to 1st) in one sudden movement when the machine is moving. Otherwise the machine will rapidly decelerate, you or others could be killed or seriously injured. When selecting lower gears, allow the engine speed to drop before each gear change.

2-1-1-9_1

!MCAUTION

Passengers Passengers in or on the machine can cause accidents. Do not carry passengers.

INT-2-2-2_1

!MWARNING

Forks/Turning The forks extend beyond the end of the boom. Make sure there is enough clearance for the forks when making turns.

5-1-5-4

!MWARNING

Entering/Leaving Entering or leaving the cab or canopy must only be made where steps and handrails are provided. Always face the machine when entering and leaving. Make sure the step(s), handrails and your boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls as handholds, use the handrails.

INT-2-1-7_1

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Safety Check List

Maintenance Safety

!MWARNING

Communications Bad communications can cause accidents. If two or more people are working on the machine, make s ure 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 injure d if these precautions are not taken.

INT-3-1-5

!MWARNING

Repairs If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result in an accident or affect your health. Do not try to do repairs or any other type of maintenance work you do not understand. T o avoid injury and/or damage get the work done by a specialist engineer.

GEN-1-5_2

!MWARNING

Metal Splinters You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper pin to remove and fit metal pins. Always wear safety glasses.

INT-3-1-3_2

!MWARNING

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

INT-3-1-4

!MWARNING

Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses and gloves. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.

INT-3-1-10_3

!MWARNING

Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open.

INT-3-1-11_2

!MWARNING

Fuel Fuel is flammable; keep naked flames away from the fuel system. Stop the engine immediately if a fuel leak is suspected. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. Completely wipe off any spilt fuel which could cause a fire. There could be a fire and injury if you do not follow these precautions.

INT-3-2-2_3

!MWARNING

Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin.

INT-3-2-3

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Safety Check List

!MCAUTION

It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants.

Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites.

INT-3-2-14

!MWARNING

Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground.

INT-3-2-4

!MWARNING

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

GEN-6-2

!MCAUTION

Rams The efficiency of the rams will be affected if they are not kept free of solidified dirt. Clean dirt from around the rams regularly. When leaving or parking the machine, close all rams if possible to reduce the risk of weather corrosion.

INT-3-2-10

Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents.

INT-3-2-1 1

!MCAUTION

Cleaning

!MCAUTION

'O' rings, Seals and Gaskets Badly fitted, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals.

INT-3-2-12

!MWARNING

Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly. Do not use the machine if a hose or hose fitting is damaged.

INT-3-3-2_4

!MCAUTION

Waxoyl contains turpentine substitute which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period.

Do not weld near the affected area dur ing the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.

5-3-1-9

!MWARNING

Working Under the Machine Make the machine safe before getting beneath it. Ensure that any fitments on the machine are secure; engage the park brake, remove the starter key, disconnect the battery.

INT-3-3-8_2

!MWARNING

When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer's instructions and safety precautions.

GEN-1-9

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Safety Check List

!MWARNING

Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton, Fluorel and Technoflon. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN.

New fluoroelastomeric components at ambient temperature require no special safety precautions.

Used fluoroelastomeric components whose temperatures have not exceeded 300°C (572°F) 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 (572°F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn:

1 Thoroughly wash contaminated area with 10%

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

2 Thoroughly wash contaminated area with

detergent and water.

3 Contain all removed material, gloves etc. used in

this operation in sealed plastic bags an d dis pose of in accordance with Local Authority

Regulations.

DO NOT BURN FLUOROELASTOMERIC MATERIALS.

INT-3-3-5_3

!MWARNING

Protect your eyes when grinding metal. Wear safety glasses or goggles. Remove or protect any combustible materials from the area which could be ignited by sparks.

GEN-1-12

!MWARNING

To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a brush to clean components.

HYD-1-3_2

!MWARNING

Arc Welding To prevent the possibility of damage to electronic components, disconnect the battery and the alternator before arc-welding on the machine or attached implements.

If the machine is equipped with sensitive electrical equipment, i.e. amplifier drivers, electronic control units (E.C.U.s), monitor displays, etc., then disconnect them before welding. Failure to disconnect the sensitive electrical equipment could result in irreparable damage to these components.

Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break . Do not weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine.

Always connect the welder earth (ground) cable to the same component that is being welded, i.e. boom or dipper, to avoid damage to pivot pins, bearings and bushes. Attach the welder earth (ground) cable no more than 0.6 metres (2 feet) from the part being welded.

INT-3-1-15_2

!MWARNING

Counterweights Y our machine may be fitted with counterweights. They are extremely heavy. Do not attempt to remove them.

INT-3-2-5

!MWARNING

Compressed air is dangerous. Wear suitable eye protection and gloves. Never point a compressed air jet at yourself or others.

0147_1

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Safety Check List

!MCAUTION

Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged.

INT-3-1-14

!MWARNING

If you try to charge a frozen battery, or jump start and run the engine, the battery could explod e. Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge.

0125

!MWARNING

Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by s horting the terminals with metal; use a hydrometer or voltmeter.

INT-3-1-8

!MDANGER

Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses.

INT-3-2-1_3

!MWARNING

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

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

!MWARNING

Accumulators The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on systems incorporating accumulators, the system pressure must be exhausted by a JCB distributor, as the sudden release of the hydraulic flui d or gas may cause injury.

INT-3-1-17

!MWARNING

Petrol Do not use petrol in this machine. Do not mix petrol with the diesel fuel; in storage tanks the petrol will rise to the top and form flammable vapours.

INT-3-1-6

!MWARNING

The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coo lant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system.

9-3-3-1_2

!MWARNING

An exploding tyre can kill. Inflated tyres can explode if over-heated or over-inflated. Follow the instructions given when inflating the tyres. Do not cut or weld the rims. Use a tyre/wheel specialist for all repair work.

2-3-2-7_2

!MWARNING

Jacking A machine can roll off jacks and crush you unless the wheels have been blocked. Always block the wheels at the opposite end of the machine that is to be jacked. Do not work underneath a machine supported only by jacks. Always support a jacked-up machine on axle stands before working underneath it.

INT-3-2-8

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

INT-3-1-9

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9803/3750-05 (2-01-01)

Under no circumstances must the engine be run with the transmission in gear and only one drivin g wheel jacked clear of the ground, since the wheel on the ground will move the machine.

INT-3-1-16

!MWARNING

Page 100

!MWARNING

Wheels and tyres are heavy. Take care when lifting or moving them.

Store with care to ensure that they cannot fall and cause injury.

13-3-1-7_1

!MCAUTION

Never use water or steam to clean inside the cab. The use of water or steam could damage the on-board computer and render the machine inoperable. Remove dirt using a brush or damp cloth.

8-3-4-8

!MWARNING

Boom Maintenance Strut A raised boom can drop suddenly and cause serious injury. Before working under a raised boom, fit the boom maintenance strut. See Boom Maintenance Strut, MAINTENANCE section.

5-1-5-7_2

Section 2-1 - Care and Safety

Safety Notices

Safety Check List

2-1-15 2-1-15

9803/3750-05 (2-01-01)

JCB 540, 550, 535 Side Engine Loadalls Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual