Jcb 504b telescopic handler service repair manual sn（277001 onwards） by freemanualdownload7dt

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General Information Care & Safety

Routine Maintenance Attachments Body & Framework

Service Manual LOADALL

Electrics Controls Hydraulics Transmission Brakes

PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE; Â© WATERLOO PARK, UTTOXETER, ST14 5PA, ENGLAND Tel. 01889 - 590312 PRINTED IN ENGLAND

Publication No. 9803/3610U-4

Steering Engine

1 2 3 A B C D E F G H K

Introduction This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 1 2 3

= = =

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

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

= =

Attachments Body & Framework

...etc.

The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual. Section contents, technical data, circuit descriptions, operation descriptions etc are inserted at the beginning of each alphabetically coded section. READ the section contents to locate machine types, machine type indentification IS NOT listed on individual pages. All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference. Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.

This Service Manual covers the following machines: 504B - from Machine Serial Number 277001 *526 - from Machine Serial Number 279289

9803/3610U

Issue 2*

General Information

Section 1

Contents Identification

1-1

Torque Settings

2-1

Service Tools - Numerical List * - Section B - Section C - Section E - Section F - Section H - Section K

3-1 3-3 4-1 5-1 6-1 7-1 7-1

Sealing and Retaining Compounds

9803/3610

Page No.

8-1

Issue 2*

Section 1

General Information

Section 1

1-1

Identification Plate

Unit Identification

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

The engine serial number is stamped on a label W which is fastened to the right side of the cylinder block, near the fuel filter.

V W

S195340

Explanation of Vehicle Identification Number (VIN)

SLP504BRE0277001 A A *B C

D E

C D

World Manufacturer Identification Machine Model Year of Manufacture P = 1993 V = 1997 R = 1994 W = 1998 S = 1995 X = 1999 T = 1996 Y = 2000 Manufacturing Location Machine Serial Number

E SLP = JCB 504B S 1 = 2001 2 = 2002 3 = 2003 4 = 2004 E = England 0277001

S195600

Typical Engine Identification Number AA 50261 U 500405 P A B C D E A Engine Type AA = 4 cylinder naturally aspirated AB = 4 cylinder turbo B Build Number C Country of Origin D Engine Sequence Number E Year of Manufacture

Machine Model Explanation

504B F G F 500 Series machine range G 4,000 lbs lift capacity 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.

9803/3610U

Issue 3*

General Information

Section 1 1-2

Y S088470

S196280

S196290

The Syncro Shuttle serial number is stamped on label Y as shown. The rear axle serial number is stamped on plate X as shown. The front axle serial number is stamped on plate Z as shown.

9803/3610

Issue 2

Section 1

General Information

Section 1

2-1

Torque Settings Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third. UNF Grade 'S' Bolts Bolt Size in 1 5 3 7 1 9 5 3 7

/4 /16 /8 /16 /2 /16 /8 /4 /8

1 11/4 11/2

(mm) (6.3) (7.9) (9.5) (11.1) (12.7) (14.3) (15.9) (19.0) (22.2) (25.4) (31.7) (38.1)

Hexagon (A/F) in 7 1 9 5 3

/16 /2 /16 /8 /4

/16

11/8 * 15/16 11/2 17/8 21/4

Nm 14 28 49 78 117 170 238 407 650 970 1940 3390

Torque Settings kgf m 1.4 2.8 5.0 8.0 12.0 17.3 24.3 41.5 66.3 99.0 198.0 345.0

lbf ft 10 20 36 58 87 125 175 300 480 715 1430 2500

Torque Settings kgf m

lbf ft

Metric Grade 8.8 Bolts Bolt Size (mm) M5 M6 M8 M10 M12 M16 M20 M24 M30 M36

(5) (6) (8) (10) (12) (16) (20) (24) (30) (36)

Hexagon (A/F) mm 8 10 13 17 19 24 30 36 46 55

7 12 28 56 98 244 476 822 1633 2854

0.7 1.2 3.0 5.7 10 25 48 84 166 291

5 9 21 42 72 180 352 607 1205 2105

Rivet Nut Bolts/Screws Bolt Size M3 M4 M5 M6 M8 M10 M12

(mm) (3) (4) (5) (6) (8) (10) (12)

Torque Settings (for steel rivet nuts) Nm kgf m lbf ft 1.2 0.12 0.9 3.0 0.3 2.0 6.0 0.6 4.5 10.0 1.0 7.5 24.0 2.5 18.0 48.0 4.9 35.5 82.0 8.4 60.5

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

9803/3610

Issue 2*

Section 1

General Information

3-1

Section 1 3-1

Service Tools Numerical List 1406/0011 1406/0014 1406/0018 1406/0021 1406/0029 1604/0003 1604/0004 1604/0006 1606/0003 1606/0004 1606/0007 1606/0008 1606/0009 1606/0012 1606/0014 1606/0015 1606/0017 1612/0006 816/00189 816/00190 816/00193 816/00196 816/00197 816/00294 816/15118 816/20008 816/55038 816/55040 816/50043 892/00039 892/00041 892/00047 892/00048 892/00049 892/00051 892/00055 892/00056 892/00057 892/00058 892/00059 892/00060 892/00071 892/00074 892/00075 892/00076 892/00077 892/00121 892/00137 892/00179 892/00180 892/00181 892/00223 892/00224 892/00225 * 892/00254 892/00255 892/00256 892/00257 892/00258 892/00259

9803/3610

Bonded Washer Bonded Washer Bonded Washer Bonded Washer Bonded Washer Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Adapter Blanking Cap Blanking Cap Blanking Cap Blanking Cap Blanking Cap Blanking Cap Pressure Test Adapter Adapter Pressure Test Adapter Pressure Test Adapter 'T' Adapter Spool Clamp De-glazing Tool 'T' Adapter 'T' Adapter 'T' Adapter 'T' Adapter Blanking Plug Blanking Plug Blanking Plug Blanking Plug Blanking Plug Blanking Plug Adapter Female Connector Female Connector Female Connector Female Connector Discharge Tester Micro-Bore Hose Bearing Press Seal Fitting Tool Plastic Boss Hand Pump Impulse Extractor Adapter - Impulse Extractor Hose 1 /4'' BSP Test Point 3 /8'' BSP Test Point 1 /2'' BSP Test Point 5 /8'' BSP Test Point 1'' BSP Test Point

Page No 5-1 5-1 5-1 5-1 5-1 5-3 5-3 5-1 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-3 5-1 5-2 5-2 5-2 5-2 5-2 5-2 5-3 5-1 5-1 5-1 5-2 5-2 7-1 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-2 5-3 5-2 5-2 5-2 5-2 4-1 5-3 6-1 7-1 7-1 5-3 6-2 6-2 5-1 5-3 5-3 5-3 5-3 5-3

Numerical List 892/00260 892/00261 892/00262 892/00263 892/00264 892/00265 892/00268 892/00269 892/00270 892/00271 892/00272 892/00274 892/00275 892/00276 892/00277 * 892/00279 * 892/00280 892/00282 892/00283 892/00284 892/00285 892/00286 892/00295 892/00298 892/00301 892/00302 892/00304 892/00333 892/00334 * 892/00346 892/00706 892/00817 892/00818 892/00819 892/00842 892/00843 892/00844 892/00846 892/00847 892/00848 892/00849 892/00891 892/00893 892/00902 892/00903 892/00904 892/00905 892/00906 892/00916 892/00918† 892/00920 892/00923 892/00943 892/00964 892/00965 892/00966 921/52600† 926/15500 992/02800 992/04000

Page No

11/4'' BSP Test Point 5 /8'' UNF Test Point 1 /4'' M BSP 1/4'' F BSP 5 /8'' M BSP 5/8'' F BSP 3 /4'' M BSP 3/4'' F BSP 1'' M BSP 1'' F BSP Flow Monitoring Unit Sensor Head Load Valve Adapter Adapter Adapter Adapter Adapter Adapter Pressure Gauge 0-400 bar (0-6000 lbf/in2) Pressure Gauge 0-600 bar (0-9000 lbf/in2) Shunt Tool Kit Case Digital Tachometer Hyd. Oil Temperature Probe Surface Temperature Probe End Float Setting Tool Fluke Meter Flow Test Adapter Flow Test Adapter Flow Test Adapter Heavy Duty Socket Seal Fitting Tool Pressure Gauge 0-70 bar (0-1000 lbf/in2) Test Probe Heavy Duty Socket Heavy Duty Socket Heavy Duty Socket Glass Lifter Glass Stand Long Knife Glass Extractor (Handles) Nylon Spatula Wire Starter Braided Cutting Wire Seal Fitting Adapter Torque Converter Alignment Bar Spanner, Track Rod End Spanner, Differential Spanner, Differential SLI Test Box Seal Fitting Adapter Spring Compression Tool Setting Tool Kit Flow Test Adaptor Test Block for A.R.V. Hand Held Test Unit Test Point (1/8 BSP) PS700 Test Point (3/8 BSP) PS700 Test Point (1/4 BSP) SS400, SS600 Spacer Kit Rubber Spacer Blocks ARV Extractor Torque Multiplier

5-3 5-3 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-1 5-3 5-1 5-1 5-1 5-1 5-1 4-1 4-1 4-1 4-1 4-1 6-1 4-1 6-1 6-1 6-1 6-2 5-4 6-1 5-3 6-2 6-2 6-2 3-3 3-3 3-4 3-4 3-3 3-4 3-4 6-3 6-2 6-3 6-3 6-3 4-1 6-3 6-4 6-5 6-1 5-3 4-3 6-4 6-4 6-4 6-5 3-3 5-2 6-2

Issue 8*

Section 1

General Information

Section 1

3-2 * Service

3-2

Tools (cont'd)

Numerical List 992/04800 992/07000 992/07603 992/07608 992/07609 992/07610 992/07611 992/07612 992/07613 992/09500 992/09700 992/10100 992/10900 992/12800 992/12801 993/59300 993/70100 993/70111 993/78200 993/99412

Drive Coupling Spanner Ram End Cap Peg Spanner Replacer- Bearing Cup Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Spanner Spanner Spool Clamp Test Harness for SLI Cut-Out Knife ‘L’ Blades 2/4 Wheel Pressure Tester & Clamp Powershift Endfloat Checking Kit Breakback Torque Wrench Mainshift Airline Adaptor Adaptor Harness

Page No 6-1 5-3 6-1 6-1 6-1 6-1 6-1 6-1 6-1 5-2 5-2 5-2 4-1 3-4 3-4 6-2 6-8 6-5 6-4 4-1

The following parts are replacement items for kits and would normally be included in the kit numbers above. Replacement item for kit no. 892/00180 892/00181 Replacement Boss

7-1

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

5-1 5-1 5-1 5-1

Replacement items for spacer kit no. 921/52600 921/52601 Spacer 12.75 mm 921/52602 Spacer 12.80 mm 921/52603 Spacer 12.85 mm 921/52604 Spacer 12.90 mm 921/52605 Spacer 12.95 mm 921/52606 Spacer 13.00 mm 921/52607 Spacer 13.05 mm 921/52608 Spacer 13.10 mm 921/52609 Spacer 13.15 mm 921/52610 Spacer 13.20 mm 921/52611 Spacer 13.25 mm 921/52612 Spacer 13.30 mm 921/52613 Spacer 13.35 mm 921/52614 Spacer 13.40 mm 921/52615 Spacer 13.45 mm 921/52616 Spacer 13.50 mm 921/52617 Spacer 13.55 mm 921/52618 Spacer 13.60 mm 921/52619 Spacer 13.65 mm 921/52620 Spacer 13.70 mm 921/52621 Spacer 13.75 mm 921/52622 Spacer 13.80 mm 921/52623 Spacer 13.85 mm 921/52624 Spacer 13.90 mm 921/52625 Spacer 13.95 mm 921/52626 Spacer 14.00 mm

9803/3610

Numerical List Replacement items for kit no. 993/70100 993/70101 Base Plate and Bolts 993/70104 Mainshaft Pillar 993/70106 Layshaft/Reverser Pillar 993/70112 Input Shaft Pillar 993/70120 Setting Assembly 993/70130 Mainshaft Adapter 993/70140 Setting Assembly 993/70160 Yoke Assembly

Page No

6-8 6-8 6-8 6-8 6-8 6-8 6-8 6-8

Note: To maintain a complete kit, order a replacement spacer for the one used. † Identifies items required for all JCB Gearboxes from September 1996, when solid spacers replaced collapsible spacers.

Ram Seal Protection Sleeves 892/01016 892/01017 892/01018 892/01019 892/01020 892/01021 892/01022 892/01023 892/01024 892/01025 892/01026

For 25 mm Rod Diameter For 30 mm Rod Diameter For 40 mm Rod Diameter For 50 mm Rod Diameter For 50 mm Rod Diameter (slew ram) For 60 mm Rod Diameter For 60 mm Rod Diameter (slew ram) For 65 mm Rod Diameter For 70 mm Rod Diameter For 75 mm Rod Diameter For 80 mm Rod Diameter

892/01027

Piston Seal Assembly Tool

5-4

6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5 6-5

Issue 6*

General Information

Section 1

3-3

Service Tools Section B - Body and Framework

826/01176 826/01106 826/01177 826/01176 826/01333

M6 x 16mm Rivet Nut M6 x 19mm Rivet Nut M8 x 18mm Rivet Nut M10 x 23mm Rivet Nut M10 x 26mm Rivet Nut

Installation Tool Available from: Bollhoff Fastenings Ltd. Midacre The Willenhall Estate Rose Hill Willenhall West Midlands, WV13 2JW S150970

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. Folding Stand for Holding Glass essential for preparing new glass prior to installation. JCB part 892/00843

number

JCB part number - 892/00842

S186280

S186300

Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame. JCB part number - 926/15500 (unit quantity = 500 off) Nylon Spatula - general tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge. JCB part number - 892/00847 S186470

9803/3610

S186550

Issue 1*

Section 1

General Information

Section 1

3-4

Service Tools (cont'd) Section B - Body & Framework

Wire Starter - used to access braided cutting wire (below) through original polyurethane seal. Cut-Out Knife - used to remove broken glass. JCB part number - 992/12800 JCB part number - 892/00848 S186340

S186310

'L' Blades - 25 mm (1 in) cut - replacement blades for cut-out knife (above). JCB part number - 992/12801 (unit quantity = 5 off)

Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass. JCB part number - 892/00846

S186350

S186320

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 - 892/00844

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

S186330

9803/3610

S186360

Issue 1*

Section 1

General Information

Section 1

4-1

Service Tools Section C - Electrics

AVO Test Kit 1

892/00283

Tool Kit Case

892/00298

Fluke Meter

892/00286

Surface Temperature Probe

892/00284

Venture Microtach Digital Tachometer

892/00282

100 amp Shunt - open type

892/00285

Hydraulic Temperature Probe

892/00121

High Rate Discharge Tester (400 amps) for testing battery condition

S188230

S188240

992/10900 993/99412

Test Harness for Safe Load Indicator Adaptor Harness

From machine Serial No. 278818 use: * 892/00905

S188250

9803/3610

Test Box For Safe Load Indicator (SLI) and Load Moment Indicator (LMI) S244692

Issue 3*

Section 1

General Information

Section 1

4-2

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

6A 6B 6C 6D 7A 7B 7C 7D 8A 8B 8C 8D 9A 9B 9C 9D 10 11 12

:7216/0002 :7216/0004 :7216/0003 :7216/0001 :7218/0002 :7218/0004 :7218/0003 :7218/0001 :7219/0002 :7219/0004 :7219/0003 :7219/0001 :7219/0006 :7219/0008 :7219/0007 :7219/0005 :7210/0001 :7210/0002 :7210/0003

6 Way Pin Housing 6 Way Pin Retainer 6 Way Socket Retainer 6 Way Socket Connector 8 Way Pin Housing 8 Way Pin Retainer 8 Way Socket Retainer 8 Way Socket Connector 10 Way Pin Housing 10 Way Pin Retainer 10 Way Socket Retainer 10 Way Socket Connector 14 Way Pin Housing 14 Way Pin Retainer 14 Way Socket Retainer 14 Way Socket Connector Dummy Plug Wire Seal (1.4 - 2.2 mm dia.) Wire Seal (2.2 - 2.9 mm dia.)

S188380

9803/3610

Issue 1

Section 1

General Information

Section 1

4-3

Service Tools (cont'd) Section C - Electrics

892/00943

Hand Held Test Unit MK II (ECU)

299920

9803/3610

Issue 1*

Section 1

General Information

Section 1

5-1

Service Tools (cont'd) Section E - Hydraulics * Hydraulic Circuit Test Gauges and Connections 1 2 3 4 5

892/00279 892/00346 892/00347 892/00254 892/00280

Pressure Gauge 0-400 bar (0-6000 lbf/in2) Pressure Gauge 0-70 bar (0-1000 lbf/in2) Connector Hose Pressure Gauge 0-600 bar (0-9000 lbf/in2)

3 1,2,5

S188130 S188140

PressureTest 'T' Adaptors

Bonded Washers

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

1406/0011 1406/0018 1406/0014 1406/0021 1406/0029

1 /4

in. BSP in. BSP 5 /8 in. BSP 3 /4 in. BSP 11/4 in. BSP 1 /2

Flow Test Equipment 892/00268 892/00269 892/00270 1406/0021 1604/0006 1612/0006 892/00271 892/00272 816/20008 892/00275 892/00276 892/00277

9803/3610

Flow Monitoring Unit Sensor Head 0 to 100 l/min (0 to 22 UK gal/min) Load Valve Bonded Washer Adapter 3/4 in M x 3/4 M BSP Adapter 3/4 in F x 3/4 M BSP Adapter 3/4 in F x 5/8 M BSP Adapter 5/8 in F x 3/4 M BSP Adapter 3/4 in F x 1/2 M BSP Adapter 1/2 in F x 3/4 M BSP Adapter 3/4 in F x 3/8 M BSP Adapter 3/4 in F x 3/4 M BSP

S188150

Issue 2*

Section 1

General Information

Section 1

5-2

Service Tools (cont'd) Section E - Hydraulics

S193880

S193870

Female Cone Blanking Cap

Male Cone Blanking Cap

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

816/00294 816/00189 816/00190 816/00197 816/00196 816/00193

1 /4

in. BSP in. BSP 1 /2 in. BSP 5 /8 in. BSP 3 /4 in. BSP 1 in. BSP 3 /8

S193900

S193890

T' Adapters

Female Connectors

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)

892/00074 892/00075 892/00076 892/00077

3 /8

in. BSP x 3/8 in. BSP in. BSP x 1/2 in. BSP 5 5 /8 in. BSP x /8 in. BSP 3 3 /4 in. BSP x /4 in. BSP 1 /2

S192410

S193930

Hexagon Spanners for Ram Pistons and End Caps

Spool Clamps

992/09500 75mm A/F 992/09700 95mm A/F

892/00039 992/10100 992/02800

9803/3610

Spool Clamp Spool Clamp ARV Extractor

Issue 1

Section 1

General Information

Section 1

5-3

Service Tools (cont'd) Section E - Hydraulics

Male Adapters - BSP x BSP 1606/0003 3/8 in. x 1/4 in. 1604/0003 3/8 in. x 3/8 in. 892/00071 3/8 in. x 3/8 in. taper 1606/0004 1/2 in. x 1/4 in. 1606/0007 1/2 in. x 3/8 in. 1604/0004 1/2 in. x 1/2 in. 1606/0017 5/8 in. x 1/2 in. 1606/0008 3/4 in. x 3/8 in. 1606/0009 3/4 in. x 1/2 in. 1604/0006 3/4 in. x 3/4 in. 1606/0012 3/4 in. x 1 in. 1606/0014 3/4 in. x 11/4 in. 1606/0015 1 in. x 11/4 in.

S193860

S193850

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

Hand Pump Equipment

S200141

892/00223 892/00137 892/00274 892/00262 892/00706 892/00279

Hand Pump Micro-bore Hose 1/4 in BSP x 5 metres Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1 1 /4 in M BSP x /4 in F BSP x Test Point Test Probe Gauge 0 - 400 bar (0-6000 lbf/in2)

S270650

*892/00923

S216060

Test Block for A. R. V

992/07000

9803/3610

Ram End Cap Peg Spanner

Issue 3*

Section 1

General Information

Section 1

6-1

Service Tools (cont'd) Section F - Transmission

S188160

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

Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter

S188170

992/07603

Replacer- Bearing Cup

S188190

S188200

892/00295 End Float Setting Tool

892/00179

Bearing Press

C A S188220

S083252

D A B C *D

892/00304 892/00301 892/00302 892/00920

9803/3610

Flow Test Adapter Flow Test Adapter Flow Test Adapter Flow Test Adapter

992/04800 Flange Spanner For locking pinion flange while nut is slackened or torque set

Issue 2*

Section 1

General Information

Section 1

6-2

Service Tools (cont'd) Section F - Transmission

*892/00893 Torque Converter Alignment Bar 992/04000 Torque Multiplier S228921

Use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts etc.

S197030

* 892/00224 Impulse Extractor Set for Hub Bearing Seats S197250

S197070

Heavy Duty Sockets for Durlok bolts 892/00817 17mm A/F x 3/4in square drive 892/00818 22mm A/F x 3/4in square drive 892/00819 15mm A/F x 1/2in square drive 892/00333 19mm A/F x 3/4in square drive

D C A

S197080

*993/59300 2/4 Wheel Drive Clutch Pressure Test Adaptor & Clamp S196750

9803/3610

892/00225

Adapter - Impulse Extractor A Small 17mm to 25mm B Medium 25mm to 45mm C Large 45mm to 80mm

993/59500

Adapter - Impulse Extractor D (syncro shuttle and powershift transmission)

Issue 3*

Section 1

General Information

Section 1

6-3

Service Tools (cont'd) Section F - Transmission

S250350

892/00902 Spanner, Track Rod End

892/00906 Seal Fitting Adaptor

S250340

S250370

892/00903 Spanner, Differential

892/00904 Spanner, Differential

S250360

892/00891 Seal Fitting Adaptor S227760

9803/3610

Issue 2*

Section 1

General Information

Section 1

6-4

Service Tools (cont'd) Section F - Transmission

S267310

892/00916

S261230

Spring Compressor Tool Forward/Reverse Clutches

Torque Measuring Tool for Wheel Hub Seals Manufacture locally, procedures in this manual show checking the wheel hub seal using a rolling force. However, the torque can be measured using using above locally manufactured tool. Bearing rolling torque is 12 to 22Nm (9 to 16lbf ft) excluding seal drag. Maximum permissible including seal drag is 40 Nm (29.5 lbf ft)

S316250

Test Point 1

892/00964

Test point (1/8 BSP) PS700

892/00965

Test point (3/8 BSP) PS700

892/00966

Test point (1/4 BSP) SS400, SS600

S197010

993/78200

Mainshaft Airline Adaptor (Powershift Transmission Only)

These test points can be left in position after testing.

9803/3610

Issue 3*

Section 1

General Information

Section 1

6-5

Service Tools (cont'd) Section F - Transmission

Solid Spacer Setting Kit

2 S316260

9803/3610

1 892/00918 2 993/70111 3 921/52600 Comprises: 921/52601 921/52602 921/52603 921/52604 921/52605 921/52606 921/52607 921/52608 921/52609 921/52610 921/52611 921/52612 921/52613 921/52614 921/52615 921/52616 921/52617 921/52618 921/52619 921/52620 921/52621 921/52622 921/52623 921/52624 921/52625 921/52626

Setting Tool Kit Breakback Torque Wrench Spacer Kit Spacer 12.75 Spacer 12.80 Spacer 12.85 Spacer 12.90 Spacer 12.95 Spacer 13.00 Spacer 13.05 Spacer 13.10 Spacer 13.15 Spacer 13.20 Spacer 13.25 Spacer 13.30 Spacer 13.35 Spacer 13.40 Spacer 13.45 Spacer 13.50 Spacer 13.55 Spacer 13.60 Spacer 13.65 Spacer 13.70 Spacer 13.75 Spacer 13.80 Spacer 13.85 Spacer 13.90 Spacer 13.95 Spacer 14.00

Issue 1*

Section 1

General Information

6-6

Section 1 6-6

Service Tools (cont'd) Section F - Transmission

Fixture for Syncro Shuttle & Powershift Gearbox removal & replacement.

Note: When removing/replacing a Syncro Shuttle Gearbox, use items 1, 2 and 3. When removing/replacing a Powershift Gearbox, use items 1 and 4.

S162580

Fixture - Item 1

9803/3610

Issue 1*

Section 1

General Information

Section 1

6-7

Service Tools (cont'd) Section F - Transmission Fixture - Item 2

Fixture - Item 3

9803/3610

Fixture - Item 4

Issue 1*

Section 1

General Information

Section 1

6-8

Service Tools (cont'd) Section F - Transmission

993/70100

Powershift Endfloat Checking Kit (Includes items 2 to 13)

1 4

993/70101

Base Plate

993/70160

Yoke Assy

993/70130

Mainshaft Adapter Assy

10 8

993/70104

Mainshaft Pillar

993/70106

Layshaft/Reverser Pillar

993/70120

Layshaft Setting Assy

6 13 2

A191642

993/70140

Reverser Setting Assy

1391/3305

Capscrew (M8x20)

10 826/01417

Setscrew (M10x30) Flanged

11 993/70111

Setting Wrench (this is not part of the kit)

12† 993/70112

Input Shaft Pillar

13† 993/70150

Input Setting Assy

A191642

†If these items are not in your kit they can be ordered separately but the base plate 2 will have to be drilled to secure item 12, see A and B. Measurements are in mm. Apply JCB Threadlocker And Sealer and tighten item 9 to 25-30 Nm (18-22 lbf ft).

8.5

15 12

A 36

17 81.75 96.35

9803/3610

A191643

Issue 1*

Section 1

General Information

Section 1

7-1

Service Tools (cont'd) Section H - Steering

892/00180 Seal Fitting Tool for fitting 'O' ring and back-up ring to Danfoss Orbitrol Unit 892/00181 Replacement Plastic Boss

S191750

Section K - Engine

892/00041 De-glazing Tool for Cylinder Bores (to assist bedding-in of new piston rings)

S192390

For details of other engine service tools refer to Perkins Service Manual Publication No. 9806/0100

9803/3610

Issue 1

Section 1

General Information

Section 1

8-1 * Sealing

8-1

and Retaining Compounds

JCB Multigasket

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

JCB High Strength Threadlocker A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important.

4102/1212

4102/0551

For all retaining parts which are unlikely to be dismantled.

4101/0651

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

4101/0252

JCB Threadseal

A medium strength thread sealing compound.

4102/1951

JCB Threadlocker and Sealer (High Strength)

A medium to high strength locking fluid for retention and sealing of ram piston heads.

4101/0552

JCB Threadlocker

A locking fluid for use on threads larger than 50 mm dia.

4101/0451

JCB Activator

A cleaning primer which speeds the curing rate of anaerobic products.

4104/0251 4104/0253

Aerosol Bottle

JCB Cleaner/Degreaser

For degreasing components prior to use of anaerobic adhesives and sealants.

4104/1557

Aerosol

JCB Retainer (High Strength)

JCB Threadlocker and Sealer

9803/3610

Issue 5*

Section 2

Care & Safety

Section 2

Contents

9803/3610

Page No.

Safety Notices

1-1

General safety

2-1

Operating safety

2-2

Maintenance safety

2-3

Lubricants - Health and Safety

3-1

Issue 1

Section 2

Care & Safety

1-1

Section 2 1-1

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

! DANGER Denotes an extreme hazard exists. If proper precautions are not taken it is highly probable that the operator (or others) could be killed or seriously injured. INT-1-2-1

! WARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-2

! CAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine. INT-1-2-3

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Issue 1

Section 2

Care & Safety

Section 2

2-1

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

As well as the warnings in this chapter, specific warnings are given throughout the book. This section is designed to give a safety code for use of the machine generally and for maintenance practices.

Do not work with the machine until you are sure that you can control it. Do not start any job until you are sure that you and those around you will be safe. If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE GEN-1-6

General Safety

! WARNING ! WARNING

Decals You can be injured if you do not obey the decal safety instructions. Keep decals clean. Replace unreadable or missing decals with new ones before operating the machine. Make sure replacement parts include warning decals where necessary. INT-1-3-4

! WARNING Clothing You can be injured if you do not wear proper clothing. Loose clothing can get caught in the machinery. Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well-fitting overall, ear-protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained. INT-1-3-6

Care and Alertness All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards. INT-1-3-5

! WARNING Raised Boom A raised boom can fall or be lowered accidentally. Do not walk under a raised boom which is not fitted with a safety strut, or you could be injured. 5-1-1-1

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

9803/3610

Issue 1

Section 2

Care & Safety

Section 2

2-2

! WARNING

Operating Safety ! WARNING Controls You or others can be killed or seriously injured if you operate the control levers from outside the cab. Operate the control levers only when you are correctly seated inside the cab.

Engine Panels The engine has exposed rotating parts. Do not open the bonnet while the engine is running. Keep other people clear while you raise the engine cover using the boom. Do not use the machine with the bonnet open or the cover raised. 5-1-2-1

! WARNING

INT-2-1-3

! WARNING Entering/Leaving Always face the machine when entering and leaving the cab. Use the step(s) and handrails. Make sure the step(s), handrails and your boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls as handholds, use the handrails. INT-2-1-7

! WARNING Passengers Passengers in or on the machine can cause accidents. The JCB Loadall is a one man machine. Do not carry passengers. INT-2-2-2

! WARNING Exhaust Gases Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, fit an exhaust extension. If you begin to feel drowsy, stop the machine at once. Get out of the cab into fresh air. INT-2-1-10

! WARNING Ramps and Trailers Water, mud, ice, grease and oil on ramps or trailers can cause serious accidents. Make sure ramps and trailers are clean before driving onto them. Use extreme caution when driving onto ramps and trailers. INT-2-2-6

! WARNING Fires If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the operator's cab until you need to use it. Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use self-contained breathing apparatus

ROPS/FOPS Structure The machine is fitted with a Roll Over Protection Structure (ROPS) and a Falling Objects Protection Structure (FOPS). You could be killed or seriously injured if you operate the machine with a damaged or missing ROPS/FOPS. If the ROPS/FOPS has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification INT-2-1-9/3

! WARNING Reversing Reversing at high speed can cause accidents. Do not reverse in third or fourth (if fitted) gear with full throttle. Always drive at a safe speed to suit working conditions. INT-2-2-9

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

! WARNING Sparks Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust. INT-2-2-10

! CAUTION Overhead Clearance A raised boom can strike overhead objects. Always check for overhead clearance before raising the boom. 5-1-5-1

INT-3-2-7/1

9803/3610

Issue 1

Section 2

Care & Safety

Section 2

2-3

Maintenance Safety ! WARNING

! WARNING

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

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

INT-3-1-3

! WARNING Boom Safety Strut A raised boom can drop suddenly and cause serious injury. Before working under a raised boom, fit the boom safety strut. See Boom Safety Strut (MAINTENANCE section). 5-1-5-7

! WARNING Communications Bad communictions 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 danger areas; examples of danger areas are: the rotating blades and belt on the engine, the attachments and linkages, and anywhere beneath or behind the machine. People can be killed or injured if these precautions are not taken. INT-3-1-5

! WARNING Asbestos Asbestos dust can damage your lungs. Some engine gaskets contain asbestos. Do not dismantle the engine or exhaust system; get these jobs done by a qualified person who has a copy of the engine service manual. 5-1-6-1

INT-3-2-8

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

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

! WARNING 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

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

! DANGER 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. See Battery (MAINTENANCE section) for First Aid treatments.

! WARNING Oil Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin. INT-3-2-3

! WARNING 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

INT-3-2-1/2

9803/3610

Issue 1

Section 2

Care & Safety

Section 2

2-4

! WARNING Hydraulic Fluid Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immediately. INT-3-1-10/1

! WARNING Battery Terminals The machine is negatively earthed. Always connect the negative pole of the battery to earth. When connecting the battery, connect the earth (-) lead last. When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9

! WARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open. INT-3-1-11/1

! WARNING Battery A battery with frozen electrolyte can explode if it is used or charged. Do not use a machine with a frozen battery. To help prevent the battery from freezing, keep the battery fully charged.

! WARNING Fluoroelastomeric Materials * Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton, Fluorel and Technoflon. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN. New fluoroelastomeric components at ambient temperature require no special safety precautions. Used fluoroelastomeric components whose temperatures have not exceeded 300Â°C require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOT TOUCH COMPONENT OR SURROUNDING AREA.

INT-3-1-7

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

Used fluoroelastomeric components subjected to temperatures greater than 300Â°C (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn: 1

Ensure that components have cooled then remove and place material into plastic bags.

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

Thoroughly wash contaminated area with 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.

INT-3-2-11

! CAUTION 'O' rings, Seals and Gaskets Badly fitted, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals. INT-3-2-12

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

! WARNING Hydraulic Hoses Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: Damaged end fittings Chafed outer covers Ballooned outer covers Kinked or crushed hoses Embedded armouring in outer covers Displaced end fittings.

DO NOT BURN FLUOROELASTOMERIC MATERIALS. If contamination of skin or eyes occurs, wash the affected area with a continuous supply of clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately. INT - 3 - 3 - 5/1

INT-3-3-2

9803/3610

Issue 2*

Section 2 3-1

Care & Safety

Section 2

Lubricants - Health and Safety

3-1

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

Apply a barrier cream to the skin before handling used engine oil.

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

Note the following when removing engine oil from skin: a Wash your skin thoroughly with soap and water. b

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

Using a nail brush will help.

c Use special hand cleansers to help clean dirty hands.

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.

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

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.

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

First Aid - Oil

Waste Disposal Eyes All waste products should be disposed of in accordance with all the relevant regulations. The collection and disposal of used engine oil should be in accordance with any local regulations. Never pour used engine oil into sewers, drains or on the ground.

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

Handling

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

New Oil

Skin

There are no special precautions needed for the handling or use of new oil, beside the normal care and hygiene practices.

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

Used Oil Used engine crankcase lubricants contain harmful contaminants. Here are precautions to protect your health when handling used engine oil: 1

Avoid prolonged, excessive or repeated skin contact with used engine oils.

9803/3610

Spillage Absorb on sand or a locally approved brand of absorbent granules. Scrape up and remove to a chemical disposal area. Fires Extinguish with carbon dioxide, dry chemical or foam extinguishers. Do not use water. Fire-fighters should use self-contained breathing apparatus.

Issue 1

Section 3

Routine Maintenance

Section 3

Contents

Page No.

* Lubricants and Capacities

- New Engines - Lubrication Charts - 504B (Rear Steer) Machines - 504B AWS Machines (Type AA and AB Builds) - 526 Machines (Type AA and AB Builds) - 504B AWS Machines - Low Emission Engines (Type AR and AK Builds) - 526 Machines - Low Emission Engines (Type AR and AK Builds)

1-1 1-1 1-2 1-3 1-4 1-5 1-6

Machine Safety

2-1

Service Schedules

3-1

* Grease

- 50 Hours - 500 Hours - 1000 Hours

4-1 4-2 4-4

Oiling

5-1

Tyres and Wheels

6-1

Foot Brake (504B machines only)

7-1

Engine Air Filter - Cleaning the Pre-Cleaner - Changing the Outer Element - Changing the Inner Element

7-1 7-2 7-3

Engine Oil and Filter - Checking the Oil level - Changing the Oil and Filter

8-1 8-1

Engine Cooling System - Checking the Coolant Level - Coolant Mixtures - Changing the Coolant

9-1 9-1 9-2

Cab Heater Filter

10 - 1

* Fuel System

- Fuel Types - Filling the Tank - Cleaning the Lift Pump Gauze - Draining the Filter (up to S/N 280299) - Changing the Filter Element (up to S/N 280299) - Draining the Filter (from S/N 280300) - Changing the Filter Element (from S/N 280300) - Draining the Sediment Bowl - Cleaning the Sediment Bowl - Bleed the System

9803/3610U

11 - 1 11 - 2 11 - 2 11 - 3 11 - 3 11 - 4 11 - 4 11 - 5 11 - 5 11 - 6

Issue 4*

Routine Maintenance

Section 3

Contents

9803/3610

Page No.

Fire Extinguisher

12 - 1

Syncro Shuttle Transmission - Checking the Oil Level - Changing the Oil and Filter

12 - 1 12 - 2

Front and Rear Axle - Checking the Axle Oil Level - Changing the Axle Oil

13 - 1 13 - 1

Front and Rear Hub - Checking the Hub Oil Levels - Oil Immersed Brakes * - Changing the Hub Oil

14 - 1 14 - 1 14 - 1

Hydraulic System - Checking the Fluid Level - Changing the Filter Element

15 - 1 15 - 1

Hose Burst Protection Valves - Checking the Hose Burst Protection Valves

16 - 1

Battery

17 - 1

Issue 2*

Section 3 1-1

Routine Maintenance Lubricants & Capacities

Section 3 1-1

New Engines New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately; glazing of the piston cylinder bores, resulting in excessive oil consumption, could occur if the engine is gently run-in. Under no circumstances should the engine be allowed to idle for extended periods; (e.g. warming up without load). Engines of new machines are filled at the factory with JCB 10W/30 Multigrade oil. This oil should be drained after the first 100 hours operation and the engine filled with the appropriate recommended grade as shown in the lubrication chart. JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted to the machine. After the first 100 hours operation, it is essential that the 10W/30 oil is replaced by the lubricant recommended in the lubrication charts.

Lubrication Charts Lubrication charts are included on the following pages for all machine models. Be sure you identify the machine and its lubricant requirements correctly.

9803/3610U

Issue 4*

Section 3

Routine Maintenance

1-2

Section 3 1-2

Lubricants & Capacities 504B (Rear Steer) Machines

ITEM

CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal

INTERNATIONAL SPECIFICATION

Fuel Tank Up to serial No. 279000 From serial No. 279001

120 160

26.4 35.2

31.7 42.2

Diesel Oil (See Types of Fuel)

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

Engine (Oil)

2.2

2.6

JCB 15W/40 Engine Oil 14°F to 122°F (-10°C to 50°C)

SAE 15W/40 API CF4/SG

JCB 10W Engine Oil -4°F to 50° F (-20°C to 10°C)

SAE 10W API CF4/SG

Engine (Coolant) 55% Antifreeze

20 11

4.4 24

5.3 2.9

Permanent Antifreeze Starts to freeze -33 °F (-36 °C)

ASTM D3306-74

Syncro Shuttle Transmission

3.7

4.5

JCB Special Transmission Fluid

ESP-M2C 33G Friction modified oils MUST NOT be used (eg Dexron ATF type).

Front Axle Housing Hubs (x2)

9.7 0.6

2.1 0.1

2.5 0.16

JCB Special Gear Oil Plus

API GL4 MUST be suitable for use with oil immersed brakes and limitedslip differentials (LSD).

Rear Axle Housing Hubs (x2)

5.0 1.5

1.1 0.3

1.3 0.4

22.0 24.2

26.4 29.0

JCB Hydraulic Fluid

ISO VG46

Grease Points

††JCB HP Grease

Lithium based No. 2 consistency

Wear Pad Runways

JCB Waxoyl

Boom Hoses

JCB Special Slide Lubricant

Hydraulic Tank Up to serial No. 279000 †100 From serial No. 279001 †110

† Note:

This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Watch level sight glass when filling.

†† Note:

If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.

9803/3610U

Issue 3*

Section 3

Routine Maintenance

Section 3

Lubricants & Capacities

1-3

504B AWS Machines (Type AA and AB Builds) ITEM

CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal

INTERNATIONAL SPECIFICATION

Fuel Tank Up to serial No. 279000 From serial No. 279001

120 160

26.4 35.2

31.7 42.2

Diesel Oil (See Types of Fuel)

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

Engine (Oil)

2.2

2.6

JCB 15W/40 Engine Oil 14°F to 122°F (-10°C to 50°C)

SAE 15W/40 API CF4/SG

JCB 10W Engine Oil -4°F to 50° F (-20°C to 10°C)

SAE 10W API CF4/SG

Engine (Coolant) 55% Antifreeze

20 11

4.4 2.4

5.3 2.9

Permanent Antifreeze Starts to freeze -33 °F (-36 °C)

ASTM D3306-74

Syncro Shuttle Transmission

3.7

4.5

JCB Special Transmission Fluid

ESP-M2C 33G Friction modified oils MUST NOT be used (eg Dexron ATF type).

Front Axle Housing Hubs (x2)

5.5 1.5

1.2 0.3

1.4 0.4

JCB Special Gear Oil Plus

API GL4 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).

Rear Axle Housing Hubs (x2)

5.0 1.5

1.1 0.3

1.3 0.4

22.0 24.2

26.4 29.0

JCB Hydraulic Fluid

ISO VG46

Grease Points

††JCB HP Grease

Lithium based No. 2 consistency

Wear Pad Runways

JCB Waxoyl

Boom Hoses

JCB Special Slide Lubricant

Hydraulic Tank Up to serial No. 279000 †100 From serial No. 279001 †110

† Note:

This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Watch level sight glass when filling.

†† Note:

If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.

9803/3610U

Issue 3*

Section 3

Routine Maintenance

Section 3

Lubricants & Capacities

1-4

526 Machines (AA and AB Builds) ITEM

CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal

INTERNATIONAL SPECIFICATION

Fuel Tank Up to serial No. 279000 From serial No. 279001

120 160

26.4 35.2

31.7 42.2

Diesel Oil (See Types of Fuel)

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

Engine (Oil)

2.2

2.6

JCB 15W/40 Engine Oil 14°F to 122°F (-10°C to 50°C)

SAE 15W/40 API CF4/SG

JCB 10W Engine Oil -4°F to 50° F (-20°C to 10°C)

SAE 10W API CF4/SG

Engine (Coolant) 55% Antifreeze

20 11

4.4 2.4

5.3 2.9

Permanent Antifreeze Starts to freeze -33 °F (-36 °C)

ASTM D3306-74

Syncro Shuttle Transmission

3.7

4.5

JCB Special Transmission Fluid

ESP-M2C 33G Friction modified oils MUST NOT be used (eg Dexron ATF type).

Front Axle Housing Hubs (x2)

9 2

1.98 0.44

2.4 0.5

JCB Special Gear Oil Plus

API GL4 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).

Rear Axle Housing Hubs (x2)

8.4 2

1.85 0.44

2.2 0.5 JCB Light Hydraulic Fluid

ISO VG15

Brake System From serial No. 280300

Do not use ordinary brake fluid Hydraulic Tank Up to serial No. 279000 †100 From serial No. 279001 †110

22.0 24.2

26.1 29.0

JCB Hydraulic Fluid

ISO VG46

Grease Points

††JCB HP Grease

Lithium based No. 2 consistency

Wear Pad Runways

JCB Waxoyl

Boom Hoses

JCB Special Slide Lubricant

† Note:

This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Watch level sight glass when filling.

†† Note:

If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals

9803/3610U

Issue 2*

Section 3

Routine Maintenance

Section 3

Lubricants & Capacities

1-5

504B AWS Machines - Low Emission Engines (Type AR and AK Builds) ITEM

CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal

INTERNATIONAL SPECIFICATION

Fuel Tank

Engine (Oil)

160

35.2

42.2

Diesel Oil (See Types of Fuel)

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

2.2

2.6

JCB 15W/40 Engine Oil 14°F to 122°F (-10°C to 50°C)

SAE 15W/40 API CF4/SG

JCB 10W Engine Oil -4°F to 50° F (-20°C to 10°C)

SAE 10W API CF4/SG

Engine (Coolant) 55% Antifreeze

20 11

4.4 2.4

5.3 2.9

Permanent Antifreeze Starts to freeze -33 °F (-36 °C)

ASTM D3306-74

Syncro Shuttle Transmission

3.7

4.5

JCB Special Transmission Fluid

ESP-M2C 33G Friction modified oils MUST NOT be used (eg Dexron ATF type).

Front Axle Housing Hubs (x2)

5.5 1.5

1.2 0.3

1.4 0.4

JCB Special Gear Oil Plus

API GL4 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).

Rear Axle Housing Hubs (x2)

5.0 1.5

1.1 0.3

1.3 0.4

†110

24.2

29.0

JCB Hydraulic Fluid

ISO VG46

Grease Points

††JCB HP Grease

Lithium based No. 2 consistency

Wear Pad Runways

JCB Waxoyl

Boom Hoses

JCB Special Slide Lubricant

Hydraulic Tank

† Note:

This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Watch level sight glass when filling.

†† Note:

If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.

9803/3610U

Issue 1*

Section 3

Routine Maintenance

Section 3

Lubricants & Capacities

1-6

526 Machines - Low Emission Engines (Type AR and AK Builds) ITEM

CAPACITY FLUID/LUBRICANT Litres UK Gal US Gal

INTERNATIONAL SPECIFICATION

Fuel Tank

Engine (Oil)

160

35.2

42.2

Diesel Oil (See Types of Fuel)

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

2.2

2.6

JCB 15W/40 Engine Oil 14°F to 122°F (-10°C to 50°C)

SAE 15W/40 API CF4/SG

JCB 10W Engine Oil -4°F to 50° F (-20°C to 10°C)

SAE 10W API CF4/SG

Engine (Coolant) 55% Antifreeze

20 11

4.4 2.4

5.3 2.9

Permanent Antifreeze Starts to freeze -33 °F (-36 °C)

ASTM D3306-74

Syncro Shuttle Transmission

3.7

4.5

JCB Special Transmission Fluid

ESP-M2C 33G Friction modified oils MUST NOT be used (eg Dexron ATF type).

Front Axle Housing Hubs (x2)

9 2

1.98 0.44

2.4 0.5

JCB Special Gear Oil Plus

API GL4 MUST be suitable for use with oil immersed brakes and limited slip differentials (LSD).

Rear Axle Housing Hubs (x2)

8.4 2.0

1.85 0.44

2.2 0.5 JCB Light Hydraulic Fluid

ISO VG15

Brake System

Do not use ordinary brake fluid Hydraulic Tank

†110

24.2

29.0

JCB Hydraulic Fluid

ISO VG46

Grease Points

††JCB HP Grease

Lithium based No. 2 consistency

Wear Pad Runways

JCB Waxoyl

Boom Hoses

JCB Special Slide Lubricant

† Note:

This is nominal machine capacity. The total hydraulic system capacity depends on the equipment being used. Fill and check with all rams closed. Watch level sight glass when filling.

†† Note:

If JCB Special MPL Grease is used, all 50 hour greasing operations must be carried out at TEN (10) HOUR intervals. All 500 hour greasing operations must be carried out at FIFTY (50) HOUR intervals.

9803/3610U

Issue 1*

Routine Maintenance

Section 3

2-1

When working on a Loadall the machine must be made safe before carrying out any servicing.

General Safety

Working with Boom Raised

Read Section 2, Care and Safety.

Carry out General Safety and the following procedure:

Position the machine on firm level ground. Apply the parking brake.

! WARNING You could be killed or injured if the boom drops while you are working under it. Install the safety strut as instructed below before doing any maintenance work with the boom raised.

Chock both sides of all four wheels. Make sure the transmission selector and gear lever are in the neutral position.

5-3-1-2

Fully retract the boom and lower to the ground. Switch OFF the engine and remove the starter key.

Before fitting the safety strut remove any load on the forks and empty buckets or attachments. Fully retract the boom (unless it needs to be extended for maintenance). Raise the boom just far enough to install the strut.

Operate the controls to vent residual pressure. Release the hydraulic tank filler cap to release residual tank pressure. When welding electrically disconnect the alternator.

Make sure the parking brake is engaged and the transmission is in neutral. Switch OFF the engine and remove the starter key.

! CAUTION You will have to climb onto the machine to fit or remove the safety strut. Take care, especially if the machine is wet. Remove mud and oil before climbing onto the machine.

5-3-1-11

! WARNING You could be killed or injured if the boom is lowered while you are under it. Keep people away from the machine while you fit the strut. 5-3-1-3

Remove the strut from its stowage position A. Place the strut around the ram piston rod as shown. Fix it in place with strap B. S195470

The strap fitted to the safety strut must be in a serviceable condition, if not fit a new strap. To prevent any chance of the boom creeping down and trapping your fingers, the boom should be lowered onto the strut. Note: Lower the boom carefully, to prevent possible damage to the strut. Stop as soon as the weight of the boom is on the strut.

S195740

9803/3610

Issue 3*

Routine Maintenance

Section 3

2-2

Working with Boom Raised (continued) Remove Safety Strut Raise the boom to take the weight off of the strut. Stop the Engine. Make sure the parking brake is engaged and the transmission is in neutral. Remove the starter key.

! CAUTION You will have to climb onto the machine to install or remove the safety strut. Take care, especially if the machine is wet. Remove mud and oil before climbing onto the machine.

5-3-1-11

! WARNING You could be killed or injured if the boom is lowered while you are under it. Keep people away from the machine while you remove the safety strut.

S195470

5-3-1-10

Start the engine and raise the boom to take the weight off the strut. Stop the engine and remove the starter key. Undo the strap B, then remove the strut. Place the strut in its stowage position A.

S195740

9803/3610

Issue 1

Section 3

Routine Maintenance

Section 3

Service Schedules

3-1

Pre-start Cold Checks Service Points and Fluid Levels

Operation

ENGINE Engine Air Filter Pre-cleaner Clean Oil Level and Condition Check Oil and Filter (1) Change Air Cleaner Dust Valve Clean Air Cleaner Outer Element Change Air Cleaner Inner Element Change Fuel System For Leaks and Contamination Check Fuel Filter Drain Fuel Filter Change Coolant Level and Antifreeze Strength Check Fuel Sedimenter Drain and clean Fan Belt Tension/Condition Check Valve Clearances (AA - AC codes) †Check and Adjust Valve Clearances (AJ - AS codes) †Check and Adjust Engine Mount Security Check Rain Cap/Pre-cleaner Installed if fitted Check Radiator Clean TRANSMISSION AND AXLES Transmission Oil Level Transmission Oil Transmission Oil Filter Axle(s) Oil Level Axle(s) Oil Hub Oil Level Hub Oil Drive Shafts and Universal Joints Axle Pivots and Linkages Axle Breather(s) Tyre Pressures/Condition Hub Wheel Bearings Transmission Strainer Wheel Nut Security Wheel Alignment Trunnion Bearings Steering Stops (if fitted) Transmission Mount Security Axle Mount Security

Check (2) Change Change Check Change Check (3) Change Security/Grease Grease Check Check Check Clean Check Check †Check/Adjust Security Check Check

3-1

Daily 10 Hr

Weekly 50 Hr

First 100 Hr

6 Monthly Yearly 500 1000 Hr Hr

2 Yearly 2000 Hr

z z

(1)

In arduous conditions (eg. refuse re-handling, waste paper reclamation etc.) change the oil after every 250 hours or three months (whichever comes first).

(2)

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 (eg. water contamination).

(3)

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 again after a further 100 hours to remove bedding-in wear. This is particularly important if new brake plates have been fitted.

Note: Jobs which should be done by a specialist are shown by †. First 100 hour service only (and after major re-builds), to be completed by JCB Distributor.

9803/3640U

Issue 2

Section 3

Service Schedules

3-2

Pre-start Cold Checks Service Points and Fluid Levels HYDRAULICS Oil Level Oil Oil Filter Suction Strainer

Operation

Daily 10 Hr

Check †Sample/Change Change †Clean

BRAKES Brake System Fluid (if applicable) Brake System Fluid (if applicable) ELECTRICS Battery Terminals for Condition & Tightness Wiring for Chaffing

3-2

Weekly 50 Hr

First 100 Hr

6 Monthly Yearly 500 1000 Hr Hr

2 Yearly 2000 Hr

z z z

Check Level Change

Check Check

BODYWORK AND CAB Lift/Displacement/Tilt/Steer Ram Pivot Pins Grease Fire Extinguisher Check Wing Mirrors Condition & Security Check ROPS/FOPS Structure Check All Pivot Pins Grease Doors and Hinges Lubricate Wear Pad Runways Waxoyl Inner Boom Hoses Grease Boom Wear Pad Clearance Check/Adjust Replace if required Wear Pad Condition/Security Change as required Control Lever Linkages Lubricate Inner Boom Extension Ram Wear Pad (if fitted) Change Windscreen Washer Fluid Level Check Cab Heater Filter (if fitted) Clean

Pre-start Cold Checks Service Points and Fluid Levels

Section 3

Routine Maintenance

Operation

BOOM CHAIN SERVICING Boom Chains Lubricate/Check Tensionl Boom Extend & Retract Chain Wear Limit Check Boom Chain Roller Wear Check Boom Roller Pivot Pin with Grease Point Grease

z z

250 Hr

500 Hr

1000 Hr

2000 Hr

Note: Jobs which should be done by a specialist are shown by †. First 100 hour service only (and after major re-builds), to be completed by JCB Distributor.

9803/3640U

Issue 3*

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