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Section 1 - General Information

Service Tools

Tool Detail Reference

1-42

9813/4050-01

Tool Detail Reference

Section B - Body and Framework

Note: Not all service tools are illustrated.

Fig 9. 993/68100 Slide Hammer Kit

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

Fig 10. Rivet Nut Tool

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

Installation Tool available from: Bollhoff
Fastenings Ltd (www.bollhof.com)

Fig 11. 892/00842 Glass Lifter

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

Содержание JS200W

Страница 1: ...E World Class Customer Support 9813 4050 01 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889...

Страница 2: ...3 4050 01 Publication No 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 Informat...

Страница 3: ...Section 1 General Information 1 0 1 0 9813 4050 01 Notes Find manuals at https best manuals com...

Страница 4: ...ttery Disconnection Connection 1 17 Removing and Replacing Components 1 18 Preparation 1 18 Original Components 1 18 New Components 1 18 Torques and Fixings 1 18 Battery Charging System Precautions 1...

Страница 5: ...formation Contents 1 ii 1 ii Page No Contents Tool Detail Reference 1 42 Section B Body and Framework 1 42 Section C Electrics 1 46 Section E Hydraulics 1 47 Section H Steering 1 59 Find manuals at ht...

Страница 6: ...1 9813 4050 01 Introduction Identifying Your Machine For information about identifying your machine and its main components refer to Section 2 About the Machine Machine and Component Identification Fi...

Страница 7: ...Section 1 General Information Introduction Identifying Your Machine 1 2 1 2 9813 4050 01 Page left intentionally blank Find manuals at https best manuals com...

Страница 8: ...nation of the safety notice signal words refer to Section 2 Introduction Safety For general safety notices refer to Section 2 Introduction Safety For maintenance safety notices refer to Section 2 Main...

Страница 9: ...Section 1 General Information Safety Introduction 1 4 1 4 9813 4050 01 Page left intentionally blank Find manuals at https best manuals com...

Страница 10: ...ns information about the structure of the manual and how to use the manual K Scope T 1 6 K Personnel T 1 6 K Applications T 1 6 K Newest Data T 1 6 K Format T 1 7 K Left Side Right Side T 1 8 K Hydrau...

Страница 11: ...rocedures and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment Finally please remember above all else SAFETY MUST COME FIRST Applications This manual co...

Страница 12: ...e components and controls Refer also to the safety and daily weekly maintenance information The remaining sections are alphabetically coded and deal with dismantling overhaul etc of specific component...

Страница 13: ...General Information Use Left Side Right Side 1 8 1 8 9813 4050 01 Left Side Right Side In this manual left A and right B mean your left and right when you are seated correctly in the machine T017280 1...

Страница 14: ...ation of a service Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure Pink Pressure Pressure that is above neutral circuit pressure but lower th...

Страница 15: ...Section 1 General Information Use Hydraulic Schematic Codes 1 10 1 10 9813 4050 01 Page left intentionally blank...

Страница 16: ...ntenance tasks listed on the maintenance schedules Refer to Section 2 Maintenance Schedules The procedures for the daily and weekly 10 and 50 hour tasks are given in Section 2 Maintenance The procedur...

Страница 17: ...Section 1 General Information Routine Maintenance Maintenance Schedules 1 12 1 12 9813 4050 01 Page left intentionally blank...

Страница 18: ...parking the machine and making it safe and venting hydraulic pressure These procedures are given here as an alternative to again and again in the manual Where applicable you will see a cross reference...

Страница 19: ...neral Procedures Parking the Machine and Making it Safe 1 14 1 14 9813 4050 01 Parking the Machine and Making it Safe For the correct procedures to park and make the machine safe refer to Section 2 Ma...

Страница 20: ...ressure Hydraulic fluid at system pressure can injure you Before disconnecting or connecting hydraulic hoses or couplings vent the pressure trapped in the hoses in accordance with the instructions giv...

Страница 21: ...c Pressure Hydraulic fluid at system pressure can injure you Before disconnecting or connecting hydraulic hoses or couplings vent the pressure trapped in the hoses in accordance with the instructions...

Страница 22: ...n General Procedures Battery Disconnection Connection 1 17 1 17 9813 4050 01 Battery Disconnection Connection For the correct procedures to disconnect connect the battery refer to Section 2 Maintenanc...

Страница 23: ...new components are installed Do not substitute components from another machine Components may look the same but may not be interchangeable Refer to the JCB parts systems Torques and Fixings When repl...

Страница 24: ...any part of the charging circuit whilst the engine is running Disregarding this instruction will result in damage to the regulator or rectifying diodes Main output cables are live even when the engine...

Страница 25: ...trogen gas with a suitable pressure reducing valve 3 Correct gas bottle adaptor depending on territory Charging kit 892 00239 Refer to Section 1 Operating charge pressures accumulators are charged to...

Страница 26: ...il the pressure reading reaches 4 bar 72 5 psi ABOVE the operating charge pressure Important DO NOT exceed the maximum working pressure of the accumulator The maximum working pressure is marked on the...

Страница 27: ...Section 1 General Information General Procedures Gas Hydraulic Bladder Accumulators 1 22 1 22 9813 4050 01 Page left intentionally blank...

Страница 28: ...1 Service Consumables Introduction Consumables such as sealing and retaining compounds are necessary to complete some procedures Before you start work make sure that the consumables show in the tables...

Страница 29: ...ealer 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 30: ...lus or minus 3 Torque figures are given for fasteners with different surface treatments Make sure you use the correct torque figures Where torques are given in topics within the other sections always...

Страница 31: ...plated bolt Note All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification Note Dacromet bolts due to their high corrosion resistance are use...

Страница 32: ...6 177 0 18 0 130 5 3 4 19 0 1 1 8 343 0 35 0 253 0 309 0 31 5 227 9 7 8 22 2 1 15 16 547 0 55 8 403 4 492 0 50 2 362 9 1 25 4 1 1 2 814 0 83 0 600 4 732 0 74 6 539 9 1 1 8 31 7 1 7 8 1181 0 120 4 871...

Страница 33: ...1 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 Siz...

Страница 34: ...c 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 lb...

Страница 35: ...ze 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 0 152...

Страница 36: ...2 D will vary depending upon the torque applied Table 10 BSP Hose Torque Settings BSP Hose Size Hexagon A F Nm kgf m lbf 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 7...

Страница 37: ...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 75...

Страница 38: ...e the double spanner method of tightening K Fig 3 T 1 33 Torque spanner 1 Open ended combination spanner 2 T044470 Fig 3 Key Points A rubber trapezoid O Ring seal 3 is pre installed in the Captive O R...

Страница 39: ...20 UNF 40 40 6 9 16 18 UNF 46 46 8 3 4 16 UNF 80 80 10 7 8 14 UNF 135 135 12 1 1 16 12 UNF 185 185 16 1 5 16 12 UNF 270 270 20 1 5 8 12 UNF 340 340 24 1 7 8 12 UNF 415 415 Dash size of tube or hose en...

Страница 40: ...ys check the torque of the hose before its disassembled If the hose or the adaptor is loose you must specify which component is the cause of the leak For example if the hose is tight and the adaptor t...

Страница 41: ...ring being damages as a result of over tightening Torque Stop Hoses have an additional shoulder 6 D which acts as a physical stop Note Minimum dimension 6 E fixed by shoulder 6 D Table 13 BSP Torque S...

Страница 42: ...the adaptor Note that the washer should not move freely if the washer is slack do not use the adaptor 3 Check the O ring 7 A is fitted and that it is free from damage or nicks Before fitting the adapt...

Страница 43: ...Section 1 General Information Torque Settings Positional Type Hydraulic Adaptors 1 38 1 38 1 05 01 Issue 02 Page left intentionally blank...

Страница 44: ...rence Section 1 for content E Hydraulic Flow Test Equipment see Tool Detail Reference Section 1 for content E Hydraulic Hand Pump Equipment see Tool Detail Reference Section 1 for content E Male Adapt...

Страница 45: ...Rod Diameter E 892 01017 Ram Protection Sleeve for 30 mm Rod Diameter E 892 01018 Ram Protection Sleeve for 40 mm Rod Diameter E 892 01019 Ram Protection Sleeve for 50 mm Rod Diameter E 892 01020 Ram...

Страница 46: ...er 95mm A F E 992 09900 Hexagon Spanner 115mm A F E 992 10000 Hexagon Spanner 125mm A F E 992 10100 Spool Clamp E 992 12300 12V Mobile Oven B 992 12400 24V Static Oven 2 Cartridge B 992 12800 Cut Out...

Страница 47: ...20 x 1 UNF 10 993 68110 Adaptor M20 x 5 8 UNF Shoulder 5 993 68105 Adaptor M20 x M20 11 993 68111 Adaptor M20 x 1 2 UNF 6 993 68106 Adaptor M20 x M24 Fig 10 Rivet Nut Tool 1 826 01099 M6 x 16 mm Rivet...

Страница 48: ...lication of sealants polyurethane materials etc Fig 14 892 00846 Glass Extractor Handles Used with braided cutting wire to cut out broken glass K Fig 17 T 1 44 Fig 15 892 00847 Nylon Spatula General t...

Страница 49: ...ame Unit quantity 500 off Fig 19 992 12300 Mobile Oven 12V 1 cartridge capacity Required to pre heat adhesive prior to use It is fitted with a male plug 703 23201 which fits into a female socket 715 0...

Страница 50: ...Section 1 General Information Service Tools Tool Detail Reference 1 45 1 45 9813 4050 01 Fig 23 4104 1310 Hand Cleaner Special blend for the removal of polyurethane adhesives 454g 1 lb tub...

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

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