jcb 8040ZTS, 8045ZTS, 8050RTS, 8050ZTS Service Manual

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

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

World Class

Customer Support

9803/9360-4

Publication No.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel [phone] Fax [phone]

Service Manual

8040ZTS, 8045ZTS, 8050RTS, 8050ZTS

Service Manual - 8040ZTS, 8045ZTS, 8050RTS, 8050ZTS

Section 1

- General Information

Section 2 - Care and Safety

Section 3 - Maintenance

Section A - Attachments

Section B - Body and Framework

Section C - Electrics

Section D - Controls
Section E - Hydraulics
Section F - Gearboxes

Section J - Track and Running Gear

Section K - Engine

4

Section 1 - General Information

1-0 1-0

9803/9360-4

Notes:

Section 1 - General Information

Contents

1-i 1-i

Page No.Contents

Introduction

About this Manual ............ .......................................................................... 1-1

Machine Model and Serial Number .......................................................1-1

Using the Service Manual .....................................................................1-1

Section Numbering ................................................................................1-1

Left Side, Right Side ..............................................................................1-2

Cross References .................... ... .... ... ... ... .... ..........................................1-2

Identifying Your Machine

Identification Plates ............................................................. ... ................... 1-3

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

Typical Vehicle Identification Number (VIN) ..........................................1-3

Typical Product Identification Number (PIN) .........................................1-3

Typical Engine Identification Number ....................................................1-4

ROPS, TOPS and FOGS ......................................................................1-5

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-7

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

Bolts and Screws ............................ ... ... .......................................... ... ....1-7

Hydraulic Connections .................................. .... ... ... ................................. 1-11

'O' Ring Face Seal System ..................................................................1-11

'Torque Stop' Hose System ..... ... .... ... ... ... .... ... ... ... .... ... ... ... ... .... ... ... ... ..1-14

Service Tools

Numerical List .......................................................................................... 1-15

Tool Detail Reference .......... ............................................. ... ... ... .... ... ... ... . 1-18

Section B - Frame and Bodywork ........................................................1-18

Section C - Electrics .......................................................................... ..1-22

Section E - Hydraulics .........................................................................1-23

Section K - Engine ...............................................................................1-28

Service Consumables

Sealing and Retaining Compounds ......................................................... 1-29

Terms and Definitions

Colour Coding .......................................................................................... 1-31

Hydraulic Schematic Colour Codes .......................... ... ... ... ... .... ... ... ... ..1-31

Section 1 - General Information

Contents

1-ii 1-ii

Page No.Contents

Section 1 - General Information

Introduction

About this Manual

1-1 1-1

9803/9360-4

Introduction

About this Manual

Machine Model and Serial Number

This manual provides information for the following
model(s) in the JCB machine range:

Using the Service Manual

T11-004

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.

The illustrations in this publication are for guidance only.
Where the machines differ, the text and/or the illustration
will specify.

General warnings in Section 2 are repeated throughout the
manual, as well as specific warnings. Read all safety
statements regularly, so you do not forget them.

Renewal of oil seals, gaskets, etc., and any component
showing obvious signs of wear or damage is expected as
a matter of course. It is expected that components will be
cleaned and lubricated where appropriate, and that any
opened hose or pipe connections will be blanked to
prevent excessive loss of hydraulic fluid and ingress of dirt.

Where a torque setting is given as a sing le figure it may be
varied by plus or minus 3%. Torque figures indicated are
for dry threads, hence for lubricated threads may be
reduced by one third.

The manufacturer's policy is one of continuous
improvement. The right to change the specification of the
machine without notice is reserved. No responsibility will

be accepted for discrepancies which may occur between
specifications of the machine and the descriptions
contained in this publication.

Finally, please remember above all else safety must come
first!

Section Numbering

T11-005

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

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

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

JCB 8040ZTS from serial number 1056000.
JCB 8045ZTS from serial number 1057000.
JCB 8050ZTS from serial number 1741500.
JCB 8050CTS from serial number 1741500.

1 General Information - includes torque settings and

service tools.

2 Care and Safety - includes warnings and cautions

pertinent to aspects of workshop procedures etc.

3 Maintenance - includes service schedules and

recommended lubricants for all the machine.

A Attachments
B Body and Framework, etc.

Section 1 - General Information

Introduction

About this Manual

1-2 1-2

9803/9360-4

Left Side, Right Side

In this manual, 'left' A and 'right' B mean your left and right
when you are seated correctly in the machine.

Fig 1.

Cross References

T1-004_2

In this publication, page cross references are made by
presenting the subject title printed in bold, italic and
underlined. It is preceeded by the 'go to' symbol. The
number of the page upon which the subject begins, is
indicated within the brackets. For example: K

Cross

References ( T 1-2).

A

B

Section 1 - General Information

Identifying Your Machine

Identification Plates

1-3 1-3

9803/9360-4

Identifying Your Machine

Identification Plates

Machine Identification Plate

Your machine has an identification plate mounted as
shown. The Product Identification Number (PIN), weight,
engine power, year of manufacture and serial number of
the machine are shown on the plate.

Note: The machine model and build specification is
indicated by the PIN. Refer to Typical Product
Identification Number (PIN).

If the engine is replaced by a new one, the serial number
on the identification plate will be wrong. Either get a
replacement identification plate from your JCB Dealer or
simply remove the old number. This will prevent the wrong
unit number being quoted when replacement parts are
ordered.

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

Fig 1.

Typical Vehicle Identification Number
(VIN)

1 World Manufacturer Identificati o n (JCB)
2 Machine Type and Model (08045 = 8045)
3 Random Check Letter
4 Year of Manufacture ( 6 = 2006, 7 = 2007, 8 = 2008,

9 = 2009)

5 Product Identification Number (1226501)

Typical Product Identification Number
(PIN)

1 World Manufacturer Identification (3 Digits).

JCB = UK Build.

2 Machine Type and Model (5 Digits).

08040 = 8040.

3 Random Check Letter (1 Digit).

The Check Letter is used to verify the authenticity of
a machine’s PIN.

4 Machine Serial Number (8 Digits).

Each machine has a unique serial number.

S

YEAR OF MANUF.

T

PIN Prod.Ident. No.

ENGINE POWER kW @ RPM

E

I

F

VIN Vehicle Ident. No.

E

R

I

R

M

R

WEIGHT Kg

G

E

D

JCB COMPACT PRODUCTS LIMITED
HAREWOOD ESTATE, LEEK ROAD,
CHEADLE, STOKE ON TRENT,
UNITED KINGDOM, ST10 2JU.

1234 5

JCB 08045 L 7 1226501

123 4

JCB 08040 L 01056000

Section 1 - General Information

Identifying Your Machine

Identification Plates

1-4 1-4

9803/9360-4

Typical Engine Identification Number

The engine data label is located on the cylinder block as
shown. The data label includes the engine identification
number.

A typical engine identification number is:

1 Engine Type (2 Digits)

2 Country of Manufacture (1 Digit)

U = United Kingdom

3 Build Number (5 Digits)
4 Engine Serial Number (6 Digits)
5 Year of Manufacture (1 Digit)

T017650-2

Fig 2.

GJ U 65692 500405 P

12 3 4 5

GJ = Naturally aspirated, 13.8kW (18.5Hp)

Section 1 - General Information

Identifying Your Machine

Identification Plates

1-5 1-5

9803/9360-4

ROPS, TOPS and FOGS

!MWARNING

Modified and wrongly repaired ROPS, TOPS & FOGS
Structures are dangerous. Do not modify the TOPS
Structure. Do not attempt to repair the ROPS, TOPS &
FOGS Structure. If the ROPS, TOPS & FOGS Structure
has been in an accident, do not use the machine until
the structure has been inspected and repaired. This
must be done by a qualified person. For as sistance,
contact your JCB dealer. Failure to take precautions
could result in death or injury to the operator.

5-3-1-7_2

Machines built to ROPS and TOPS standards have an
identification label fitted to the cab. K Fig 3. ( T 1-5).

A bolt on falling object guard is available which also carries
a certified label. This label certifies the cab to FOGS
standard. K

Fig 4. ( T 1-5)

When a machine is used in an application with the risk of
falling objects, the machine must be equipped with the
optional FOGS guard. This guard is compliant to
ISO10262 level 1 and is intended for protection from small
objects, e.g. small rocks, small debris and other small
objects encountered in operations such as highway
maintenance, landscaping and other construction site
services.

332/L7066

Fig 3.

Fig 4.

Section 1 - General Information

Identifying Your Machine

Identification Plates

1-6 1-6

9803/9360-4

Page left intentionally blank

Section 1 - General Information

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

1-7 1-7

9803/9360-3

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

T11-002

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

Table 1. Fastener Types

( T 1-7).

T ab le1. Fastener Types

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.

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.

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

Fig 1.

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

Fastener
Type

Colour Part No. Suffix

Zinc and
Yellow

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

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

Section 1 - General Information

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

1-8 1-8

9803/9360-3

Table 2. Torque Settings - UNF Grade 'S' Fasteners

Table 3. Torque Settings - Metric Grade 8.8 Fasteners

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 - General Information

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

1-9 1-9

9803/9360-3

Table 4. Metric Grade 10.9 Fasteners

Table 5. Metric Grade 12.9 Fasteners

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 - General Information

Standard Torque Settings

Zinc Plated Fasteners and Dacromet Fasteners

1-10 1-10

9803/9360-3

Table 6. Torque Settings - Rivet Nut Bolts/Screws

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

Bolt Size

Nm kgf m lbf ft

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

Bolt Size

Nm kgf m lbf ft

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

Section 1 - General Information

Standard Torque Settings

Hydraulic Connections

1-11 1-11

9803/9360-3

Hydraulic Connections

T11-003

'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

Table 9. Torque Settings - SAE Connections

BSP Adaptor

Size

Hexagon (A/F)

Nm kgf m lbf ftin. mm

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

SAE Tube

Size

SAE Port

Thread Size

Hexagon (A/F)

Nm kgf m lbf ftmm

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

Section 1 - General Information

Standard Torque Settings

Hydraulic Connections

1-12 1-12

9803/9360-3

Hoses Screwed into Adaptors

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.

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

Table 10. BSP Hose - Torque Settings

BSP Hose Size Hexagon (A/F)

Nm kgf m lbf ftin. mm

1/8 14.0 14.0 - 16.00 1.4 - 1.6 10.3 - 11.8
1/4 19.0 24.0 - 27.0 2.4 - 2.7 17.7 - 19.9
3/8 22.0 33.0 - 40.0 3.4 - 4.1 24.3 - 29.5
1/2 27.0 44.0 - 50.0 4.5 - 5.1 32.4 - 36.9
5/8 30.0 58.0 - 65.0 5.9 - 6.6 42.8 - 47.9
3/4 32.0 84.0 - 92.0 8.6 - 9.4 61.9 - 67.8

1 38.0 115.0 - 126.0 11.7 - 12.8 84.8 - 92.9
1 1/4 50.0 189.0 - 200.0 19.3 - 20.4 139.4 - 147.5
1 1/2 55.0 244.0 - 260.0 24.9 - 26.5 180.0 - 191.8

Section 1 - General Information

Standard Torque Settings

Hydraulic Connections

1-13 1-13

9803/9360-3

Adaptors into Component Connections with Bonded W ashers

Table 11. BSP Adaptors with Bonded Washers - 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

Section 1 - General Information

Standard Torque Settings

Hydraulic Connections

1-14 1-14

9803/9360-3

'Torque Stop' Hose System

Fig 3.

`Tor que 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

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

Note: Mini mum dimension 3-E fixed by shoulder 3-D.

T able 12. BSP `Torque Stop' Hose - Torque Settings

BSP Hose Size Hexagon (A/F)

Nm kgf m lbf ftin. mm

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

Section 1 - General Information

Service Tools

Numerical List

1-15 1-15

9803/9360-3

Service Tools

Numerical List

The tools listed in the table are special tools required for
carrying out the procedures described in this manual.
These tools are available from JCB Service.

Some tools are available as kits or sets, the part numbers
for parts within such kits or sets are not listed here. For full
details of all tools, including the content of kits and sets,
refer to Tool Detail Reference, Section 1.

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

Part
Number

Description See Section

- Bonded Washers - see Tool Detail Reference (Section 1) for content E

- Female Cone Blanking Plugs - see Tool Detail Reference (Section 1) for content E

- Female Connectors - see Tool Detail Reference (Section 1) for content E

- Hydraulic Flow Test Equipment - see Tool Detail Reference (Section 1) for content E

- Hydraulic Hand Pump Equipment - see Tool Detail Reference (Section 1) for content E

- Male Adapters - BSP x BSP - see Tool Detail Reference (Section 1) for content E

- Male Adapters - BSP x NPT (USA only) - see Tool Detail Reference (Section 1) for
content

E

- Male Cone Blanking Caps - see Tool Detail Reference (Section 1) for content E

- Pressure Test Points - Adaptors - see Tool Detail Reference (Section 1) for content E

- Pressure Test Points - 'T' Adaptors - see Tool Detail Reference (Section 1) for content E

- Rivet Nut Tool - see Tool Detail Reference (Section 1) for content B

331/22966 Pump Drive Alignment Tool E
331/31069 T e st Block for A.R.V. E
4104/1310 Hand Cleaner B
892/00039 Spool Clamp E
892/00041 De-glazing Tool K
892/00137 Micro-Bore Hose E
892/00223 Hand Pump E
892/00253 Hydraulic Circuit Pressure Test Kit - see Tool Detail Reference (Section 1) for content E
892/00254 Hose E
892/00271 Adapter E
892/00272 Adapter E
892/00273 Adapter E
892/00274 Adapter E
892/00275 Adapter E
892/00276 Adapter E

Section 1 - General Information

Service Tools

Numerical List

1-16 1-16

9803/9360-3

892/00277 Adapter E
892/00279 Gauge E
892/00280 Gauge E
892/00281 AVO Meter C
892/00284 Digital Tachometer C
892/00285 Hyd. Oil Temperature Probe C
892/00298 Fluke Meter C
892/00334 Ram Seal Fitting Tool E
892/00346 Gauge E
892/00347 Connector E
892/00706 T est Probe E
892/00842 Glass Lifter B
892/00843 Folding Stand for Holding Glass B
892/00845 Cartridge Gun B
892/00846 Glass Extractor (Handles) B
892/00847 Nylon Spatula B
892/00848 Wire Starter B
892/00849 Braided Cutting Wire B
892/01016 Ram Protection Sleeve for 25 mm Rod Diameter E
892/01017 Ram Protection Sleeve for 30 mm Rod Diameter E
892/01018 Ram Protection Sleeve for 40 mm Rod Diameter E
892/01019 Ram Protection Sleeve for 50 mm Rod Diameter E
892/01020 Ram Protection Sleeve for 50 mm Rod Diameter (slew ram) E
892/01021 Ram Protection Sleeve for 60 mm Rod Diameter E
892/01022 Ram Protection Sleeve for 60 mm Rod Diameter (slew ram) E
892/01023 Ram Protection Sleeve for 65 mm Rod Diameter E
892/01024 Ram Protection Sleeve for 70 mm Rod Diameter E
892/01025 Ram Protection Sleeve for 75 mm Rod Diameter E
892/01026 Ram Protection Sleeve for 80 mm Rod Diameter E
892/01027 Piston Seal Assembly Tool E
926/15500 Rubber Spacer Blocks B
992/02800 ARV Extractor E
992/04000 Torque Multiplier F
992/09300 Hexagon Spanner 55mm A/F E
992/09400 Hexagon Spanner 65mm A/F E
992/09500 Hexagon Spanner 75mm A/F E
992/09600 Hexagon Spanner 85mm A/F E

Part
Number

Description See Section

Section 1 - General Information

Service Tools

Numerical List

1-17 1-17

9803/9360-3

992/09700 Hexagon Spanner 95mm A/F E
992/09900 Hexagon Spanner 115mm A/F E
992/10000 Hexagon Spanner 125mm A/F E
992/10100 Spool Clamp E
992/12300 12V Mobile Oven B
992/12400 24V Static Oven (2 Cartridge) B
992/12800 Cut-Out Knife B
992/12801 'L' Blades B
993/68100 Slide Hammer Kit - see Tool Detail Reference (Section 1) for content B

Part
Number

Description See Section

Section 1 - General Information

Service Tools

Tool Detail Reference

1-18 1-18

9803/9360-3

Tool Detail Reference

Section B - Frame and Bodywork

Fig 1. 993/6810 0 Slide Hammer Kit

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. Rivet Nut Tool

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 M 10 x 26 mm Rivet Nut

2 - Installation Tool available from: Bollhoff

Fastenings Ltd (www.bollhof.com)

Section 1 - General Information

Service Tools

Tool Detail Reference

1-19 1-19

9803/9360-3

Fig 3. 892/0 0842 Glass Lifter

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

Fig 4. 892/0 0843 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 6. 892/00846 Glass Extractor (Handles)

Used with braided cutting wire to cut out broken glass.

K

Fig 9. ( T 1-20).

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 1-20).

Section 1 - General Information

Service Tools

Tool Detail Reference

1-20 1-20

9803/9360-3

Fig 9. 892/00849 Braided Cutting Wire

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

Fig 6. ( T 1-19). Approx 25 m length.

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 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 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 14. 992/12801 'L' Blades

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

K

Fig 13. ( T 1-20). Unit quantity = 5 off.

Section 1 - General Information

Service Tools

Tool Detail Reference

1-21 1-21

9803/9360-3

Fig 15. 4104/1310 Hand Cleaner

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

Section 1 - General Information

Service Tools

Tool Detail Reference

1-22 1-22

9803/9360-3

Section C - Electrics

Fig 16. 892/00298 Fluke Meter

Fig 17. 892/00285 Hydraulic Temperature Probe

Fig 18. 892/00284 Venture Microtach Digita l

Tachometer

Section 1 - General Information

Service Tools

Tool Detail Reference

1-23 1-23

9803/9360-3

Section E - Hydraulics

Fig 19. Male Adaptors

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.
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.

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 20. Pressure Test Adapters

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

Fig 21. 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

Section 1 - General Information

Service Tools

Tool Detail Reference

1-24 1-24

9803/9360-3

Fig 22. 'T' Adapters

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)

Fig 23. Female Blanking Caps

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 24. Male Cone Blanking Caps

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

Fig 25. Female Connecto rs

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

Fig 26. Bonded Washers

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

Section 1 - General Information

Service Tools

Tool Detail Reference

1-25 1-25

9803/9360-3

Fig 27. Ram Protection Sleeves

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

Fig 28. 892/00334 Ram Seal Fitting Tool

Fig 29. Hexagon Spanners for Ram Pistons and End

Caps

992/09300 55mm A/F
992/09400 65mm A/F
992/09500 75mm A/F
992/09600 85mm A/F
992/09700 95mm A/F
992/09900 115mm A/F
992/10000 125mm A/F

Fig 30. 892/01027 Piston Seal Assembly Tool

110mm

175mm

R 1.4mm

3

o

R3m

m

7mm

11

o

10mm

2

0mm

5mm

Section 1 - General Information

Service Tools

Tool Detail Reference

1-26 1-26

9803/9360-3

Fig 31. Flow Test Equipment

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
1604/0008 Adapter 1 in M x 3/4 in M BSP
816/20013 Adapter 3/4 in F x 1 in M BSP

Fig 32. 892/ 00253 Hydraulic Circuit Pressure Test Kit

892/00201

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

2

)

892/00202

Replacement Gauge 0-40 bar (0-600 lbf/in2)

892/00203

Replacement Gauge 0-400 bar (0-6000 lbf/in2)
892/00254 Replacement Hose
993/69800 Seal Kit for 892/00254 (can also be used with

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

3

2

1

Section 1 - General Information

Service Tools

Tool Detail Reference

1-27 1-27

9803/9360-3

Fig 33. Hydraulic Circuit Test Gauges and

Connections

892/00279

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

2

)

892/00346

Pressure Gauge 0-70 bar (0-1000 lbf/in2)
892/00347 Connector
892/00254 Hose
892/00280

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

2

)

Fig 34. Hand Pump Equipment

892/00223 Hand Pump
892/00137 Micro-bore Hose 1/4 in BSP x 3 metres
892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper
892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point
892/00706 Test Probe
892/00278

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

2

)

892/00279

Gauge 0 - 400 bar (0 - 6000 lbf/in2)

Fig 35. Spool Clamps

892/00039 Spool Clamp
992/10100 Spool Clamp - Diameter 19mm (3/4 in)
992/02800 ARV Extractor

Fig 36. 331/31069 - Test Block for A.R.V.

Fig 37. 331/22966 Pump Drive Alignment Tool

Section 1 - General Information

Service Tools

Tool Detail Reference

1-28 1-28

9803/9360-3

Section K - Engine

For details of other engine service tools refer to:

– Publication No. 9806/2100 English
– Publication No. 9806/2101 French
– Publication No. 9806/2102 German
– Publication No. 9806/2103 Spanish
– Publication No. 9806/2104 Italian

Fig 38. 892/00041 - De-glazing Tool for Cylinder

Bores

To assist bedding -in of new piston ring s.

Section 1 - General Information

Service Consumables

Sealing and Retaining Compounds

1-29 1-29

9803/9360-3

Service Consumables

Sealing and Retaining Compounds

T11-001_4

Table 1.

Type Description Part No. Quant ity

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

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

4102/1212 50 ml

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

components. Gasketing for all sizes of flange where
the strength of the joint is important.

4102/0551 50 ml

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

dismantled.

4101/0601 10 ml
4101/0651 50 ml

JCB Threadlocker and Sealer A medium 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.

4101/0250 10 ml
4101/0251 50 ml

JCB Threadlocker and Sealer
(High Strength)

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.

4101/0550 10 ml
4101/0552 200 ml

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

anaerobic products.

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

JCB Cleaner/Degreaser For degreasing components prior to use of

anaerobic adhesives and sealants.

4104/1557 400 ml (Aerosol)

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

– 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.

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

Section 1 - General Information

Service Consumables

Sealing and Retaining Compounds

1-30 1-30

9803/9360-3

Page left intentionally blank

Section 1 - General Information

Terms and Definitions

Colour Coding

1-31 1-31

9803/9360-3

Terms and Definitions

Colour Coding

Hydraulic Schematic Colour Codes

T11-006

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

Red

Full Pressure: Pressure generated from operation of a service. Depending on application this

may be anything between neutral circuit pressure and MRV operating pressure.

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

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

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).

Section 1 - General Information

Terms and Definitions

Colour Coding

1-32 1-32

9803/9360-3

Page left intentionally blank

Section 2 - Care and Safety

2-0 2-0

9803/9360-4

Notes:

Page No.Contents

Section 2 - Care and Safety

2-i 2-i

Safety Notices

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

The Operator Manual ............................................................................2-1

Safety Warnings ....................................................................................2-1

Safety Check List ....................................................................................... 2-2

Safety - Yours and Others ................................................................. ....2-2

General Safety ......................................................................................2-2

Operating Safety ...................................................................................2-4

Maintenance Safety ...............................................................................2-8

Safety Labels .......... ... ... ... .... ... ... ... ... .... ... ... ... .......................................... . 2-12

Introduction ..................................... ............. ............. ............ ............. ..2-12

Safety Label Identification ...................................................................2-13

Page No.Contents

Section 2 - Care and Safety

2-ii 2-ii

Section 2 - Care and Safety

2-1 2-1

9803/9360-4

Safety Notices

Important Information

T1-042

The Operator Manual

!MWARNING

You 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 Manual,
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

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

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.

Section 2 - Care and Safety

Safety Notices

Safety Check List

2-2 2-2

9803/9360-4

Safety Check List

P11-1010_3

Safety - Yours and Others

INT-1-3-1_3

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

In this manual and on the machine you will fin d 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 th at you
can control it.

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

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

Remember

BE CAREFUL
BE ALERT
BE SAFE

General Safety

T1-043

!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 job 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

Section 2 - Care and Safety

Safety Notices

Safety Check List

2-3 2-3

9803/9360-4

!MWARNING

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

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 c a n be inj ure d if y ou us e in c orrec t or fa ulty lifting
equipment. You 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

!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 - Care and Safety

Safety Notices

Safety Check List

2-4 2-4

9803/9360-4

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 u ntil
the fault has been corrected.

INT-2-1-5

!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

Work Sites
Work sites can be hazardous. Inspect the site before
working on it. You could be killed or injured if the
ground gives way under your machine or if piled
material collapses onto it. Check for potholes and
hidden debris, logs, ironwork etc. Any of these could
cause you to lose control of your machine. Check for
utilities such as electric cables (overhead and
underground), gas and water pipes etc. Mark the
positions of the underground cables and pip es. Make
sure that you have enough clearance beneath
overhead cables and structures.

INT-2-2-1_2

!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

!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

Section 2 - Care and Safety

Safety Notices

Safety Check List

2-5 2-5

9803/9360-4

!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 nor mal 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 seriously 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

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 of each
work shift or more often if required. Before opening
the engine cover, ensure that the top is clear of debris.

5-3-1-12_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 mac hi ne.

2-2-3-6

!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 advised 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 yourself or others.

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

2-4-5-2_1

Section 2 - Care and Safety

Safety Notices

Safety Check List

2-6 2-6

9803/9360-4

!MDANGER

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

5-1-5-9

!MWARNING

Machine Safety
Stop work at once if a fault develops. Abnormal
sounds and smells can be signs of trouble. Ins pect
and repair before resuming work.

8-1-2-3

!MWARNING

Touching hot surfaces can burn skin. The engine and
machine components will be hot after the unit has
been running. Allow the engine and components to
cool before servicing the unit.

10-1-1-40

!MWARNING

Travelling at High Speeds
Travelling at high speeds can cause accidents. Do not
reverse in a high gear with full throttle. Always travel
at a safe speed to suit working conditions.

INT-5-3-3

!MWARNING

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

5-2-6-5

!MWARNING

You could be killed or seriously injured if you operate
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 th e 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

Machines with a TOPS structure are equipped with a
seat belt. The TOPS structure is designed to give you
protection in an accident. If you do not wear the seat
belt you could be thrown off the machine and crushed.
You must wear a seat belt when using the machine.
Fasten the seat belt before starting the engine.

2-2-1-9

!MWARNING

Hillsides
Operating the machine on hillsides can be dangerous
if proper precautions are not taken. Ground
conditions can be changed by rain, snow, ice etc.
Check the site carefully. When applicable, keep all
attachments low to the ground.

8-1-1-1

!MWARNING

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

Do not operate the machine if you cannot see clearly.

5-1-4-7

!MWARNING

Keep Your Hands and Feet Inside the Vehicle
When using the machine, keep your hands and feet
clear of moving parts. Keep your hands and feet within
the operator compartment while the vehicle is in
motion.

13-1-1-17

!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

Section 2 - Care and Safety

Safety Notices

Safety Check List

2-7 2-7

9803/9360-4

!MCAUTION

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

INT-2-2-2_1

!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

!MWARNING

Seat Belt
Operating the machine without a seat belt can be
dangerous. Before starting the engine, make sure your
seat belt is fastened. Check the tightness and
condition of the seat belt securing bolts regularly (see
maintenance schedules).

INT-2-1-8_1

!MWARNING

Safe Working Loads
Overloading the machine can damage it and make it
unstable. Study the specifications in the Operator
Manual before using the machine.

7-1-1-8_2

!MWARNING

Machine Safety
Stop work at once if a fault develops. Abnormal
sounds and smells can be signs of trouble. Inspect
and repair before resuming work.

8-1-2-3

!MWARNING

Machines with a TOPS structure are equipped with a
seat belt. The TOPS structure is designed to give you
protection in an accident. If you do not wear the seat
belt you could be thrown off the machine and crushed.
You must wear a seat belt when using the machine.
Fasten the seat belt before starting the engine.

2-2-1-9

Section 2 - Care and Safety

Safety Notices

Safety Check List

2-8 2-8

9803/9360-4

Maintenance Safety

!MWARNING

Communications
Bad communications can cause accidents. If two or
more people are working on the machine, make sure
each is aware of what the others are doing. Before
starting the engine make sure the others are clear of
the danger areas; examples of danger areas are: the
rotating blades and belt on the engine, the
attachments and linkages, and anywhere beneath or
behind the machine. People can be killed or injured if
these precautions are not taken.

INT-3-1-5

!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. To 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

Section 2 - Care and Safety

Safety Notices

Safety Check List

2-9 2-9

9803/9360-4

!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

!MCAUTION

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

INT-3-2-11

!MWARNING

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

GEN-1-9

!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 during the drying
period. Take the same precautions as for oil to keep
Waxoyl off your skin. Do not breathe the fumes. Apply
in a well-ventilated area.

5-3-1-9

!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

Section 2 - Care and Safety

Safety Notices

Safety Check List

2-10 2-10

9803/9360-4

!MWARNING

Certain seals and gaskets (e.g. crankshaft oil seal) on
JCB machines contain fluoroelastomeric materials
such as Viton®, FluorelTM 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 and dis p os e
of in accordance with Local Authority
Regulations.

DO NOT BURN FLUOROELASTOMERIC MATERIALS.

INT-3-3-5_4

!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
Your 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 a ir
jet at yourself or others.

0147_1

Section 2 - Care and Safety

Safety Notices

Safety Check List

2-11 2-11

9803/9360-4

!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 fluid 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

!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 explode. 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 sho rting
the terminals with metal; use an approved battery
tester.

INT-3-1-8_2

!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.

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

INT-3-1-9

!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

Asbestos
Asbestos dust can damage your lungs. Some engine
gaskets contain asbestos. Do not dismantle the
engine or exhaust system; get these jobs done by a
qualified person who has a copy of the engine service
manual.

5-1-6-1

!MDANGER

Before removing the boom from the machine, ensure
that the counterweight is adequately supported as in
certain ground conditions the machine could tip
backwards. Never travel or transport the machine with
the boom removed.

BF-6-3

Section 2 - Care and Safety

Safety Notices

Safety Labels

2-12 2-12

9803/9360-4

Safety Labels

Introduction

T1-014_2

!MWARNING

Safety Labels
Safety labels on the machine warn you of particular
hazards. You can be injured if you do not obey the
safety instructions shown.

INT-1-3-11

Safety labels are strategically placed around the machine
to remind you of possible hazards.

If you need eye-glasses for reading, make sure you wear
them when reading the safety labels. Do not over-stretch
or place yourself in dangerous positions to read the safety
labels. If you do not understand the hazard shown on the
safety label, then refer to Safety Label Identification.

Note: The illustration(s) show a typical machine model.
Your machine may look different from the model shown.

Keep all safety labels clean and readable. Repl ace lost o r
damaged safety labels. Make sure replacement parts
include safety labels where necessary. Each safety label
has a part number printed on it, use this number to order a
new safety label from your JCB distributor.

Section 2 - Care and Safety

Safety Notices

Safety Labels

2-14 2-14

9803/9360-4

ISO-07B

817-70018-2

Part Number: 817/70018
Description: Crush hazard. Do not

operate the controls from outside of
the machine.

ISO-07D

817-70112-2

Part Number: 817/70112
Description: Crush hazard. Keep a

safe distance from the moving parts.

ISO-09A

332-P4581-1

Part Number: 332/P4581
Description: Severing of hands or

fingers. Keep clear of/do not reach
into the moving parts. Stop the engine
and remove the starter key before you
start maintenance work. Refer to

Making the Machine Safe (Routine
Maintenance Section).

ISO-09C

817-70102-3

Part Number: 817/70102
Description: Crushing of fingers or

hands. Remove the starter key and
refer to the Service Manual before you
start maintenance work.

ISO-010A

817-70029-3

Part Number: 817/70029
Description: Crush hazard. Wear the

seatbelt when you operate the
machine.

ISO-12A

817-70106-2

Part Number: 817/70106
Description: Strike to whole body

(machine swing). Keep a safe
distance from the machine.

ISO-11D

817-70100-2

Part Number: 817/70100
Description: Fall. Enter and dismount

safely. Refer to Entering and

Leaving the Cab (Operation
Section).

ISO-11E

817-70006-2

Part Number: 817/70006
Description: Fall. Unexpected

machine movement because of
accidental contact with the machine
controls if the hydraulic functions are
not isolated..

Section 2 - Care and Safety

Safety Notices

Safety Labels

2-15 2-15

9803/9360-4

ISO-15E

332-V3761-1

Part Number: 332/V3761
Description: Flying debris warning.

Refer to Optional Attachments.

ISO-09A

332-P4581-1

Part Number: 332/P4581
Description: Severing of hands or

fingers. Keep clear of/do not reach
into the moving parts. Stop the engine
and remove the starter key before you
start maintenance work. Refer to

Making the Machine Safe (Routine
Maintenance Section).

ISO-11A

332-T9356-2

Part Number: 332/T9356
Description: Falling hazard. Lift the

lever lock.

Section 2 - Care and Safety

Safety Notices

Safety Labels

2-16 2-16

9803/9360-4

Page left intentionally blank

Section 3 - Maintenance

3-0 3-0

9803/9360-4

Notes:

Page No.Contents

Section 3 - Maintenance

3-i 3-i

Routine Maintenance

Service Requirements ............................................................................... 3-1

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

Owner/Operator Support .......................................................................3-1

Service/Maintenance Agreements ........................................................3-1

Fit for Purpose Tests for Lifting Equipment ........... .... ... ... ... ... .... .............3-1

Obtaining Replacement Parts ................................................................3-2

Health and Safety ...................................................................................... 3-3

Lubricants ................................................ .............................................. 3-3

Battery ..................................... .............................................................. 3-5

Service Schedules .. ... ... ... .... ... ... .......................................... ... ... .... ... ... ...... 3-7

Introduction ................................. ................. ............. ............ ............. ....3-7

How to Use the Service Schedules .......................................................3-7

Calendar Equivalents ............................................................................3-8

Pre-Start Cold Checks, Service Points and Fluid Levels .......................3-9

Functional Test and Final Inspection ...................................................3-11

Fluids, Lubricants and Capacities ............................................................ 3-12

Coolant Mixtures ........ .... ... ... ... ... .... ... ... ... .......................................... ..3-13

Fuels ..................................... ............. ............. ............. ............. ...........3-14

Tools ........................................................................................................ 3-17

Toolbox (if fitted) ...................................... .... ... ... ... .... ... ... ... ... .... ...........3-17

Carrying Tools onto the Machine .........................................................3-17

Prepare the Machine for Maintenance .................................................... 3-18

Introduction ..................................... ............. ............. ............ ............. ..3-18

How to Make the Machine Safe (Excavator Lowered) ........................3-18

Cleaning the Machine ............. ... ............................................. ... .... ... ... .... 3-19

Introduction ..................................... ............. ............. ............ ............. ..3-19

Preparing the Machine for Cleaning ....................................................3-19

Cleaning the Machine ..........................................................................3-20

Cleaning the Tracks .............................................................................3-20

Checking for Damage ............. ... ... ... .... ... ............................................. ... . 3-22

Check the Machine Body and Structure .............................................. 3-22

Check the Seat and Seat Belt ........................................ ... ... .... ... ... ... ..3-22

Check the Hydraulic Hoses and Fittings .............................................3-22

Check the Electrical Circuits ........... ... .......................................... ... ... ..3-22

Checking the ROPS/FOPS Structure ..................................................3-23

Checking the Ram Piston Rods .............. .... ... ... ... .... ... ... ... ... .... ... ... ... ..3-23

Greasing .................................... ............................................................. . 3-24

Introduction ..................................... ............. ............. ............ ............. ..3-24

Pivot Pins ............................................................................................3-24

Slew Ring Bearings .................................................. ... ... ... ... ...............3-27

Slew Ring Gear Teeth .........................................................................3-27

Access Panels ......................................................................................... 3-29

Introduction ..................................... ............. ............. ............ ............. ..3-29

Engine Cover .......................................................................................3-29

Hydraulic Bay Cover ............................................................................3-30

Electrical System ..................................................................................... 3-31

Battery ..................................... ............................................................ 3-31

Fuses .......................................... ............. ............. ............. ............. .....3-35

Engine ..................................................................................................... 3-37

Oil and Filter ........................................................................................3-37

Cooling System ...................................................................................3-39

Fan Belt ...... ... .... ... ... ... .... ... ... ... ... .......................................... .... ... ... ... ..3-41

Air Filter ...............................................................................................3-42

Section 3 - Maintenance

Contents

3-ii 3-ii

Page No.Contents

Fuel System ............................................................................................. 3-43

Introduction ..................................... ............. ............. ............ ............. ..3-43

Water Separator and Engine Fuel Filter .............................................. 3-44

Bleeding the System ............ ... ... .... ... ... ... .... ... ... ... .... ...........................3-47

Hydraulic System .................................... ... ... .... ... .................................... 3-48

Introduction ..................................... ............. ............. ............ ............. ..3-48

Releasing the Hydraulic Pressure .......................................................3-49

Oil and Filter ........................................................................................3-50

Tracks and Running Gear ....................................................................... 3-51

Checking the Track Gearbox Oil Level ................................................3-51

Changing the Track Gearbox Oil .........................................................3-51

Checking the Track Tension ................................................................3-52

Windscreen Washer ...................................................... ... ... ... ... .... ... ... ... . 3-53

Checking the Level ..............................................................................3-53

Fire Extinguisher (if fitted) ........................................................................ 3-54

Checking the Fire Extinguisher ...........................................................3-54

Section 3 - Maintenance

3-1 3-1

9803/9360-4

Routine Maintenance

Service Requirements

Introduction

T3-095

Your machine has been designed and built to give
maximum performance, economy and ease of use under a
wide variety of operating conditions. Prior to delivery, your
machine was inspected both at the Factory and by your
Distributor to ensure that it reaches you in optimum
condition. To maintain this condition and ensure trouble
free operation it is important that the routine services, as
specified in this Manual, are carried out by an approved
JCB Distributor at the recommended intervals.

This section of the Manual gives full details of the service
requirements necessary to maintain your JCB machine at
peak efficiency.

A Service Manual for your machine is available from your
JCB Distributor. The Service Manual contains information
on how to repair, dismantle and assemble your machine
correctly.

It can be seen from the Service Schedules on the following
pages that many essential service checks should only be
carried out by a JCB trained specialist. Only JCB
Distributor Service Engineers have been trained by JCB to
carry out such specialist tasks, and only JCB Distributor
Service Engineers are equipped with the necessary
special tools and test equipment to perform such tasks,
thoroughly, safely, accurately and efficiently.

JCB regularly updates its Distributors advising them of any
product developments, changes in specifications and
procedures. Therefore only a JCB Distributor is fully able
to maintain and service your machine.

A Service Record Sheet or Book is provided which will
enable you to plan your service requirements and keep a
service history record. It should be dated, signed and
stamped by your Distributor each time your machine is
serviced.

Remember, if your machine has been correctly
maintained, not only will it give you improved reliability but
its resale value will be greatly enhanced.

Owner/Operator Support

JCB together with your Distributor wants you to be
completely satisfied with your new JCB machine. If you do
encounter a problem however, you should contact your
Distributor's Service Department who are there to help
you!

Y ou will have been given the names of the relevant service
contacts at your Distributor when the machine was
installed.

To ge t the most from your Distributor plea se help them to
satisfy you by:

1 Giving your name, address and telephone number.
2 Quoting your machine model and serial number.
3 Date of purchase and hours of work.
4 Nature of the problem.

Remember, only your JCB Distributor has access to the
vast resources available at JCB to help support you. In
addition, your Distributor is able to offer a variety of
programmes covering Warranty, Fixed Price Servicing,
Safety Inspections, including weight tests, covering both
legal and insurance requirements.

Service/Maintenance Agreements

To help plan and spread the costs of maintaining your
machine, we strongly recommend you take advantage of
the many Service and Maintenance Agreements your
Distributor can offer. These can be tailor made to meet
your operating conditions, work schedule etc.

Please consult your JCB Distributor for details.

Fit for Purpose Tests for Lifting
Equipment

T3-097

All lifting equipment (for example forks, lifting hooks and
shackles) need regular inspection and testing by a
competent person to ensure they are fit for purpose.

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