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

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

World Class

Customer Support

9803/4180-08

Publication No.

Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377

Section 2

Care and Safety

Section 1 - General Information

Section 2 - Care and Safety

Section 3 - Routine Maintenance

Section A - Section A

Section B - Body and Framework

Section C - Electrics

Section E - Hydraulics

Section F - Transmission

Section G - Brakes

Section H - Steering

Section K - Engine

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Содержание 446

Страница 1: ...rt 9803 4180 11 Publication No Issued by JCB Technical Publications JCB Service World Parts Centre Beamhurst Uttoxeter Staffordshire ST14 5PA England Tel 44 1889 590312 Fax 44 1889 593377 Service Manu...

Страница 2: ...0 08 Publication No Issued by JCB Technical Publications JCB Service World Parts Centre Beamhurst Uttoxeter Staffordshire ST14 5PA England Tel 44 1889 590312 Fax 44 1889 593377 Section 1 General Infor...

Страница 3: ...Section 1 General Information 1 0 1 0 9803 4180 08 Notes Find manuals at https best manuals com...

Страница 4: ...ettings Zinc Plated Fasteners and Dacromet Fasteners 1 7 Introduction 1 7 Bolts and Screws 1 7 Hydraulic Connections 1 11 O Ring Face Seal System 1 11 Torque Stop Hose System 1 14 Service Tools Numeri...

Страница 5: ...Page No Contents Section 1 General Information 1 ii 1 ii Find manuals at https best manuals com...

Страница 6: ...se or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt Where a torque setting is given as a single figure it may be varied by plus or minus 3 Torque fi...

Страница 7: ...rrectly in the machine T033800 1 Fig 1 Cross References T1 004_2 In this publication page cross references are made by presenting the subject title printed in bold italic and underlined It is preceede...

Страница 8: ...acement parts are ordered The machine and engine serial numbers can help identify exactly the type of equipment you have T033550 2 Fig 2 Typical Vehicle Identification Number 1 World Manufacturer Iden...

Страница 9: ...ck Letter 1 Digit The Check Letter is used to verify the authenticity of the machine s PIN 6 Year of Manufacture 1 Digit 7 Machine Serial Number 7 Digits Each machine has a unique serial number Note O...

Страница 10: ...4180 08 Component Identification Plates Unit Identification Fig 4 The engine serial number is stamped on a plate 4Y which is fastened to the right side of the cylinder block Fig 5 The transmission ser...

Страница 11: ...cts e g trees rocks for machines involved in site clearing overhead demolition or forestry ROPS Data Plate MWARNING You could be killed or seriously injured if you operate a machine with a damaged or...

Страница 12: ...Zinc or Yellow plated bolt Note All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification Note Dacromet bolts due to their high corrosion resi...

Страница 13: ...4 6 177 0 18 0 130 5 3 4 19 0 1 1 8 343 0 35 0 253 0 309 0 31 5 227 9 7 8 22 2 1 15 16 547 0 55 8 403 4 492 0 50 2 362 9 1 25 4 1 1 2 814 0 83 0 600 4 732 0 74 6 539 9 1 1 8 31 7 1 7 8 1181 0 120 4 87...

Страница 14: ...191 0 M20 20 30 562 0 57 3 414 5 506 0 51 6 373 2 M24 24 36 971 0 99 0 716 9 874 0 89 1 644 6 M30 30 46 1930 0 196 8 1423 5 1737 0 177 1 1281 1 M36 36 55 3374 0 344 0 2488 5 3036 0 309 6 2239 2 Bolt S...

Страница 15: ...inc Bolt Size Nm kgf m lbf ft ISO Metric Thread mm M3 3 1 2 0 1 0 9 M4 4 3 0 0 3 2 0 M5 5 6 0 0 6 4 5 M6 6 10 0 1 0 7 5 M8 8 24 0 2 5 18 0 M10 10 48 0 4 9 35 5 M12 12 82 0 8 4 60 5 Bolt Size Nm kgf m...

Страница 16: ...tor Size Hexagon A F Nm kgf m lbf ft in mm 1 4 19 0 18 0 1 8 13 0 3 8 22 0 31 0 3 2 23 0 1 2 27 0 49 0 5 0 36 0 5 8 30 0 60 0 6 1 44 0 3 4 32 0 81 0 8 2 60 0 1 38 0 129 0 13 1 95 0 1 1 4 50 0 206 0 21...

Страница 17: ...on 8 D will vary depending upon the torque applied Table 10 BSP Hose Torque Settings BSP Hose Size Hexagon A F Nm kgf m lbf ft in 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...

Страница 18: ...to Component Connections with Bonded Washers Table 11 BSP Adaptors with Bonded Washers Torque Settings BSP Size Nm kgf m lbf ft in 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...

Страница 19: ...O ring being damages as a result of over tightening Torque Stop Hoses have an additional shoulder 9 D which acts as a physical stop Note Minimum dimension 9 E fixed by shoulder 9 D Table 12 BSP Torqu...

Страница 20: ...JCB Service Some tools are available as kits or sets the part numbers for parts within such kits or sets are not listed here For full details of all tools including the content of kits and sets refer...

Страница 21: ...103 Adaptor M20 x 5 8 UNF 9 993 68109 Adaptor M20 x M12 4 993 68104 Adaptor M20 x 1 UNF 10 993 68110 Adaptor M20 x 5 8 UNF Shoulder 5 993 68105 Adaptor M20 x M20 11 993 68111 Adaptor M20 x 1 2 UNF 6 9...

Страница 22: ...glass prior to installation Fig 14 892 00845 Cartridge Gun Hand operated Essential for the application of sealants polyurethane materials etc Fig 15 892 00846 Glass Extractor Handles Used with braided...

Страница 23: ...b frame Unit quantity 500 off Fig 20 992 12300 Mobile Oven 12V 1 cartridge capacity Required to pre heat adhesive prior to use It is fitted with a male plug 703 23201 which fits into a female socket 7...

Страница 24: ...1 19 1 19 9803 4180 08 Fig 24 4104 1310 Hand Cleaner Special blend for the removal of polyurethane adhesives 454g 1 lb tub Fig 25 825 99849 Note used with bearing locator to set up Upper Centre Pivot...

Страница 25: ...4180 08 Fig 27 Cab Prop Note used to support cab in the raised position A minimum of 2 are required to support the side where work is being carried out It is recommended that 4 are used to support the...

Страница 26: ...803 4180 08 Section C Electrics Fig 28 1 892 00283 Tool Kit Case 2 892 00298 Fluke Meter 3 892 00286 Surface Temperature Probe 4 892 00284 Venture Microtach Digital Tachometer 5 892 00282 100 amp Shun...

Страница 27: ...Section 1 General Information Service Tools Tool Detail Reference Section 1 22 1 22 9803 4180 08 Fig 31 892 01174 Fig 32 718 20237 MACHINE CANBUS J1700 POWER COMPUTER ELECTRONIC SERVICE TOOL C031270...

Страница 28: ...T Adapters 892 00262 1 4 in 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 BSP x 5 8 in F BSP x...

Страница 29: ...2 in BSP x Test Point 892 00258 5 8 in BSP x Test Point 816 15118 3 4 in BSP x Test Point 892 00259 1 in BSP x Test Point 892 00260 1 1 4 in BSP x Test Point 892 00261 5 8 in UNF x Test Point Fig 39...

Страница 30: ...F x 3 4 in Square Drive 892 00818 22 mm A F x 3 4 in Square Drive 892 00819 15 mm A F x 1 2 in Square Drive Fig 42 992 04000 Note Use in conjunction with a torque wrench to give a 5 1 multiplication w...

Страница 31: ...Detail Reference Section 1 26 1 26 9803 4180 08 Fig 45 892 00863 Fig 46 892 00891 Fig 47 892 01000 Bearing Puller 892 01003 Bearing Puller Fig 48 892 01001 Bearing Tool 892 01004 Bearing Tool 892 0100...

Страница 32: ...s Tool Detail Reference Section 1 27 1 27 9803 4180 08 Fig 51 892 01013 Lifting Eye 892 01015 Lifting Eye Fig 52 892 01007 Pipe Swaging Tool 892 01008 Pipe Swaging Tool 892 01009 Pipe Swaging Tool 892...

Страница 33: ...ral Information Service Tools Tool Detail Reference Section 1 28 1 28 9803 4180 08 Section G Brakes Fig 54 892 00239 Fig 55 892 00041 Note De glazing Tool for Cylinder Bores to assist bedding in of ne...

Страница 34: ...Sealer High Strength A high strength locking fluid for sealing and retaining nuts bolts and screws up to 50 mm diameter and for hydraulic fittings up to 25 mm diameter 4101 0550 10 ml 4101 0552 200 ml...

Страница 35: ...Section 1 General Information Service Aids Sealing and Retaining Compounds 1 30 1 30 9803 4180 08 Page left intentionally blank...

Страница 36: ...operation of a service Depending on application this may be anything between neutral circuit pressure and MRV operating pressure Pink Pressure Pressure that is above neutral circuit pressure but lowe...

Страница 37: ...Circuit Pressure Pressure generated by the operation of a service Depending on application this may be anything between Neutral Circuit Pressure and MRV Operation Pressure Oil trapped within a chambe...

Страница 38: ...ower The towing vehicle s must have enough pulling and braking power to move and stop the machine 4 2 5 4_2 MWARNING Block the loader arms before attaching the towbar 4 2 5 2 1 Engage the parking brak...

Страница 39: ...Section 1 General Information Basic Operation Preparation for Towing 1 34 1 34 9803 4180 08 Page left intentionally blank...

Страница 40: ...tomer Support 9803 4180 08 Publication No Issued by JCB Technical Publications JCB Service World Parts Centre Beamhurst Uttoxeter Staffordshire ST14 5PA England Tel 44 1889 590312 Fax 44 1889 593377 S...

Страница 41: ...Section 2 Care and Safety 2 0 2 0 9803 4180 08 Notes...

Страница 42: ...nformation 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 7 Safety Labels 2 13 Introduct...

Страница 43: ...Page No Contents Section 2 Care and Safety 2 ii 2 ii...

Страница 44: ...becomes unreadable Safety Warnings In this publication and on the machine there are safety notices Each notice starts with a signal word The signal word meanings are given below MDANGER Denotes an ex...

Страница 45: ...fely you must know the machine and have the skill to use it You must abide by all relevant laws health and safety regulations that apply to the country you are operating in The Operator Manual instruc...

Страница 46: ...th all local regulations INT 1 3 7_2 MWARNING Raised Equipment Never walk or work under raised equipment unless it is supported by a mechanical device Equipment which is supported only by a hydraulic...

Страница 47: ...e ground gives way under your machine or if piled material collapses onto it Check for potholes and hidden debris logs ironwork etc Any of these could cause you to lose control of your machine Check f...

Страница 48: ...do them safely INT 2 1 1 MWARNING Airborne particles of light combustible material such as straw grass wood shavings etc must not be allowed to accumulate within the engine compartment or in the props...

Страница 49: ...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 certifica...

Страница 50: ...machine can damage it and make it unstable Study the specifications in the Operator Manual before using the machine 7 1 1 8_2 Maintenance Safety MWARNING Communications Bad communications can cause ac...

Страница 51: ...This as a preview PDF file from best manuals com Download full PDF manual at best manuals com...

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