JCB 7200 FASTRAC Service Repair Manual SN：01350005-01359999 by 163114103

Service Manual JCB 7000 Series Fastrac Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Optional Equipment Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section S - Suspension

Publication No.

9803/8060-3

World Class Customer Support Copyright Â© 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Section 1 - General Informtion

Notes:

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9803/8060-3

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Section 1 - General Informtion Contents Page No. Introduction About This Manual ..................................................................................... 1-1 Machine Model and Serial Number .......................................................1-1 Using the Service Manual .....................................................................1-1 Units of Measurement ...........................................................................1-1 Section Numbering ................................................................................1-1 Identifying your Machine ............................................................................ 1-2 Machine Identification Plate ..................................................................1-2 Component Identification Plates ............................................................1-3 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-6 Introduction ............................................................................................1-6 Zinc Plated Fasteners (golden finish) ....................................................1-7 Dacromet Fasteners (mottled silver finish) ............................................1-8 Hydraulic Connections ............................................................................... 1-9 'O' Ring Face Seal System ....................................................................1-9 'Torque Stop' Hose System .................................................................1-12 Special Tools Numerical List .......................................................................................... 1-13 Tool Detail Reference .............................................................................. 1-17 Section B - Body and Framework ........................................................1-17 Section C - Electrics ............................................................................1-24 Section E - Hydraulics .........................................................................1-27 Section F - Transmission .....................................................................1-32 Section G - Brakes ..............................................................................1-32 Section S - Suspension .......................................................................1-32 Service Consumables Sealing and Retaining Compounds ......................................................... 1-38

1-i

Section 1 - General Informtion Contents

1-ii

Page No.

1-ii

Section 1 - General Information

Introduction About This Manual Machine Model and Serial Number

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

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

Units of Measurement T1-001_2

Fastrac 7170, 7200 and 7230 P-TRONIC machines from serial number 1350000.

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.

In this publication, the S.I. system of units is used. For example, liquid capacities are given in litres. The Imperial units follow in parentheses ( ) eg 28 litres (6 gal).

Section Numbering T11-005

The manual is compiled in sections, the first three are numbered and contain information as follows: 1

General Information - includes torque settings and service tools.

Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.

Maintenance - includes service schedules and recommended lubricants for all the machine.

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

Attachments

Body and Framework, etc.

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

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

1-1

9803-8060-3

1-1

Section 1 - General Information Introduction Identifying your Machine

Identifying your Machine Machine Identification Plate Your machine has an identification plate mounted as shown. 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. Refer to Typical Product Identification Number (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 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.

1-2

9803-8060-3

C072450

1-2

Section 1 - General Information Introduction Identifying your Machine

Component Identification Plates

Typical Product Identification Number (PIN)

Engine Identification Number The data plate label A contains important information and includes the engine identification number. T040900

Fig 2. 1

World Manufacturer Identification (3 Digits)

Engine Type (2 Digits) 27 = QSB 6.7 230Hp (7230) 28 = QSB 6.7 200Hp (7200) 29 = QSB 6.7 173Hp (7170) 30 = QSB 6.7 260Hp (7270)

Transmission Type (1 Digit) G = P-TRONIC Transmission

Vehicle Maximum Speed kph (2 Digits)

Fig 3.

C072510

40 = 40kph 5

Check Letter (1 Digit) The Check Letter is used to verify the authenticity of the machine's PIN.

Year of Manufacture (1 Digit) 7 = 2007

A = 2010

8 = 2008

B = 2011

9 = 2009

C = 2012

Machine Serial Number (7 Digits) Each machine has a unique serial number.

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9803-8060-3

1-3

Section 1 - General Information Introduction Identifying your Machine Transmission Identification Numbers

Axles

Gearbox

The axles have a serial number stamped on a data plate label C as shown.

The gearbox has a serial number stamped on a data plate label B as shown.

C Fig 5. Front Axle

C071430

C B Fig 4.

C056890-B3

Fig 6. Rear Axle

1-4

9803-8060-3

C075410-B17

1-4

Section 1 - General Information Introduction Identifying your Machine ROPS Certification Label

JCB CAB SYSTEMS LTD ROCESTER UTTOXETER STAFFORDSHIRE ST14 5JP

JCB FASTRAC 7000/8000 SERIES MAXIMUM UNLADEN MASS xxxxx KG CAB FRAME WA: xxxxxxx ROPS: OECD CODE x TEST REPORT NUMBER: xxxxxx

Fig 7.

332/T2819

C071600

Machines built with Roll Over Protection Structure (ROPS) have identification label A located behind panel B inside the cab.

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9803-8060-3

1-5

Section 1 - General Informtion

Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Introduction Some external fasteners on Fastrac machines are assembled 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 as follows: Fastener Type

Colour

Part Number

Zinc and Yellow

Golden finish

Z (e.g. 1315/3712Z)

Dacromet

Mottled silver finish

D (e.g. 1315/3712D)

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 fasteners. A Dacromet bolt should not be used in conjunction with a Zinc and Yellow plated nut, as this could change the torque characteristics of the torque settings further. For the same reason, a Dacromet nut should not be used in conjunction with a Zinc and Yellow plated bolt. 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 and engine joint seams or internal applications. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

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Section 1 - General Informtion Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners

Zinc Plated Fasteners (golden finish)

Metric - All Internal Hexagon Headed Cap Screws

Use the values on these pages only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third.

Diameter

Torque Settings

kgf m

lbf ft

0.2

1.5

0.6

4.5

1.1

1.9

4.7

M10

9.3

M12

159

16.2

117

M16

395

292

M18

550

406

770

568

1332 136

Metric Grade 8.8 Bolts Size

Torque Settings Nm

Diameter (mm) M5

(5)

kgf m lbf ft

Hexagon (A/F) mm 8

0.7

(6)

1.2

M20

(8)

3.0

M24

M10

(10)

5.7

M12

(12)

M16

(16)

244

180

M18

(18)

350

258

M20

(20)

476

352

M24

(24)

822

607

M30

(30)

1633 166

1205

M36

(36)

2854 291

2105

Metric Grade 10.9 Bolts Size

Torque Settings Nm

1-7

983

Verbus Ripp Bolts

Fig 8. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

kgf m lbf ft

Diameter (mm)

Hexagon (A/F) mm

(6)

1.6

(8)

M10

(10)

M12

(12)

137

101

M16

(16)

343

253

M20

(20)

657

485

M24

(24)

1157

118

853

9803/8060-3

1-7

Section 1 - General Informtion Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners

Dacromet Fasteners (mottled silver finish)

Metric Grade 12.9 Bolts

Use the values on these pages only where no torque setting is specified in the text. Note: Dacromet fasteners are lubricated as part of the plating process. Do not lubricate Metric Grade 8.8 Bolts

Bolt size

Torque Settings

Dia.

kgf m lbf ft

M6 x 1.0

1.5

M8 x 1.25

4.1

M10 x 1.5

8.2

M12 x 1.75

133

13.6

M14 x 2

225

166

Bolt size

Torque Settings

M16 x 2

350

35.7

258

Dia.

kgf m lbf ft

M18 x 2.5

463

342

M6 x 1.0

0.9

M20 x 2.5

654

482

M8 x 1.25

22.5

2.3

M24 x 3

1125

115

830

M30 x 3.5

2247 229

M10 x 1.5

47.5

4.8

M12 x 1.75

8.2

M14 x 2

133

13.6

M16 x 2

200

20.4

148

M18 x 2.5

278

28.4

205

M20 x 2.5

392

289

M24 x 3

675

498

M30 x 3.5

1348 138

1657

994

Metric Grade 10.9 Bolts Bolt size

Torque Settings

Dia.

kgf m lbf ft

M6 x 1.0

13.5

1.4

M8 x 1.25

3.6

M10 x 1.5

62.5

6.4

M12 x 1.75

115

11.7

M14 x 2

175

17.9

129

M16 x 2

300

30.6

221

M18 x 2.5

395

291

M20 x 2.5

559

412

M24 x 3

962

710

M30 x 3.5

1920 196

1-8

1416

9803/8060-3

1-8

Section 1 - General Informtion Standard Torque Settings Hydraulic Connections

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 45Â° seat machined into the face of the tapped port. Table 1. Torque Settings - BSP Adaptors BSP Adaptor Hexagon (A/F) Size

1-9

in.

kgf m

lbf ft

1/4

19.0

18.0

1.8

13.0

3/8

22.0

31.0

3.2

23.0

1/2

27.0

49.0

5.0

36.0

5/8

30.0

60.0

6.1

44.0

3/4

32.0

81.0

8.2

60.0

38.0

129.0

13.1

95.0

1 1/4

50.0

206.0

21.0

152.0

Table 2. Torque Settings - SAE Connections SAE Port Hexagon (A/F)

SAE Tube Size

Thread Size

kgf m

lbf ft

7/16 - 20

15.9

20.0 - 28.0

2.0 - 2.8

16.5 - 18.5

9/16 - 18

19.1

46.0 - 54.0

4.7 - 5.5

34.0 - 40.0

3/4 - 16

22.2

95.0 - 105.0

9.7 - 10.7

69.0 - 77.0

7/8 - 14

27.0

130.0 - 140.0

13.2 - 14.3

96.0 - 104.0

1 1/16 - 12

31.8

190.0 - 210.0

19.4 - 21.4

141.0 - 155.0

1 5/16 - 12

38.1

290.0 - 310.0

29.6 - 31.6

216.0 - 230.0

1 5/8

47.6

280.0 - 380.0

28.5 - 38.7

210.0 - 280.0

9803/8060-3

1-9

Section 1 - General Informtion Standard Torque Settings Hydraulic Connections Hoses Screwed into Adaptors

Fig 9. Hoses 9-B screwed into adaptors 9-A seal onto an `O' ring 9-C which is compressed into a 45Â° seat machined into the face of the adaptor port.

BSP Hose Size in.

1-10

Note: Dimension 9-D will vary depending upon the torque applied.

Table 3. BSP Hose - Torque Settings Hexagon (A/F) 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

38.0

115.0 - 126.0

11.7 - 12.8

84.8 - 92.9

1 1/4

50.0

189.0 - 200.0

19.3 - 20.4

139.4 - 147.5

1 1/2

55.0

244.0 - 260.0

24.9 - 26.5

180.0 - 191.8

9803/8060-3

kgf m

lbf ft

1-10

Section 1 - General Informtion Standard Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 4. BSP Adaptors with Bonded Washers - Torque Settings BSP Size

1-11

in.

kgf m

lbf ft

1/8

20.0

2.1

15.0

1/4

34.0

3.4

25.0

3/8

75.0

7.6

55.0

1/2

102.0

10.3

75.0

5/8

122.0

12.4

90.0

3/4

183.0

18.7

135.0

203.0

20.7

150.0

1 1/4

305.0

31.0

225.0

1 1/2

305.0

31.0

225.0

9803/8060-3

1-11

Section 1 - General Informtion Standard Torque Settings Hydraulic Connections

'Torque Stop' Hose System

Fig 10. `Torque Stop' Hoses 10-B screwed into adaptors 10-A seal onto an 'O' ring 10-C which is compressed into a 45Â° 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 10-D, which acts as a physical stop. Note: Minimum dimension 10-E fixed by shoulder 10-D.

Table 5. BSP `Torque Stop' Hose - Torque Settings BSP Hose Size Hexagon (A/F) in.

kgf m

lbf ft

1/8

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

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

Table 6.

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1-12

Section 1 - General Informtion

Special Tools Numerical List The tools listed in the table are special tools required for removal and replacement of Body and Framework parts. These tools are available from JCB Service.

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

Tool Detail Reference

1406/0011

Bonded Washer

K Fig 48. ( T 1-28)

1406/0014

Bonded Washer

K Fig 48. ( T 1-28)

1406/0018

Bonded Washer

K Fig 48. ( T 1-28)

1406/0021

Bonded Washer

K Fig 48. ( T 1-28)

1406/0029

Bonded Washer

K Fig 48. ( T 1-28)

1604/0003A Adapter

K Fig 41. ( T 1-27)

1604/0004A Adapter

K Fig 41. ( T 1-27)

1604/0006A Adapter

K Fig 49. ( T 1-29)

1604/2055

Adapter

K Fig 41. ( T 1-27)

1606/0004

Adapter

K Fig 41. ( T 1-27)

1606/0007A Adapter

K Fig 41. ( T 1-27)

1606/0008

Adapter

K Fig 41. ( T 1-27)

1606/0009

Adapter

K Fig 41. ( T 1-27)

1606/0012

Adapter

K Fig 41. ( T 1-27)

1606/0014

Adapter

K Fig 41. ( T 1-27)

1606/0015

Adapter

K Fig 41. ( T 1-27)

1606/0016

Adapter

K Fig 41. ( T 1-27)

1606/0017

Adapter

K Fig 41. ( T 1-27)

1606/2052

Adapter

K Fig 41. ( T 1-27)

1612/2054

Adapter

K Fig 49. ( T 1-29)

4104/1310

Hand Cleaner

K Fig 14. ( T 1-19)

816/00017

Adapter

K Fig 44. ( T 1-28)

816/00189A Blanking Cap

K Fig 46. ( T 1-28)

816/00190A Blanking Cap

K Fig 46. ( T 1-28)

816/00439

Adapter

K Fig 41. ( T 1-27)

816/00440

Adapter

K Fig 41. ( T 1-27)

816/15007A Adapter

K Fig 41. ( T 1-27)

816/15008

K Fig 41. ( T 1-27)

1-13

Adapter

9803/8060-3

1-13

Section 1 - General Informtion Special Tools Numerical List Part Number

Description

Tool Detail Reference

816/15118

Adapter

K Fig 42. ( T 1-27)

816/20008

Adapter

K Fig 49. ( T 1-29)

816/20013

Adapter

K Fig 49. ( T 1-29)

816/50005

Adapter

K Fig 44. ( T 1-28)

816/50043

Adapter

K Fig 44. ( T 1-28)

816/55038

Adapter

K Fig 43. ( T 1-27)

816/55040

Adapter

K Fig 43. ( T 1-27)

816/55045

Adapter

K Fig 43. ( T 1-27)

816/60096

Adapter

K Fig 44. ( T 1-28)

816/90022

Blanking Cap

K Fig 46. ( T 1-28)

816/90045

Blanking Cap

K Fig 46. ( T 1-28)

816/90205

Blanking Cap

K Fig 46. ( T 1-28)

816/90274

Blanking Cap

K Fig 46. ( T 1-28)

826/01099

Rivet Nut

K Fig 12. ( T 1-17)

826/01101

Rivet Nut

K Fig 12. ( T 1-17)

826/01102

Rivet Nut

K Fig 12. ( T 1-17)

826/01103

Rivet Nut

K Fig 12. ( T 1-17)

826/01104

Rivet Nut

K Fig 12. ( T 1-17)

826/01105A Rivet Nut

K Fig 12. ( T 1-17)

892/00047

Adapter

K Fig 44. ( T 1-28)

892/00048

Adapter

K Fig 44. ( T 1-28)

892/00049

Adapter

K Fig 44. ( T 1-28)

892/00055A Blanking Cap

K Fig 45. ( T 1-28)

892/00056A Blanking Cap

K Fig 45. ( T 1-28)

892/00057

Blanking Cap

K Fig 45. ( T 1-28)

892/00058A Blanking Cap

K Fig 45. ( T 1-28)

892/00059A Blanking Cap

K Fig 45. ( T 1-28)

892/00060

Blanking Cap

K Fig 45. ( T 1-28)

892/00051

Adapter

K Fig 44. ( T 1-28)

892/00074

Connector

K Fig 47. ( T 1-28)

892/00075

Connector

K Fig 47. ( T 1-28)

892/00076

Connector

K Fig 47. ( T 1-28)

892/00077

Connector

K Fig 47. ( T 1-28)

892/00078

Connector

K Fig 49. ( T 1-29)

892/00137

Hose

K Fig 54. ( T 1-31)

892/00201

Replacement Gauge

K Fig 51. ( T 1-30)

892/00202

Replacement Gauge

K Fig 51. ( T 1-30)

1-14

9803/8060-3

1-14

Section 1 - General Informtion Special Tools Numerical List Part Number

Description

Tool Detail Reference

892/00203

Replacement Gauge

K Fig 51. ( T 1-30)

892/00223

Hand Pump

K Fig 54. ( T 1-31)

892/00254

Replacement Hose

K Fig 53. ( T 1-30)

892/00255

Adapter

K Fig 42. ( T 1-27)

892/00256

Adapter

K Fig 42. ( T 1-27)

892/00257

Adapter

K Fig 42. ( T 1-27)

892/00258

Adapter

K Fig 42. ( T 1-27)

892/00259

Adapter

K Fig 42. ( T 1-27)

892/00260

Adapter

K Fig 42. ( T 1-27)

892/00261

Adapter

K Fig 42. ( T 1-27)

892/00262

Adapter

K Fig 54. ( T 1-31)

892/00263

Adapter

K Fig 43. ( T 1-27)

892/00264

Adapter

K Fig 43. ( T 1-27)

892/00265

Adapter

K Fig 43. ( T 1-27)

892/00266

Adapter

K Fig 43. ( T 1-27)

892/00267

Adapter

K Fig 43. ( T 1-27)

892/00268

Flow Monitoring Unit

K Fig 49. ( T 1-29)

892/00269

Sensor Head

K Fig 49. ( T 1-29)

892/00270

Load Valve

K Fig 49. ( T 1-29)

892/00271

Adapter

K Fig 49. ( T 1-29)

892/00272

Adapter

K Fig 49. ( T 1-29)

892/00273

Sensor Head

K Fig 49. ( T 1-29)

892/00274

Adapter

K Fig 49. ( T 1-29)

892/00275

Adapter

K Fig 49. ( T 1-29)

892/00276

Adapter

K Fig 49. ( T 1-29)

892/00277

Adapter

K Fig 49. ( T 1-29)

892/00278

Gauge

K Fig 54. ( T 1-31)

892/00279

Gauge

K Fig 53. ( T 1-30)

892/00284

Tachometer

K Fig 35. ( T 1-24)

892/00285

Hydraulic Oil Temperature Probe

K Fig 34. ( T 1-24)

892/00293

Connector Pipe

K Fig 49. ( T 1-29)

892/00298

Fluke Meter

K Fig 33. ( T 1-24)

892/00311

Brake Test Kit

K Fig 56. ( T 1-32)

892/00314

Accumulator Adapter

K Fig 57. ( T 1-32)

892/00314

Accumulator and Gas Spring Pressure Test Adapter

K Fig 57. ( T 1-32)

892/00318

Hose and Adapter Kit

K Fig 55. ( T 1-31)

892/00347

Connector

K Fig 51. ( T 1-30)

1-15

9803/8060-3

1-15

Section 1 - General Informtion Special Tools Numerical List Part Number

Description

Tool Detail Reference

892/00706

Test Probe

K Fig 54. ( T 1-31)

892/00801

Clutch spanner

K Fig 28. ( T 1-22)

892/00802

Rotor puller set

K Fig 30. ( T 1-22)

892/00803

Rotor installer set

K Fig 32. ( T 1-23)

892/00807

Front plate puller

K Fig 29. ( T 1-22)

892/00808

Shaft protector

K Fig 31. ( T 1-22)

892/00842

Glass Lifter

K Fig 19. ( T 1-20)

892/00843

Folding Stand

K Fig 17. ( T 1-19)

892/00844

Long Knife

K Fig 25. ( T 1-21)

892/00845

Cartridge Gun

K Fig 15. ( T 1-19)

892/00846

Glass Extractor

K Fig 22. ( T 1-21)

892/00847

Nylon Spatula

K Fig 26. ( T 1-22)

892/00848

Wire Starter

K Fig 20. ( T 1-20)

892/00849

Braided Cutting Wire

K Fig 24. ( T 1-21)

892/01033

Data Link Adapter Kit - ABS

K Fig 36. ( T 1-24)

992/12300

Mobile Oven

K Fig 16. ( T 1-19)

992/12400

Static Oven

K Fig 18. ( T 1-20)

992/12600

Static Oven

K Fig 18. ( T 1-20)

992/12800

Cut-out Knife

K Fig 21. ( T 1-20)

992/12801

‘L’ Blades

K Fig 23. ( T 1-21)

992/15500

Rubber Spacer Blocks

K Fig 27. ( T 1-22)

993/68101

Slide Hammer

K Fig 11. ( T 1-17)

993/68102

End Stops

K Fig 11. ( T 1-17)

993/68103

Adapter

K Fig 11. ( T 1-17)

993/68104

Adapter

K Fig 11. ( T 1-17)

993/68105

Adapter

K Fig 11. ( T 1-17)

993/68106

Adapter

K Fig 11. ( T 1-17)

993/68107

Bar

K Fig 11. ( T 1-17)

993/68108

Adapter

K Fig 11. ( T 1-17)

993/68109

Adapter

K Fig 11. ( T 1-17)

993/68110

Adapter

K Fig 11. ( T 1-17)

993/68111

Adapter

K Fig 11. ( T 1-17)

993/69800

Seal Kit

K Fig 51. ( T 1-30)

1-16

9803/8060-3

1-16

Section 1 - General Informtion Special Tools Tool Detail Reference

Tool Detail Reference Section B - Body and Framework Note: Not all service tools are illustrated.

Fig 11. 993/68100 Slide Hammer Kit 1

993/68101

Slide Hammer

993/68107

Bar - M20 x M20 X 800 mm

993/68102

End Stops

993/68108

Adaptor - M20 x 7/8" UNF

993/68103

Adaptor - M20 x 5/8" UNF

993/68109

Adaptor - M20 x M12

993/68104

Adaptor - M20 x 1" UNF

993/68110

Adaptor - M20 x 5/8" UNF (Shoulder)

993/68105

Adaptor - M20 x M20

993/68111

Adaptor - M20 x 1/2" UNF

993/68106

Adaptor - M20 x M24 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)

Fig 12. Rivet Nut Tool

1-17

9803/8060-3

1-17

Section 1 - General Informtion Special Tools Tool Detail Reference

Fig 13.

C071920

Cab Lifting Frame: Produce locally to dimensions shown. Test to Safe Working Load (SWL) of 1200 kg (2645 lb).

1-18

9803/8060-3

1-18

Section 1 - General Informtion Special Tools Tool Detail Reference

Fig 14. Fig 15. Hand Cleaner - special blend for the removal of polyurethane adhesives.

Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc.

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

JCB part number - 892/00845

Fig 16.

Fig 17. 12V Mobile Oven - 1 cartridge capacity - required to pre- Folding Stand for holding glass - essential for preparing heat adhesive prior to use. It is fitted with a male plug (703/ new glass prior to installation. 23201) which fits into a female socket (715/04300). JCB part number - 992/12300

1-19

JCB part number - 892/00843

9803/8060-3

1-19

Section 1 - General Informtion Special Tools Tool Detail Reference

Fig 18. Fig 19. 240V Static Oven - available with 2 or 6 cartridge capacity - required to pre-heat adhesive prior to use. No plug supplied. Note: 110V models available upon request contact JCB Technical Service.

Glass Lifter - minimum 2 off - essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage.

JCB part number:

JCB part number - 892/00842

992/12400 - 2 Cartridge x 240V9 992/12600 - 6 Cartridge x 240V

Fig 21. Fig 20. Wire Starter - used to access braided cutting wire (below) Cut-Out Knife - used to remove broken glass. through original polyurethane seal. JCB part number - 892/00848

1-20

JCB part number - 992/12800

9803/8060-3

1-20

Section 1 - General Informtion Special Tools Tool Detail Reference

Fig 23.

Fig 22. Glass Extractor (Handles) - used with braided cutting wire 'L' Blades - 25 mm (1 in) cut - replacement blades for cut(below) to cut out broken glass. out knife (above). JCB part number - 892/00846

JCB part number - 992/12801 (unit quantity = 5 off)

Fig 24.

Fig 25. Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool (above).

Long Knife - used to give extended reach for normally inaccessible areas.

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

JCB part number - 892/00844

1-21

9803/8060-3

1-21

Section 1 - General Informtion Special Tools Tool Detail Reference

Fig 26.

Fig 27.

Nylon Spatula - general tool used for smoothing sealants - Rubber Spacer Blocks - used to provide the correct set also used to re-install glass in rubber glazing because metal clearance between glass edge and cab frame. tools will chip the glass edge. JCB part number - 892/00847

JCB part number - 992/15500 (unit quantity = 500 off)

Fig 28. Fig 29. 892/00801 Clutch Spanner for air conditioning compressor

892/00807 Font Plate Puller for air conditioning compressor

Fig 31.

Fig 30.

892/00802 Rotor Puller Set for air conditioning compressor 892/00808 Shaft Protector for air conditioning compressor

1-22

9803/8060-3

1-22

Section 1 - General Informtion Special Tools Tool Detail Reference

Fig 32. 892/00803 Rotor Installer Set for air conditioning compressor

1-23

9803/8060-3

1-23

Section 1 - General Informtion Special Tools Tool Detail Reference

Section C - Electrics

Fig 34. 892/00285 Hydraulic Temperature Probe

Fig 35. 892/00284 Venture Microtach Digital Tachometer

Fig 33. 892/00298 Fluke Meter

892/01033 Data Link Adapter Kit Note: Item A of the Data Link Adapter Kit is unsuitable for use with the Fastrac and must be replaced by the HarnessDiagnostic (J1939) K Fig 37. ( T 1-25)

Fig 36.

1-24

9803/8060-3

1-24

Section 1 - General Informtion Special Tools Tool Detail Reference 721/10885 Harness - Diagnostic (J1939)

Fig 37. 721/00664 Connecting Lead - Wingst

Fig 38. 892/01066 Combination Lead (alternative to 721/00664, K Fig 38. ( T 1-25))

Fig 39.

1-25

9803/8060-3

1-25

Section 1 - General Informtion Special Tools Tool Detail Reference 1

Electrical Repair Kit

:7212/0002

2 Way Pin Housing

:7212/0004

2 Way Pin Retainer

:7212/0003

2 Way Socket Retainer

:7212/0001

2 Way Socket Connector

:7213/0002

3 Way Pin Housing

:7213/0004

3 Way Pin Retainer

:7213/0003

3 Way Socket Retainer

:7213/0001

3 Way Socket Connector

:7213/0006

3 Way Pin Housing (DT)

:7213/0008

3 Way Pin Retainer (DT)

:7213/0007

3 Way Socket Retainer (DT)

:7213/0005

3 Way Socket Connector (DT)

:7214/0002

4 Way Pin Housing

:7214/0004

4 Way Pin Retainer

:7214/0003

4 Way Socket Retainer

:7214/0001

4 Way Socket Connector

:7216/0002

6 Way Pin Housing

:7216/0004

6 Way Pin Retainer

:7216/0003

6 Way Socket Retainer

:7216/0001

6 Way Socket Connector

:7218/0002

8 Way Pin Housing

:7218/0004

8 Way Pin Retainer

:7218/0003

8 Way Socket Retainer

:7218/0001

8 Way Socket Connector

:7219/0002

10 Way Pin Housing

:7219/0004

10 Way Pin Retainer

:7219/0003

10 Way Socket Retainer

:7219/0001

10 Way Socket Connector

:7219/0006

14 Way Pin Housing

:7219/0008

14 Way Pin Retainer

:7219/0007

14 Way Socket Retainer

:7219/0005

14 Way Socket Connector

:7210/0001

Dummy Plug

:7210/0002

Wire Seal (1.4 - 2.2 mm dia.)

:7210/0003

Wire Seal (2.2 - 2.9 mm dia.)

1-26

Fig 40.

9803/8060-3

1-26

Section 1 - General Informtion Special Tools Tool Detail Reference

Section E - Hydraulics 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 41. Male Adaptors

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

1606/0015

1 in. x 1.1/4 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

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

1/2 in. x 3/8 in.

Fig 42. Pressure Test Adapters

Fig 43. Pressure Test 'T' Adapters

1-27

9803/8060-3

1-27

Section 1 - General Informtion Special Tools Tool Detail Reference

Fig 44. '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)

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 Fig 45. Female Blanking Caps

892/00060

1 in. BSP

816/90045

1/4 in. BSP

816/00189A 3/8 in. BSP 816/00190A 1/2 in. BSP

Fig 46. Male Cone Blanking Caps

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

Fig 47. Female Connectors

Fig 48. Bonded Washers

1-28

1406/0021

3/4 in. BSP

1406/0029

1.1/4 in. BSP

9803/8060-3

1-28

Section 1 - General Informtion Special Tools Tool Detail Reference Note: No longer available, refer to 998/11046 JCB ServiceMaster Flow Test Kit. K Fig 50. ( T 1-29).

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

Fig 49. Flow Test Equipment

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

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 (125Â°C Max)

Fig 50. 998/11046 JCB ServiceMaster Flow Test Kit

1-29

9803/8060-3

1-29

Section 1 - General Informtion Special Tools Tool Detail Reference Note: No longer available, refer to 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit. K Fig 52. ( T 1-30).

892/00201

Replacement Gauge 0-20 bar (0-300 lbf/in2)

892/00202

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

892/00203

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

892/00254

Replacement Hose

993/69800

Seal Kit for 892/00254 (can also be used with probe 892/00706)

892/00706

Test Probe

892/00347

Connector - Hose to gauge

998/11052

Hand Held 4-Channel ServiceMaster Unit

998/11053

SensoWin Software Kit and PC Cable

998/11054

Equiment Case SCC-750

998/11055

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 90Â° HSP to M16 x2

998/11061

400mm Test Hose Straight HSP to M16 x2

892/00280

Pressure Gauge 0-600 bar (0-9000 lbf/in2)

892/00279

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

892/00346

Pressure Gauge 0-70 bar (0-1000 lbf/in2)

892/00347

Connector

892/00254

Hose

Fig 51. 892/ 00253 Hydraulic Circuit Pressure Test Kit

Fig 52. 998/11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit

Fig 53. Hydraulic Circuit Test Gauges and Connections

1-30

9803/8060-3

1-30

Section 1 - General Informtion Special Tools Tool Detail Reference 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/in2)

892/00279

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

Fig 54. Hand Pump Equipment

Fig 55. 892/00318 Hose and Adapter Kit To enable flow and pressure test equipment to be connected to adapters fitted with `O' ring face seals.

1-31

9803/8060-3

1-31

Section 1 - General Informtion Special Tools Tool Detail Reference

Section F - Transmission Transmission tools are shown in Section F.

Section G - Brakes 892/00311

Brake Test Kit 3 x Calibrated Test Gauges - 0-20 bar (0 - 290 lbf/in2) 3 x 5 Metre Hoses with Quick Release Adapters 3 x ISO Test Point Adapters

Fig 56.

Section S - Suspension 892/00314

Accumulator and Gas Spring Pressure Test Adapter

Fig 57.

1-32

9803/8060-3

1-32

Section 1 - General Informtion Special Tools Tool Detail Reference Suspension Calibration Tools Make the following two welded assemblies as per the details on the drawings. They are both made from the

same components: items 1, 2 and 3, welded together in different configurations to make left hand and right hand versions.

ENSURE FACE REMAINS CLEAN OF SPATTER

ITEM 1 TO ITEM 2

+0.2 -0.2

BETWEEN FACES +0.2 -0.2

143 30

ITEM 1 TO ITEM 2

106

NOTE: DO NOT WELD ON INSIDE

2 3

2 X 10 (20)

ITEM 2 TO ITEM 3

PART VIEW FOR CLARIFICATION

Fig 58.

C072390

Calibration Tool Welded Assembly, front left hand and rear right hand. Make by welding together items 1, 2 and 3 as shown on drawing above. 1

Body K Fig 60. ( T 1-35)

Side plate K Fig 61. ( T 1-35)

Keeper plate K Fig 62. ( T 1-36)

1-33

9803/8060-3

1-33

Section 1 - General Informtion Special Tools Tool Detail Reference

ENSURE FACE REMAINS CLEAN OF SPATTER

+0.2 -0.2

(FACE 'A')

ITEM 1 TO ITEM 2

106

FROM 'FACE A' OF ITEM 1

143

BETWEEN FACES

NOTE: DO NOT WELD ON INSIDE FACE

30 ITEM 2 TO ITEM 3

2 X 10 (20)

PART VIEW FOR CLARITY

Fig 59.

C072400

Calibration Tool Welded Assembly, front right hand and rear left hand. Make by welding together items 1, 2 and 3 as shown on drawing above. 1

Body K Fig 60. ( T 1-35)

Side plate K Fig 61. ( T 1-35)

Keeper plate K Fig 62. ( T 1-36)

1-34

9803/8060-3

1-34

Section 1 - General Informtion Special Tools Tool Detail Reference

17.3

(BEND ZONE)

17.3

(BEND ZONE)

46.9 (BEND CENTRE)

56.92

163 143

116 172.9

1 BETWEEN FACES 241.8

SYMMETRICAL ABOUT CENTRELINE

(BEND CENTRE)

288.7

106

R 20

131 R 20

90 VIEW FOR IDENTIFICATION ONLY

SUSPENSION CALIBRATION TOOL: TOOL BODY

C072360

Fig 60.

Calibration Tool Body (item 1). Make to drawing above and use to make calibration tools as shown on previous pages. K Fig 58. ( T 1-33) K Fig 59. ( T 1-34)

15 TYP

169

SUSPENSION CALIBRATION TOOL: SIDE PLATE VIEW FOR IDENTIFICATION ONLY

Fig 61.

C072370

Calibration Tool Side Plate (item 2). Make to drawing above and use to make calibration tools as shown on previous pages. K Fig 58. ( T 1-33) K Fig 59. ( T 1-34)

1-35

9803/8060-3

1-35

Section 1 - General Informtion Special Tools Tool Detail Reference

R 3 TYP. 3 POS

R 15

SUSPENSION CALIBRTAION TOOL: KEEPER PLATE VIEW FOR IDENTIFICATION ONLY

Fig 62.

C072380

Calibration Tool Keeper Plate (item 3). Make to drawing above and use to make calibration tools as shown on previous pages. K Fig 58. ( T 1-33) K Fig 59. ( T 1-34)

1-36

9803/8060-3

1-36

Section 1 - General Informtion Special Tools Tool Detail Reference

Page left intentionally blank

1-37

9803/8060-3

1-37

Section 1 - General Informtion Service Consumables Sealing and Retaining Compounds

Service Consumables Sealing and Retaining Compounds T11-001_4

Table 7. Type

Description

JCB Multi-Gasket

A medium strength sealant suitable for all sizes of 4102/1212 gasket flanges, and for hydraulic fittings of 25-65 mm diameter.

50 ml

JCB High Strength Threadlocker

A high strength locking fluid for use with threaded 4102/0551 components. Gasketing for all sizes of flange where the strength of the joint is important.

50 ml

JCB Retainer (High Strength)

For all retaining parts which are unlikely to be dismantled.

4101/0601

10 ml

4101/0651

50 ml

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 4101/0550 nuts, bolts, and screws up to 50 mm diameter, and 4101/0552 for hydraulic fittings up to 25 mm diameter.

10 ml 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:

993/55700

JCB Threadlocker and Sealer

Part No.

Quantity

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

For direct glazing.

4103/2109

310 ml

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

1-38

9803/8060-3

1-38

Section 2 - Care and Safety

Notes:

2-0

9803/8060-1

2-0

Section 2 - Care and Safety Contents Page No. Safety First 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 ...............................................................................2-9

2-i

Section 2 - Care and Safety Contents

2-ii

Page No.

2-ii

Section 2 - Care and Safety

Safety First Important Information T1-015

The Operator Manual

Safety Warnings

!MWARNING Study the Operator Manual before starting the machine. You must understand and follow the instructions in the Operator Manual. You must observe all relevant laws and regulations. If you are unsure about anything, ask your JCB dealer or employer. Do not guess, you or others could be killed or seriously injured. INT-1-1-1_2

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

Do not operate the machine without an Operator Manual. Treat the Operator Manual as part of the machine. Keep it clean and in good condition. Replace the Operator Manual immediately if it is lost, damaged or becomes unreadable.

!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

2-1

9803/8060-1

2-1

Section 2 - Care and Safety Safety First Safety Check List

Safety Check List Safety - Yours and Others

General Safety INT-1-3-1_3

All machinery can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. In this manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB distributor to explain them. But safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them. Do not work with the machine until you are sure that you can control it. Do not start any job until you are sure that you and those around you will be safe. If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE

!MWARNING

T1-007_3

Operator Manual You and others can be injured if you operate or maintain the machine without first studying the Operator Manual. Read the safety instructions before operating the machine. If you do not understand anything, ask your employer or JCB dealer to explain it. Keep the Operator Manual clean and in good condition. Do not operate the machine without an Operator Manual in the cab, or if there is anything on the machine you do not understand. INT-1-3-2_2

!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. INT-1-3-6

!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

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Section 2 - Care and Safety Safety First Safety Check List

!MWARNING

!MDANGER

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.

Lightning Lightning can kill you. Do not use the machine if there is lightning in your area. 5-1-1-2

8-1-2-4

!MWARNING

!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.

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

INT-3-3-9

!MWARNING Lifting Equipment You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job. INT-1-3-7

!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). 13-2-3-7_2

!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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!MWARNING

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

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 the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification. INT-2-1-9_6

!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

!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

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 compartment. Do not use the machine with the engine cover open.

!MWARNING Communications Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with other people, make sure any hand signals that may be used are understood by everybody. Work sites can be noisy, do not rely on spoken commands. INT-2-2-3

5-2-6-5

!MWARNING

!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

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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Section 2 - Care and Safety Safety First 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.

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-2-2-6

INT-2-1-1

!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.

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

INT-2-2-8

INT-2-2-9_1

!MDANGER

!MWARNING

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.

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.

INT-2-2-10

!MWARNING

5-3-1-12_3

Hazardous Atmospheres This machine is designed for use in normal 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.

!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 machine. 2-2-3-6

!MWARNING

INT-2-1-14

!MCAUTION Regulations Obey all laws, work site and local regulations which affect you and your machine. INT-1-3-3

Visibility Accidents can be caused by working in poor visibility. Use your lights to improve visibility. Keep the road lights, windows and mirrors clean. Do not operate the machine if you cannot see clearly. 5-1-4-7

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Section 2 - Care and Safety Safety First Safety Check List

!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.

Starting/Using the Machine Start only from the operator's seat, with the transmission in neutral. Make sure everyone is clear of the machine before starting or using the machine.

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.

13-2-3_13

!MWARNING Do not start the machine until all shields are in place.

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

13-2-3-12

!MWARNING

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

Starting/Using the Machine Reduce speed when towing or operating around hazards, on rough ground or steep slopes.

2-2-5-4

13-2-3_14

!MCAUTION

!MWARNING

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.

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.

5-5-1-1_2

13-1-1-17

!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.

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 in the machine.

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

0179

!MWARNING

2-4-5-2_1

!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

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

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Section 2 - Care and Safety Safety First Safety Check List

!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.

Be aware of the load the machine is carrying or towing and the speed at which you are travelling. Do not corner fast when carrying heavy mounted implements or towing trailers. Reduce speed when towing nonsuspended implements on rough ground. (Consult the implement operator's manual for recommended transport speeds).

INT-2-1-12

!MWARNING

13-2-2-1_1

Passengers Ensure that passengers use the seat provided in the cab. Passengers must not be carried on the rear deck of the vehicle under any circumstances. 13-1-1-1_1

!MWARNING Ensure that any load carried on the rear deck of the machine is firmly secured. 13-1-1-10

The JCB Fastrac is capable of operating at high speeds. Implements or trailers you tow behind the Fastrac may not be designed for high speed operation. BE AWARE of the manufacturer's specified maximum speed rating for any trailers or implements that you tow behind the Fastrac. DO NOT EXCEED THE MAXIMUM DESIGN SPEED OF TRAILERS OR IMPLEMENTS AS INJURY OR DEATH MAY RESULT. 13-2-3-5

!MWARNING The machine must never be loaded such that less than 20% of the vehicle weight is carried on the front axle. 13-1-1-11_1

!MWARNING Certain tyres fitted as after-market/optional equipment may have maximum permitted speeds below the maximum speed of the vehicle. Brake efficiency is slightly reduced and stopping distance is increased when these tyres are fitted. They will suffer damage if operated at speeds higher than those recommended and may endanger life. 13-3-2-5

!MWARNING You could be killed or injured if a machine tyre bursts. Do not use the machine with damaged, incorrectly inflated or excessively worn tyres. Recognise the speed limitation of the tyres fitted and do not operate at more than their recommended maximum speed. 13-2-1-2

!MDANGER

!MWARNING Hitching Trailers and Equipment When the vehicle is approaching a trailer or equipment to be hitched, make sure that no persons are present between vehicle and trailer or equipment. When mounting equipment at the rear of the vehicle, you must ensure that proper steering control is maintained. The machine must never be loaded such that less than 20% of the vehicle weight is carried on the front axle. 13-1-1-13_1

!MWARNING Dragged or towed loads should be hitched only to the drawbar. Hitching loads to any other part of the machine can cause machine instability. We recommend that a safety chain is used between the tractor and the implement, as detailed in this manual. 13-2-3-10

!MWARNING Make sure all drawbar pins are properly fitted otherwise an implement or trailer could become detached and cause injury and damage. 13-1-1-30

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Section 2 - Care and Safety Safety First Safety Check List

!MCAUTION

Leaving the cab

Trailers with single line hydraulic brakes used in the United Kingdom are subject to a maximum speed of 20 mph (32 kph).

Attempting to attach or detach an implement to or from a PTO shaft or

Working on or cleaning an implement connected to the machine via a PTO shaft.

13-2-2-8

!MCAUTION Trailers with single line air brakes used in the Republic of Germany are subject to a maximum speed of 25 km/ h (15 mph). 13-2-2-13

Always ensure that the PTO shaft and driveline are fully guarded before use. When using stationary PTO equipment, ensure that the park brake is applied. 13-2-1-6

!MWARNING Brakes Do not coast the machine with the engine stopped as the main brakes will only operate for a limited number of applications and trailer brakes may not function at all. Also the steering will become very heavy. 13-1-1-5_2

!MWARNING If the PTO becomes jammed, disengage the PTO, stop the engine and clear the blockage. Wait until the PTO shaft stops before working on the equipment. If the PTO clutch slips, immediately disengage the PTO and stop the engine. 13-2-2-2

!MWARNING When driving the machine on the road, use the accelerator pedal and not the hand throttle to control the engine speed. Always set the hand throttle to 'idle' before using the accelerator pedal.

!MCAUTION Do not use an external PTO button or a joystick button for an emergency PTO stop. 13-3-2-32

13-2-1-8_1

!MWARNING

!MWARNING When driving the machine on the road with an implement or trailer connected to the machine, the transport locks must be engaged to prevent unintentional operation of electronic linkage, front and rear PTO or external hydraulics. 13-2-4-13

!MWARNING When operating PTO equipment, always observe the following safety precautions:

When you hear an audible warning, stop the machine as soon as possible. Get the fault put right before using the machine again. 13-2-1-9

!MWARNING The cab air filter is designed to remove dirt from the outside air. When using chemicals (e.g. for crop spraying) follow the chemical manufacturer's recommendations for protection from dangerous chemicals. 13-2-3-6

Follow the instructions in the implement Operator Manual. Rotating equipment is dangerous. Do not wear loose fitting clothing when working close to rotating shafts. Always disengage the PTO, stop the engine and wait until the equipment stops, before:

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Section 2 - Care and Safety Safety First Safety Check List

!MWARNING

Maintenance Safety

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

!MDANGER Leaving the machine in gear will not prevent it running away. Do not leave the driving seat under any circumstances unless the park brake is on.

!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

13-2-1-10

!MWARNING The exhaust pipe becomes extremely hot when the engine is running and will remain so for some time after the engine is stopped. If you touch the hot pipe you could be severely burned. 13-2-4-11

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

!MCAUTION Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. INT-3-1-14

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Section 2 - Care and Safety Safety First Safety Check List

!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.

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.

0125

!MWARNING

INT-3-1-10_3

Battery Gases Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter. INT-3-1-8

!MDANGER

!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

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

!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

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.

!MWARNING Diesel Fuel Diesel fuel is flammable; keep naked flames away from the fuel system. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions. INT-3-2-2_1

INT-3-1-9

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!MWARNING

!MCAUTION

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.

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

INT-3-2-3

!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

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

Soft Ground A machine can sink into soft ground. Never work under a machine on soft ground. INT-3-2-4

!MWARNING Hot Coolant The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the filler cap. Let the system cool before removing the filler cap. To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap. INT-3-2-9_1

!MWARNING

!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 for: – Damaged hose ends

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

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

– Chafed outer covers – Ballooned outer covers – Kinked or crushed hoses – Embedded armouring in outer covers – Displaced end fittings. INT-3-3-2

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Section 2 - Care and Safety Safety First Safety Check List

!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.

Thoroughly wash contaminated detergent and water.

Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.

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

with

DO NOT BURN FLUOROELASTOMERIC MATERIALS. INT-3-3-5_3

!MWARNING

5-3-1-9

!MWARNING

area

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.

!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.

HYD-1-3_2

!MWARNING

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

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.

Used fluoroelastomeric components whose temperatures have not exceeded 300째C (572째F) 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.

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.

Used fluoroelastomeric components subjected to temperatures greater than 300째C (572째F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn:

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.

Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.

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

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!MWARNING

Turning the Engine Do not try to turn the engine by pulling the fan or fan belt. This could cause injury or premature component failure.

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

0094

Store with care to ensure that they cannot fall and cause injury. 13-3-1-7_1

!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.

!MWARNING You can be killed or injured by moving machinery. Wait for all movement to stop before servicing machinery. 13-3-2-3

!MWARNING Do not open the high pressure fuel system with the engine running. Engine operation causes high fuel pressure. High pressure fuel spray can cause serious injury or death.

INT-3-1-17

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

13-3-2-16

!MWARNING

0147_1

!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.

The injector solenoids receive high voltage when the engine is operating. To reduce the possibility of personal injury from electrical shock, do not wear jewellery or damp clothing, and do not touch the injector solenoids or the solenoid wires when the engine is operating. GEN-1-19

2-3-2-7_2

!MWARNING

!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.

The transmission is in 4 wheel drive until de-selected by hydraulic pressure to 2 wheel drive. If the machine is to be raised and the engine/transmission run, make sure all four wheels are off the ground and supported by axle stands. If only the rear wheels were raised, the machine could still drive through the front axle. TRANS-8-5

!MCAUTION

INT-3-2-8

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

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

INT-3-1-16

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!MWARNING

Radar Speed Sensor (if fitted) To avoid possible eye damage from microwave signals do not look directly into the sensor face.

When gaining access for maintenance work, make sure no-one is in a position to be trapped by the wheels as the steering wheel is turned.

13-1-1-15

13-3-2-15

Note: For radar speed sensor locationl.

!MWARNING Upon completion of any work on the brake system of machines fitted with ABS, the ABS test within Servicemaster must be run satisfactorily before the machine is driven. It is not sufficient to rely on the ABS self-check which can only check for the presence of components, not that they are correctly installed. 0091

!MWARNING Always renew brake pads and locating pins in complete axle sets, using genuine JCB parts, otherwise braking will be unsafe. 13-3-1-10

!MWARNING Before working on or around the brake system, always observe the following precautions: 1

Stop the engine and block all four wheels.

When the air system is being exhausted, keep hands away from the park brake actuator pushrod and caliper, as they may move and trap your fingers.

Take care if disconnecting an air hose containing pressure as it may whip as air escapes.

Never remove or dismantle a component until air pressure has been exhausted and you have read and understood the recommended procedures.

BRAK-8-3_1

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Section 3 - Maintenance

Notes:

3-0

9803/8060-2

3-0

Section 3 - Maintenance Contents Page No. Rountine Maintenance Service Requirements ............................................................................... 3-1 Introduction ............................................................................................3-1 Owner/Operator Support .......................................................................3-1 Service/Maintenance Agreements ........................................................3-1 Initial Service and Inspection (100 Hours) .............................................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 ............................................................................3-7 Pre-start Cold Checks, Service Points and Fluid Levels .......................3-8 Functional Test and Final Inspection ...................................................3-12 Fluids, Lubricants and Capacities ............................................................ 3-14 Coolant Mixtures .................................................................................3-15 Fuel .....................................................................................................3-15 Carrying Tools onto the Machine ............................................................. 3-17 Cleaning the Machine .............................................................................. 3-18 Introduction ..........................................................................................3-18 Preparing the Machine for Cleaning ....................................................3-18 Cleaning the Machine ..........................................................................3-19 Checking for Damage .............................................................................. 3-21 Check the Machine Body and Structure ..............................................3-21 Check the Tyres ..................................................................................3-21 Check the Seat and Seat Belt .............................................................3-21 Check the Hydraulic Hoses and Fittings .............................................3-21 Checking the ROPS Structure .............................................................3-22 Access Panels ......................................................................................... 3-23 Engine Covers .....................................................................................3-23 Panniers ..............................................................................................3-23 Greasing .................................................................................................. 3-25 Introduction ..........................................................................................3-25 Drive Shafts .........................................................................................3-26 Front 3-Point Linkage (Optional) .........................................................3-27 Front Axle Steering Swivels .................................................................3-28 Suspension Cylinder Pivots .................................................................3-29 Hydraulic Lift and 3-Point Linkage .......................................................3-30 Pick-up Hitch .......................................................................................3-31 Automatic Trailer Coupling (if fitted) ....................................................3-32 Air Conditioning and Heater .................................................................... 3-33 Cleaning the Fresh Air Filter ................................................................3-33 Cleaning the Recirculation Air Filter ....................................................3-34 Brakes ..................................................................................................... 3-35 Checking the Foot Brake Fluid Level ..................................................3-35 Checking the Trailer Air Tank ..............................................................3-36 Checking the Air Tank Warning Lights .................................................3-36 Checking and Renewing Foot Brake Pads ..........................................3-37 Testing the Park Brake ........................................................................3-39 Checking the Park Brake Pads ...........................................................3-40

3-i

Section 3 - Maintenance Contents Contents Page No. Electrical System ..................................................................................... 3-41 Battery .................................................................................................3-41 Jump-starting the Engine ....................................................................3-43 Fuses and Relays ................................................................................3-45 Relay Identification ..............................................................................3-49 Checking the Beam Alignment ............................................................3-51 Engine ..................................................................................................... 3-52 Changing the Air Filter Elements .........................................................3-52 Checking the Oil Level ........................................................................3-54 Changing the Oil and Filter ..................................................................3-55 Cooling System ....................................................................................... 3-57 Checking the Coolant Level ................................................................3-57 Draining and Refilling the Coolant .......................................................3-58 Fan Belt ...............................................................................................3-60 Fuel System ............................................................................................. 3-62 Introduction ..........................................................................................3-62 Draining the Fuel Pre-Filter .................................................................3-64 Changing the Fuel Pre-Filter Element .................................................3-65 Changing the Fuel Filter Element ........................................................3-66 Bleeding the Fuel System ...................................................................3-67 Hydraulic System ..................................................................................... 3-68 Introduction ..........................................................................................3-68 Checking the Fluid Level .....................................................................3-69 Changing the Filter ..............................................................................3-70 Emptying the Hydraulic Coupling Drain Reservoirs ............................3-72 Transmission ........................................................................................... 3-73 Checking the Transmission Oil Level ..................................................3-73 Changing the Transmission Oil Filter ..................................................3-74 Changing the Transmission Oil and Cleaning the Strainer ..................3-75 Axles ........................................................................................................ 3-77 Front Axle ............................................................................................3-77 Rear Axle .............................................................................................3-80 Tyres and Wheels .................................................................................... 3-82 General ................................................................................................3-82 Wheel and Tyre Replacement .............................................................3-82 Adjustable Track Width ........................................................................3-83 Wheel Nut Torques ..............................................................................3-84 Tyre Inflation ........................................................................................3-85 Checking and Adjusting the Front Wheel Alignment ...........................3-86 Front Fender Adjustment .....................................................................3-87 Windscreen Washer ................................................................................ 3-88 Checking Fluid Level ...........................................................................3-88 Automatic Trailer Coupling (Optional) ..................................................... 3-89 Checking for Wear ...............................................................................3-89

3-ii

Section 3 - Maintenance

Rountine Maintenance Service Requirements Introduction T3-002

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.

Distributor's Service Department who are there to help you! You will have been given the names of the relevant service contacts at your Distributor when the machine was installed. To get the most from your Distributor please help them to satisfy you by: 1

Giving your name, address and telephone number.

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

Quoting your machine model and serial number.

Date of purchase and hours of work.

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.

Nature of the problem.

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

3-1

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.

Initial Service and Inspection (100 Hours) T3-005

To further protect your machine's performance it is essential your JCB Distributor carries out an initial service and inspection when the machine is one month old or when it has completed 100 hours of operation (whichever occurs first). You should notify your Distributor in advance to allow the necessary arrangements to be made.

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Section 3 - Maintenance Rountine Maintenance Service Requirements

Obtaining Replacement Parts T3-004_3

We recommend that you use only JCB Genuine Parts. A Parts Book for your machine is available from your JCB Distributor. The Parts Book will help you identify parts and order them from your JCB distributor. Your dealer will need to know the exact model, build and serial number of your machine. See Identifying Your Machine in INTRODUCTION section. The data plate also shows the serial numbers of the engine, transmission and axle(s), where applicable. But remember if any of these units have been changed, the serial number on the data plate may be wrong. Check on the unit itself.

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Section 3 - Maintenance Rountine Maintenance Health and Safety

Health and Safety Lubricants T3-060_2

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

Hygiene JCB lubricants are not a health risk when used properly for their intended purposes. However, excessive or prolonged skin contact can remove the natural fats from your skin, causing dryness and irritation.

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

Handling

!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

Low viscosity oils are more likely to do this, so take special care when handling used oils, which might be diluted with fuel contamination. Whenever you are handling oil products you should maintain good standards of care and personal and plant hygiene. For details of these precautions we advise you to read the relevant publications issued by your local health authority, plus the following.

Storage

New Oil There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices. Used Oil Used engine crankcase lubricants contain harmful contaminants. Here are precautions to protect your health when handling used engine oil:

Always keep lubricants out of the reach of children. Never store lubricants in open or unlabelled containers.

Avoid prolonged, excessive or repeated skin contact with used oil.

Apply a barrier cream to the skin before handling used oil. Note the following when removing engine oil from skin:

Waste Disposal

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

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Wash your skin thoroughly with soap and water.

b Using a nail brush will help. c

Use special hand cleansers to help clean dirty hands.

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

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Section 3 - Maintenance Rountine Maintenance Health and Safety 3

Avoid skin contact with oil soaked clothing.

Don't keep oily rags in pockets.

Wash dirty clothing before re-use.

Throw away oil-soaked shoes.

First Aid - Oil Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention. Swallowing If oil is swallowed do not induce vomiting. Get medical advice. Skin In the case of excessive skin contact, wash with soap and water.

Spillage Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area.

Fires

!MWARNING Do not use water to put out an oil fire. This will only spread it because oil floats on water. Extinguish oil and lubricant fires with carbon dioxide, dry chemical or foam. Fire fighters should use self contained breathing apparatus. 7-3-1-3_1

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Section 3 - Maintenance Rountine Maintenance Health and Safety

!MCAUTION

Battery

!MWARNING

T3-061

Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames. Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery carefully to prevent spillage. Keep metallic items (watches, rings, zips etc) away from the battery terminals. Such items could short the terminals and burn you. Set all switches to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first.

Damaged or spent batteries and any residue from fires or spillage should be put in a closed acid proof receptacle and must be disposed of in accordance with local environmental waste regulations. INT-3-1-12

!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 shorting the terminals with metal; use a hydrometer or voltmeter. INT-3-1-8

Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up. When reconnecting, fit the positive (+) lead first. 5-3-4-12

!MCAUTION Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged. INT-3-1-14

!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

!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

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Section 3 - Maintenance Rountine Maintenance Health and Safety Warning Symbols

First Aid - Electrolyte

The following warning symbols may be found on the battery.

Do the following if electrolyte: Gets into your eyes

Symbol

Meaning

Immediately flush with water for 15 minutes, always get medical help.

Keep away from children.

Is swallowed A289230-1

Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help.

Shield eyes.

Gets onto your skin

A289260-1

No smoking, no naked flames, no sparks.

Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.

A289280

Explosive Gas.

A289250

Battery acid.

A289240

Note operating instructions.

A289270

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3-6

Section 3 - Maintenance Rountine Maintenance Service Schedules

Service Schedules Introduction

How to Use the Service Schedules T3-036

T3-012_3

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

In the example shown, A shows all service requirements to be carried out every 10 hours and B shows the requirements to be carried out every 500 hours.

!MWARNING

Important: Services should be carried out at either the hourly interval or calendar interval, whichever occurs first. Refer to Calendar Equivalents.

Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe. It should be correctly parked on firm level ground. To prevent anyone starting the engine, remove the starter key. Disconnect the battery and block the wheels when you are working beneath the machine. If you do not take these precautions you could be killed or injured. 9-3-1-1

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

795390-1

Calendar Equivalents Every 10 Hours = Daily

T3-088

Every 50 Hours = Weekly Every 500 Hours = Six Months Every 1000 Hours = Yearly Every 2000 Hours = 2 Years Every 5000 Hours = 5 Years

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Section 3 - Maintenance Rountine Maintenance Service Schedules

Pre-start Cold Checks, Service Points and Fluid Levels Operation 10 Hr 50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

5000 Hr

ENGINE Oil level

- Check

Oil and Filter

Air Cleaner Outer Element

- Change

Air Cleaner Inner Element

- Change

(3)

Air Cleaner Hose and Clamp Security

- Check

Air Compressor Mountings

- Check

Air Compressor Discharge Lines(4)

- Check

(4)

Fuel Pre-filter Fuel Pre-filter Fuel Filter

- Drain (3)

(3)

- Change

- Check

Coolant Antifreeze and Coolant Additive Concentration(4)

- Check

Coolant

- Change

Fan Belt Condition

- Check

Fan Hub

- Check

Fan Belt Tensioner Condition(4)

- Check

Vibration Damper(4)

- Check

Valve Clearances(4)

- Check and Adjust

(4)

Crankcase Breather Tube

- Check

Engine Mounting Bolts for Tightness(4)

- Check

Fuel Injection Pump Mounting Bolts for Tightness(4)

- Check

Radiator and Coolers

- Clean

Charge Air Cooler Hose and Clamp Security

- Check

Charge Air Cooler

- Check

Turbocharger(4)

- Check

3-8

- Change

Coolant Level

Engine

- Change

(2)(3)

- Steam Clean

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Section 3 - Maintenance Rountine Maintenance Service Schedules Operation 10 Hr 50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

5000 Hr

TRANSMISSION, AXLES AND STEERING Transmission Oil Level Transmission Oil

- Check

- Change

(5)

Transmission Strainer

- Clean

Transmission Filter

- Change

Clutch Fluid Level

- Check

Axle Oil Level (incl. Hubs)

(6)

- Check

- Security/ Grease

Steer Axle Pivots

- Grease

Steering Column Universal Joints

- Grease

Axle Oil (incl. Hubs)

(7)

Tyre Pressures/Condition Oil Cooler and Pipework Drive Shafts (8)

- Change - Check

- Check and Clean

Steering Axle Wheel Alignment

- Check

Pitman Arm, Drag Link, Track Rod End, Steering Ram and Damper Condition and Security(4)(9)

- Check

Wheel Nut Security

- Check

HYDRAULICS Oil Level Oil(4)

- Sample/ Change

Oil Filter

- Change

Hydraulic System Hydraulic Lift and 3 Point Linkage, Front and Rear

- Check for Leaks

- Check

Ram Piston Rods Condition

- Check

Hydraulic Oil Cooler and Pipework

- Check and Clean

Hydraulic Oil Strainer

- Clean

Hydraulic Coupling Drain Reservoir

- Empty

Security of Front Weight

- Check

3-9

- Grease

Rear 3 Point Linkage Cross-shaft Oil level

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Section 3 - Maintenance Rountine Maintenance Service Schedules Operation 10 Hr 50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

5000 Hr

BRAKES Air System Tank Air System Drier Canister

- Drain (4)

- Clean

Brake System Fluid Level

- Check

Park Brake

- Change

Trailer Brake Control Line Air Filter(4)

Brake System Fluid

- Change - Check and Adjust

Park Brake Pad Condition and Security

- Check

Service Brake Pad Condition and Security

- Check

Calliper Bolt Torque(4)

- Check

Pipework Security

- Check

Battery Electrolyte Level (if applicable)

- Check

Wiring for Chaffing/Routing

- Check

Battery Terminals for Condition and Tightness

- Check

Battery Charge Condition(4)

- Check

Headlamp Alignment

- Check

ELECTRICS

BODY AND FRAMEWORK Chassis Fabrication

- Visually Inspect for Damage

Engine Cover Hinges

- Lubricate

Seat Belt Condition and Security

- Check

Air Conditioning Condensor

- Clean

ROPS Structure

- Check

Cab Air Intake Filter (standard type only)(10)

- Clean

Door Locks

- Check

Windscreen Washer Fluid Level

- Check

Condition of Paintwork

- Check

(4)

Machine Generally Automatic Trailer Coupling (if fitted)

3-10

- Check and Clean - Grease

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Section 3 - Maintenance Rountine Maintenance Service Schedules Operation 10 Hr 50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

5000 Hr

SUSPENSION Cylinder Pivots Panhard Rod Condition and Torque Tightness

- Grease (4)(9)

- Check

Rear Anti-roll Bar Condition and Torque Tightness(4)(9)

- Check

Control Arms Condition and Torque Tightness(4)

- Check

`V' Link Condition and Torque Tightness(4)

- Check

Accumulator Pressure(4)

- Check

Gas Spring Pressure(4)

- Check

(1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) Applies only if recommended oil is available. If this is not available, this job should be carried out every 250 hours. See Fluids, Lubricants and Capacities for suitable alternative oil. (3) If the machine is operating in ambient temperatures below -18°C [0°F] or above 38°C [100°F], change engine oil and filter, air and fuel filters at shorter intervals. Shorter maintenance intervals are also required if the machine is operated in a dusty environment or if frequent stops are made. (4) Jobs which should only be done by a specialist. (5) After a major transmission repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil and filter after a further 100 hours if the oil was heavily contaminated because of, or from the failure (e.g. water contamination). (6) Check for leaks every 50 hours, check level if leaking. (7) After a hub repair, the new oil should be run to operating temperature and changed again to remove any contamination which entered during the repair. Change the oil again after a further 100 hours to remove any bedding-in wear. This is particularly important if new brake plates have been fitted. (8) If working in muddy conditions the propshafts and PTO driveshafts must be greased daily. (9) After any of these items are refitted, recheck the torque tightness after a short road test. (10) Heavy duty carbon type filters must be changed at 250 hour intervals.

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Section 3 - Maintenance Rountine Maintenance Service Schedules

Functional Test and Final Inspection Operation

10 Hr

50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

ENGINE - Check

Idle Speed(2) Maximum No Load Speed

- Check

(2)

Exhaust System Security

- Check

Cooling System for Leaks

- Check

Fuel System for Leaks and Contamination

- Check

Lubrication System for Leaks

- Check

Stop Control

- Check

(2)

TRANSMISSION, AXLES AND STEERING 2WD/4WD/Differential Lock Selection

- Check

Oil Leakage

- Check

Transmission Lubrication Pressure(2)

- Check

4WD/PTO Supply Pressure

- Check

(2)

Differential Lock Pressure Relief Valve(2)

- Check

Neutral Start Operation

- Check

PTO Selection and Operation

- Check

Transmission Calibration(2)

- Check

Selection of Transmission Modes and Ranges

- Check

Steering Operation

- Check

Steering Pressure Relief Valve(2)

- Check

HYDRAULICS Maximum System Pressure(2)

- Check and Adjust

Operation All Services

- Check

System for Oil Leakage

- Check

Oil Cooler and Pipework for Damage or Leakage

- Check

BRAKES Foot Brake - Operation

- Check

Park Brake - Operation

- Check

Air System Warning Lights

- Check

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Section 3 - Maintenance Rountine Maintenance Service Schedules Operation

10 Hr

50 Hr

100 Hr(1)

500 Hr

1000 Hr

2000 Hr

- System Test

Starter Motor

- Check

Alternator - Output(2)

- Check

All Electrical Equipment Operation, (e.g. warning lights, beacon, alarms, horn, wipers etc.)

- Check

ABS(2) ELECTRICS

Error Codes for all systems, Engine, ABS, Electronic Draft Control, Transmission(2)

- Download and Rectify

Machine Datalog(2)

- Download and Rectify

- Check

Circuit Pressure(2)

- Check

Axle to Chassis Clearance(2)

- Check

Ride Height Operation

- Check

Brake Light Switch Input to ABS ECU using computer diagnostic tool(2) SUSPENSION

(2)

(1) First 100 Hours Service only, to be completed by your JCB Distributor. (2) Jobs which should only be done by a specialist.

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Section 3 - Maintenance Rountine Maintenance Fluids, Lubricants and Capacities

Fluids, Lubricants and Capacities ITEM

CAPACITY

Table 1. FLUID/LUBRICANT

Litres UK Gal

INTERNATIONAL SPECIFICATION

Fuel Tank

430

Diesel Oil

Engine (Oil)

3.5

JCB Engine Oil EP 15W/40 (-20 to +40 deg C) (1) API CH-4 or ACEA E3/ B3A3, SAE15W/40(2)

Engine (Coolant)

6.6

JCB High Performance Antifreeze & Inhibitor/ Water K Coolant Mixtures ( T 3-15)

ASTM D6210

43.5

9.5

JCB Super Universal Agricultural Oil

API-GL-4, MIL-L-2105

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

3.3

3.75

0.8

9.2

JCB HD90 Gear Oil

API-GL-5, MIL-L-2105C

JCB Brake Fluid Dot 4 (capacity given is for each reservoir)

SAE J1703 DOT 4

JCB Hydraulic Fluid HP46

ISO VG46

Transmission Front Axle - Axle Beam - Hubs (each) Rear Axle Brake System - Front - Rear (2 reservoirs) Hydraulic System

(3)

0.75

0.2

0.75

0.2

147

ASTM D975-66T Nos. 1D, 2D

(Above 38ºC,100ºF) JCB Hydraulic Fluid HP32

ISO VG32

(Below 38ºC,100ºF) Grease Points

JCB HP Grease

Lithium complex NLGI No.2 consistency including extreme pressure additives

(1) While 15W/40 oil is recommended for most climates, limited use of low viscosity oils such as 10W/30 is permitted to provide easier starting and sufficient oil flow at temperatures below -5ºC (23ºF). Continued use of low viscosity oils can decrease engine life and will require different service intervals. (2) If API CH-4 or ACEA E3/B3A3 engine oil AT SAE 15W/40 is not available, the engine oil must be changed at 250 hours, using the following alternative oils: For -20ºC to +40ºC: JCB Engine Oil HP15W/40 or for -25ºC to +30 ºC: JCB Engine Oil HP10W/30. (3) The total hydraulic system capacity depends on the equipment being used. Watch level indicator on hydraulic tank

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Section 3 - Maintenance Rountine Maintenance Fluids, Lubricants and Capacities

Coolant Mixtures

Fuel T3-009_3

T3-089

Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period.

Use good quality diesel fuel to get the correct power and performance from your engine.

Replace the coolant mixture according to the intervals shown in the machine's Service Schedule.

Recommended Fuel Specification – EN590 Diesel Fuel Types - Auto/Co/C1/C2/C3/C4.

!MWARNING

– BS2869 Class A2. – ASTM D975-91 Class 2-2DA, US DF1, US DF2, US DFA.

Antifreeze can be harmful. Obey the manufacturer's instructions when handling full strength or diluted antifreeze.

– JIS K2204 (1992) Grades 1, 2, 3, and Special Grade 3.

7-3-4-4_1

You must dilute full strength antifreeze with clean water before use. Use clean water of no more than a moderate hardness (pH value 8.5). If this cannot be obtained, use de-ionized water. For further information advice on water hardness, contact your local water authority. The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion.

Note: Where low sulphur/low aromatic fuels are used it is important that lubricity additives are used. The additives listed below are advertised as being suitable for bringing the lubricity levels of kerosene/low sulphur fuels up to those of diesel fuels. They have not been tested or approved by the engine manufacturer. They should be added by your fuel supplier who should understand the concentration level necessary. 1

Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%), specifically for Indian Superior Kerosene (SKO) but may be applicable to other fuels.

Lubrizol 539N. Dosage (on Swedish low sulphur fuel) 250 ppm.

Paradyne 7505 (from Infineum). Dosage 500 ppm (0.05%).

The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below. 50% Concentration (Standard) Protects against damage down to -40 °C (-39 °F) 60% Concentration (Extreme Conditions Only)

!MCAUTION

Protects against damage down to -56 °C (-68 °F) Important: Do not exceed a 60% concentration, as the freezing protection provided reduces beyond this point.

Consult your fuel supplier or JCB distributor about the suitability of any fuel you are unsure of. GEN-9-2

If you use any other brand of antifreeze: – Ensure that the antifreeze complies with International Specification ASTM D6210. – Always read and understand the manufacturer's instructions. – Ensure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used. – Ensure that the antifreeze is ethylene glycol based and does not use Organic Acid Technology (OAT).

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Section 3 - Maintenance Rountine Maintenance Fluids, Lubricants and Capacities Acceptable Fuel Specification

Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels

!MCAUTION The fuel specification below is acceptable, however this fuel may reduce the life of the fuel injection equipment. The use of this fuel may also affect the engine performance.

Fuel resources such as Rape Methyl Ester and Soybean Methyl ester, collectively known as Fatty Acid Methyl Esters are being used as alternatives and extenders for mineral oil. Fatty Acid Methyl Esters must conform to certain standards to be of acceptable quality, just as mineral oils do at present.

GEN-9-3

– ASTM D975-91 Class 1-1DA. – JP7, MIL T38219 XF63.

Consult your JCB distributor for advice about the use of Fatty Acid Methyl Ester fuels, as improper application may impair engine performance.

– NATO F63.

Sulphur Content

!MCAUTION A combination of water and sulphur will have a corrosive chemical effect on fuel injection equipment. It is essential that water is eradicated from the fuel system when high sulphur fuels are used. ENG-3-2

High sulphur content can cause engine wear. (High sulphur fuel is not normally found in North America, Europe or Australia.) If you have to use high sulphur fuel you must change the engine oil more frequently. Table 2. Percentage of sulphur in Oil Change Interval the fuel (%) Less than 0.5

Normal

0.5 to 1.0

0.75 of normal

More than 1.0

0.50 of normal

Aviation Kerosene Fuels Note: Aviation kerosene fuels are not approved and their use may cause damage to components. Warranty will not be allowed on any component where damage is found to have been caused by the use of aviation kerosene.

Low Temperature Fuels Special winter fuels may be available for engine operation at temperatures below 0°C (32°F). These fuels have a lower viscosity. They also limit wax formation in the fuel at low temperatures. (Wax forming in the fuel can stop the fuel flowing through the filter.)

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Section 3 - Maintenance Rountine Maintenance Carrying Tools onto the Machine

Carrying Tools onto the Machine When you carry tools onto the machine you must maintain three points of contact with the machine at all times. Lift tools onto the machines in intervals if necessary. Place the tools down before you adjust your grips on the machine. Do not try to adjust your grips on the machine while holding tools.

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Section 3 - Maintenance Rountine Maintenance Cleaning the Machine

Cleaning the Machine

!MCAUTION

Introduction T3-062_2

Clean the machine using water and or steam. Do not allow mud, debris etc. to build upon the machine. Before carrying out any service procedures that require components to be removed: 1

Cleaning must be carried out either in the area of components to be removed or, in the case of major work, or work on the fuel system, the whole engine and surrounding machine must be cleaned. When cleaning is complete move the machine away from the wash area, or alternatively, clean away the material washed from the machine.

Important: When removing components be aware of any dirt or debris that may be exposed. Cover any open ports and clean away the deposits before proceeding.

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

The engine or certain components could be damaged by high pressure washing systems; special precautions must be taken if the engine is to be washed using a high pressure system. Ensure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by the high pressure cleaning system. ENG-3-3

Important: Do not aim the water jet directly at bearings, oil seals or electrical and electronic components such as the engine electronic control unit (ECU), alternator or fuel injectors. Use a low pressure water jet and brush to soak off caked mud or dirt. Use a pressure washer to remove soft dirt and oil. Note: The machine must always be greased after pressure washing or steam cleaning.

Preparing the Machine for Cleaning

!MWARNING

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

Make sure the engine cannot be started. Disconnect the battery before doing this job.

Pressure Washing and Steam Cleaning

2-3-3-5

!MWARNING When using a steam cleaner, wear safety glasses or a face shield as well as protective clothing. Steam can cause serious personal injury. 13-3-2-10_2

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Important: Stop the engine and allow it to cool for at least one hour. Do not attempt to clean any part of the engine while it is running. Make sure that all electrical connectors are correctly coupled. If connectors are open fit the correct caps or seal with water proof tape.

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Section 3 - Maintenance Rountine Maintenance Cleaning the Machine

Cleaning the Machine

h Check the charge air piping E for leaks, holes, cracks or loose connections. Tighten the hose clamps if required.

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

If any damage is found, contact your JCB dealer.

Reposition the coolers and the condensor. Fasten latches A.

Close the engine cover.

HYD-1-3_2

!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

!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.

C E

8-3-4-8

Pay particular attention to the underside. Do not allow mud to build up on the engine and transmission. 1

The radiator and coolers. If the tubes or fins become clogged, the radiator and coolers will be less efficient. a

Stop the engine.

b Open the engine cover. c

Open latches A (one each side) and pull forward the bottom of condensor B.

d Lift lever C and slide backwards the cooler pack D. e

Brush off both sides of the condensor, coolers and radiator.

Make sure all the loosened material is brushed out of the cooling area.

Fig 1. 2

g Check for cracks, holes or other damage.

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C078230-B2

Engine Do not allow mud to build up on the engine and transmission. Pay particular attention to the exhaust area, remove all combustible material. The engine or certain components could be damaged by high pressure washing systems, special

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Section 3 - Maintenance Rountine Maintenance Cleaning the Machine precautions must be taken if the engine is to be washed using a high pressure system.

Important: Do not place the jet nozzle closer than 600mm (24 in) to any part of the engine. Do not attempt to clean any part of the engine while it is running. Stop the engine and allow it to cool for at least one hour. a

Disconnect the battery.

b Do not wash any part of the: i

Fuel injection pump.

Cold start device.

iii Electrical shut off solenoid (ESOS).

iv Electrical connections. c

Fig 2.

T027040-B2

Ensure that the alternator, starter motor and any other electrical components are shielded and not directly cleaned by high pressure cleaning system.

Transmission On ABS machines, take special care to avoid directing high power water jets at the electrical connections to the front and rear axle ABS sensors.

Seats Keep the upholstery clean, using a commercially available upholstery or plastic cleaner. Test first for compatibility on a small concealed area of the seat.

!MWARNING Take care with the backrest frame. It may jerk forward and cause injury. 13-3-2-9_2

During cleaning, the upholstery should not be soaked through. If required, the cushion and backrest can be removed for cleaning by removing screws B. Keep the seat slide runners lightly greased.

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Section 3 - Maintenance Rountine Maintenance Checking for Damage

Checking for Damage Check the Machine Body and Structure

Check the Seat and Seat Belt

T3-063

T3-008_2

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

!MWARNING

Check pivot pins are correctly in place and secured by their locking devices.

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

Check steps and handrails are undamaged and secure.

2-3-1-7_1

Check for broken, cracked or crazed window glass and mirrors. Replace damaged items. Check all lamp lenses for damage. Check all attachment teeth are undamaged and secure. Check all safety decals are in place and undamaged. Fit new decals where necessary.

Check the Tyres

!MWARNING

T3-065_2

Inspect the seat belt for signs of fraying and stretching. Check that the stitching is not loose or damaged. Check that the buckle assembly is undamaged and works correctly. Check that the belt mounting bolts are undamaged, correctly fitted and tightened. Check seats are undamaged and secure. Check seat adjustments for correct operation.

Check the Hydraulic Hoses and Fittings

!MWARNING

T3-072

You could be killed or injured if a machine tyre bursts. Do not use the machine with damaged, incorrectly inflated or excessively worn tyres. Recognise the speed limitation of the tyres fitted and do not operate at more than their recommended maximum speed.

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.

13-2-1-2

INT-3-3-2_4

Always drive with consideration for the condition of the tyres. Incorrect tyre pressures will affect the stability of the machine. Check the tyres daily for the correct tyre pressure and signs of damage. For example:

Inspect the hoses regularly for:

– Chafed outer covers – Ballooned outer covers

– Signs of distortion (bulges)

– Kinked or crushed hoses

– Cuts or wear

– Embedded armouring in outer covers

– Embedded objects (nails, etc.)

– Displaced end fittings

Install the valve caps firmly to prevent dirt from entering the valve. Inspect for leaks when you check the tyre pressures. Inspect the tyre valve for leaks, when you check the tyre pressures.

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– Damaged hose ends

Do not use the machine if a hose or hose fitting is damaged. Replace damaged hoses before you use the machine again. Replacement hoses must be of the same size and standard.

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Section 3 - Maintenance Rountine Maintenance Checking for Damage

Checking the ROPS Structure

!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 the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification. INT-2-1-9_6

Check the structure for damage. Check that the four mounting bolts are installed and undamaged. Check that torque tightness of nuts A and B is 365 Nm (270 lbf ft). Tighten them to the correct torque if necessary.

Fig 3.

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C070490

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