Page 1

Service Manual Articulated Dump Truck - 714/718 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Hydraulic Steering Section K - Engine Section S - Suspension

Publication No.

9813/0550-1

World Class Customer Support 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. 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 0 - Service Manual

Notes:

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9813-0550-1

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Section 1 - General Information Contents Page No. Identification About this Manual ...................................................................................... 1-1 Machine Model and Serial Number .......................................................1-1 Using the Service Manual .....................................................................1-1 Section Numbering ................................................................................1-1 Left Side, Right Side ..............................................................................1-1 Cross References ..................................................................................1-1 Identifying Your Machine ........................................................................... 1-2 Machine Identification Plate ..................................................................1-2 Component Identification Plates ............................................................1-3 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-5 Introduction ............................................................................................1-5 Bolts and Screws ...................................................................................1-5 Service Tools Numerical List Section B - Body and Framework ...................................... 1-9 Section B - Body and Framework ............................................................ 1-10 Numerical List Section C - Electrics ........................................................ 1-13 Section C - Electrics ................................................................................ 1-14 Numerical List Section E - Hydraulics ..................................................... 1-15 Section E - Hydraulics ............................................................................. 1-17 Numerical List Section F - Transmission ................................................. 1-20 Section F - Transmission ......................................................................... 1-21 Numerical List Section K - Transmission ................................................. 1-24 Section K - Engine ................................................................................... 1-25 Service Consumables Sealing and Retaining Compounds ......................................................... 1-27 Terms and Definitions Colour Coding .......................................................................................... 1-29 Hydraulic Schematic Colour Codes .....................................................1-29 Hydraulic Hoses Connecting/Disconnecting Hydraulic Hoses ............................................ 1-31 Introduction ..........................................................................................1-31 Connecting the Hydraulic Hoses .........................................................1-31 Disconnecting the Hydraulic Hoses .....................................................1-32 Quick Release Couplings ....................................................................1-33 Disabled Machine Moving a Disabled Machine .................................................................... 1-35 Introduction ..........................................................................................1-35 Emergency Lowering of the Body .......................................................1-35 Lifting the Machine ..............................................................................1-36 Prepare the Machine for Towing ..........................................................1-37 Transporting the Machine ........................................................................ 1-39 Articulation Lock ..................................................................................1-40 Drive Position ......................................................................................1-40

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Section 1 - General Information Contents

1-ii

Page No.

1-ii


Section 1 - General Information

Identification 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:

Section Numbering T11-005

– 714 Articulated Dump Truck (ADT) from machine serial number 1304500

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

– 718 ADT from machine serial number 1304600 1

General Information - includes torque settings and service tools.

2

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

3

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

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.

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

Attachments

B

Body and Framework, etc.

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.

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

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.

Left Side, Right Side

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.

In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The number of the page upon which the subject begins, is indicated within the brackets. For example: K Cross References ( T 1-1).

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

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

Cross References T1-004_2

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Section 1 - General Information Identification Identifying Your Machine

Identifying Your Machine Machine Identification Plate

Typical 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. PRODUCT IDENTIFICATION NUMBER, PIN ISO 10261

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

OPERATING MASS kg ISO 6016

MACHINE TYPE

MACHINE MODEL

YEAR OF MANUFACTURE

ENGINE SERIAL NUMBER

HOMOLOGATION No.

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.

ENGINE POWER kW@RPM ISO 14396

MAXIMUM MASS kg

TRANSMISSION SERIAL NUMBER

MAX FRONT AXLE LOAD kg

FRONT AXLE SERIAL NUMBER

MAX MIDDLE AXLE LOAD kg

MIDDLE AXLE SERIAL NUMBER

MAX REAR AXLE LOAD kg

REAR AXLE SERIAL NUMBER

CE 332/T5730

332/T5730

Fig 2.

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

J C B 7 1 8 T 3 D A 1 3 0 4 6 0 0

T033160-13

Fig 3. 1

World Manufacturer Identification (3 Digits) JCB = UK Build

2

Model Number (5 Digits) 718T3 = 718 Tier 3

3

The check letter is used to verify the authenticity of the machine's PIN.

T

T 345230

Fig 1. T = Identification Plate

Check Letter (1 Digit)

4

5

Year of Manufacture (1 Digit) A = 2010

D = 2013

B = 2011

E = 2014

C = 2012

F = 2015

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

Note: On later models, the year of manufacture digit will be removed and the machine serial number increased to 8 digits.

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Section 1 - General Information Identification Identifying Your Machine

Component Identification Plates

Transmission Identification Number

Axle

The transmission identification number is stamped on a plate A mounted on the bottom front of the unit.

The axle identification number is stamped on a plate mounted on the axle arm casing. This is applicable to both front and rear axles.

Engine Identification Number The engine identification number is stamped on a plate A mounted on the rear of the valve cover.

A

A 344670-1

Fig 5.

862230-2

Fig 4.

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Section 1 - General Information Identification Identifying Your Machine ROPS/FOPS Data Plates

ROPS Data Plate

!MWARNING

FOPS Data Plate

!MWARNING Do not use the machine if the falling objects protection level provided by the structure is not sufficient for the application. Falling objects can cause serious injury. 8-2-8-17

If the machine is used in any application where there is a risk of falling objects then a falling-objects protective structure (FOPS) must be installed. For further information contact your JCB Dealer The falling objects protection structure (FOPS) is fitted with a dataplate. The dataplate indicates what level protection the structure provides. There are two levels of FOPS: – Level I Impact Protection - impact strength for protection from small falling objects (e.g. bricks, small concrete blocks, hand tools) encountered in operations such as highway maintenance, landscaping and other construction site services.

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 Seat Belts The ROPS/FOPS is designed to give you protection in an accident. If you do not wear your seat belt, you could be thrown out of the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine. 0153

Machines built to ROPS/FOPS standards have a data plate attached to the inside of the cab.

– Level II Impact Protection - impact strength for protection from heavy falling objects (e.g. trees, rocks) for machines involved in site clearing, overhead demolition or forestry.

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Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners

Torque Settings Zinc Plated Fasteners and Dacromet Fasteners T11-002

Introduction

Bolts and Screws

Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.

Use the following torque setting tables only where no torque setting is specified in the text.

The two types of fasteners can be readily identified by colour and part number suffix. K Table 1. Fastener Types ( T 1-5).

Torque settings are given for the following conditions:

Fastener Type

Table 1. Fastener Types Colour Part No. Suffix

Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate.

Condition 1 – Un-lubricated fasteners – Zinc fasteners – Yellow plated fasteners

Zinc and Yellow

Golden finish

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

Dacromet

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

Condition 2 – Zinc flake (Dacromet) fasteners

Note: As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener. Note: A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt.

– Lubricated zinc and yellow plated fasteners – Where there is a natural lubrication. For example, cast iron components

Verbus Ripp Bolts

Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. Note: Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.

1-5

Fig 6. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

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Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Hexagon (A/F) Condition 1

Bolt Size in.

mm

in.

Nm

kgf m

lbf ft

Nm

kgf m

lbf ft

1/4

6.3

7/16

11.2

1.1

8.3

10.0

1.0

7.4

5/16

7.9

1/2

22.3

2.3

16.4

20.0

2.0

14.7

3/8

9.5

9/16

40.0

4.1

29.5

36.0

3.7

26.5

7/16

11.1

5/8

64.0

6.5

47.2

57.0

5.8

42.0

1/2

12.7

3/4

98.00

10.0

72.3

88.0

9.0

64.9

9/16

14.3

13/16

140.0

14.3

103.2

126.0

12.8

92.9

5/8

15.9

15/16

196.0

20.0

144.6

177.0

18.0

130.5

3/4

19.0

1 1/8

343.0

35.0

253.0

309.0

31.5

227.9

7/8

22.2

1 15/16

547.0

55.8

403.4

492.0

50.2

362.9

1

25.4

1 1/2

814.0

83.0

600.4

732.0

74.6

539.9

1 1/8

31.7

1 7/8

1181.0

120.4

871.1

1063.0

108.4

784.0

1 1/4

38.1

2 1/4

1646.0

167.8

1214.0

1481.0

151.0

1092.3

Table 3. Torque Settings - Metric Grade 8.8 Fasteners Hexagon (A/F) Condition 1

Bolt Size ISO Metric Thread

1-6

Condition 2

mm

mm

Nm

kgf m

Condition 2

lbf ft

Nm

kgf m

lbf ft

M5

5

8

5.8

0.6

4.3

5.2

0.5

3.8

M6

6

10

9.9

1.0

7.3

9.0

0.9

6.6

M8

8

13

24.0

2.4

17.7

22.0

2.2

16.2

M10

10

17

47.0

4.8

34.7

43.0

4.4

31.7

M12

12

19

83.0

8.5

61.2

74.0

7.5

54.6

M16

16

24

205.0

20.9

151.2

184.0

18.8

135.7

M20

20

30

400.0

40.8

295.0

360.0

36.7

265.5

M24

24

36

690.0

70.4

508.9

621.0

63.3

458.0

M30

30

46

1372.0

139.9

1011.9

1235.0

125.9

910.9

M36

36

55

2399.0

244.6

1769.4

2159.0

220.0

1592.4

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Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Hexagon (A/F) Condition 1

Bolt Size ISO Metric Thread

mm

mm

Nm

kgf m

Condition 2 lbf ft

Nm

kgf m

lbf ft

M5

5

8

8.1

0.8

6.0

7.3

0.7

5.4

M6

6

10

13.9

1.4

10.2

12.5

1.3

9.2

M8

8

13

34.0

3.5

25.0

30.0

3.0

22.1

M10

10

17

67.0

6.8

49.4

60.0

6.1

44.2

M12

12

19

116.0

11.8

85.5

104.0

10.6

76.7

M16

16

24

288.0

29.4

212.4

259.0

26.4

191.0

M20

20

30

562.0

57.3

414.5

506.0

51.6

373.2

M24

24

36

971.0

99.0

716.9

874.0

89.1

644.6

M30

30

46

1930.0

196.8

1423.5

1737.0

177.1

1281.1

M36

36

55

3374.0

344.0

2488.5

3036.0

309.6

2239.2

Table 5. Metric Grade 12.9 Fasteners Hexagon (A/F) Condition 1

Bolt Size

Condition 2

ISO Metric Thread

mm

mm

Nm

kgf m

lbf ft

Nm

kgf m

lbf ft

M5

5

8

9.8

1.0

7.2

8.8

0.9

6.5

M6

6

10

16.6

1.7

12.2

15.0

1.5

11.1

M8

8

13

40.0

4.1

29.5

36.0

3.7

26.5

M10

10

17

80.0

8.1

59.0

72.0

7.3

53.1

M12

12

19

139.0

14.2

102.5

125.0

12.7

92.2

M16

16

24

345.0

35.2

254.4

311.0

31.7

229.4

M20

20

30

674.0

68.7

497.1

607.0

61.9

447.7

M24

24

36

1165.0

118.8

859.2

1048.0

106.9

773.0

M30

30

46

2316.0

236.2

1708.2

2084.0

212.5

1537.1

M36

36

55

4049.0

412.9

2986.4

3644.0

371.6

2687.7

1-7

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Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread

mm

Nm

kgf m

lbf ft

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

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

1-8

ISO Metric Thread

Nm

kgf m

lbf ft

M3

2.0

0.2

1.5

M4

6.0

0.6

4.5

M5

11.0

1.1

8.0

M6

19.0

1.9

14.0

M8

46.0

4.7

34.0

M10

91.0

9.3

67.0

M12

159.0

16.2

117.0

M16

395.0

40.0

292.0

M18

550.0

56.0

406.0

M20

770.0

79.0

568.0

M24

1332.0

136.0

983.0

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Section 1 - General Information

Service Tools Numerical List Section B - Body and Framework 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

825/99849

Dummy Bush

K Fig 18. ( T 1-12)

825/99852

Bearing Locator

K Fig 19. ( T 1-12)

826/01106

M6 x 19mm Rivet Nut

K Fig 7. ( T 1-10)

826/01177

M8 x 18mm Rivet Nut

K Fig 7. ( T 1-10)

826/01176

M10 x 23mm Rivet Nut

K Fig 7. ( T 1-10)

826/01179

M6 x 16mm Rivet Nut

K Fig 7. ( T 1-10)

826/01333

M10 x 26mm Rivet Nut

K Fig 7. ( T 1-10)

892/00842

Glass Lifter

K Fig 9. ( T 1-10)

892/00843

Glass Stand

K Fig 8. ( T 1-10)

892/00844

Long Knife

K Fig 17. ( T 1-12)

892/00846

Glass Extractor (Handles)

K Fig 13. ( T 1-11)

892/00847

Nylon Spatula

K Fig 10. ( T 1-10)

892/00848

Wire Starter

K Fig 12. ( T 1-11)

893/00849

Braided Cutting Wire

K Fig 14. ( T 1-11)s

926/15500

Rubber Spacer Blocks

K Fig 11. ( T 1-11)

992/12800

Cut-Out Knife

K Fig 16. ( T 1-12)

992/12801

‘L’ Blades

K Fig 15. ( T 1-12)

1-9

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Section 1 - General Information Service Tools Section B - Body and Framework

Section B - Body and Framework Folding Stand for Holding Glass- essential for preparing new glass prior to installation.

Fig 7.

Fig 9.

Note: 826/01179 M6 x 16mm Rivet Nut, 826/01106 M6 x 19mm Rivet Nut, 826/01177 M8 x 18mm Rivet Nut, 826/01176 M10 x 23mm Rivet Nut, 826/01333 M10 x 26mm Rivet Nut

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

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

Fig 10. Nylon Spatula - general tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge.

Fig 8.

1 - 10

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Section 1 - General Information Service Tools Section B - Body and Framework

Fig 11.

Fig 13.

Rubber Spacer Blocks - used to provide the correct set clearance between glass edge and cab frame.

Glass Extractor (Handles) - used with braided cutting wire (below) to cut out broken glass.

Fig 14. Braided Cutting Wire - consumable heavy duty cut-out wire used with the glass extraction tool (above)

Fig 12. Wire Starter - used to access braided cutting wire (below) through original polyurethane seal.

1 - 11

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Section 1 - General Information Service Tools Section B - Body and Framework

Fig 15. ‘L’ Blades - 25mm (1in) cut - replacement blades for cut-out knife (below)

Fig 18. Dummy Bush - used with bearing locator to set up Upper Centre Pivot.

Fig 16. Cut-out Knife - used to remove broken glass.

Fig 19. Bearing Locator - used with bearing dummy bush to set up Upper Centre Pivot.

Fig 17. Long Knife - consumable heavy duty cut-out wire used with the glass extraction tool (above)

1 - 12

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Section 1 - General Information Service Tools Numerical List Section C - Electrics

Numerical List Section C - Electrics The tools listed in the table are special tools required for testing electrics. 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

892/00282

Shunt

K Fig 20. ( T 1-14)

892/00283

Tool Kit Case

K Fig 20. ( T 1-14)

892/00284

Digital Tachometer

K Fig 20. ( T 1-14)

892/00285

Hyd. Oil Temperature Probe

K Fig 20. ( T 1-14)

892/00286

Surface Temperature Probe

K Fig 20. ( T 1-14)

892/00298

Fluke Meter

K Fig 20. ( T 1-14)

892/01033

Diagnostic Lead

K Fig 22. ( T 1-14)

1 - 13

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Section 1 - General Information Service Tools Section C - Electrics

Section C - Electrics

D

C

B

A

J

E F

H

G

C027740

Fig 21. Electronic Test Kit

Fig 20. AVO Test Kit 1

892/00283 Tool Kit Case

2

892/00298 Fluke Meter

3

892/00286 Surface Temperature Probe

A

J

892/00284 Venture Microtach Digital Tachometer

5

892/00282 100 amp Shunt - open type

6

892/00285 Hydraulic Temperature Probe

E F

H

4

D

C

B

G

A408030

Fig 22. Diagnostic Lead

1 - 14

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1 - 14


Section 1 - General Information Service Tools Numerical List Section E - Hydraulics

Numerical List Section E - Hydraulics The tools listed in the table are special tools required for testing, removing and replacing hydraulics. 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 26. ( T 1-17)

1406/0014

Bonded Washer

K Fig 26. ( T 1-17)

1406/0018

Bonded Washer

K Fig 26. ( T 1-17)

1406/0021

Bonded Washer

K Fig 26. ( T 1-17)

1406/0029

Bonded Washer

K Fig 26. ( T 1-17)

816/00189

Blanking Cap

K Fig 27. ( T 1-18)

816/00190

Blanking Cap

K Fig 27. ( T 1-18)

816/00193

Blanking Cap

K Fig 27. ( T 1-18)

816/00196

Blanking Cap

K Fig 27. ( T 1-18)

816/00197

Blanking Cap

K Fig 27. ( T 1-18)

816/00294

Blanking Cap

K Fig 27. ( T 1-18)

816/15118

Pressure Test Adapter

K Fig 24. ( T 1-17)

816/55038

Pressure Test Adapter

K Fig 24. ( T 1-17)

816/55040

Pressure Test Adapter

K Fig 24. ( T 1-17)

892/00055

Blanking Plug

K Fig 25. ( T 1-17)

892/00056

Blanking Plug

K Fig 25. ( T 1-17)

892/00057

Blanking Plug

K Fig 25. ( T 1-17)

892/00058

Blanking Plug

K Fig 25. ( T 1-17)

892/00059

Blanking Plug

K Fig 25. ( T 1-17)

892/00060

Blanking Plug

K Fig 25. ( T 1-17)

892/00137

Micro-Bore Hose

K Fig 31. ( T 1-18)

892/00167

Ram Seal Protection Sleeve

K Fig 34. ( T 1-19)

892/00180

Seal Fitting Tool

K Fig 32. ( T 1-19)

892/00181

Replacement Plastic Boss for 892/00180

K Fig 32. ( T 1-19)

892/00223

Hand Pump

K Fig 31. ( T 1-18)

892/00253

Pressure Test Kit

K Fig 23. ( T 1-17)

892/00255

Pressure Test Adaptor

K Fig 28. ( T 1-18)

892/00256

Pressure Test Adaptor

K Fig 28. ( T 1-18)

892/00257

Pressure Test Adaptor

K Fig 28. ( T 1-18)

892/00258

Pressure Test Adaptor

K Fig 28. ( T 1-18)

892/00259

Pressure Test Adaptor

K Fig 28. ( T 1-18)

1 - 15

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1 - 15


Section 1 - General Information Service Tools Numerical List Section E - Hydraulics Part Number

Description

Tool Detail Reference

892/00260

Pressure Test Adaptor

K Fig 28. ( T 1-18)

892/00261

Pressure Test Adaptor

K Fig 28. ( T 1-18)

892/00262

Pressure Test Adaptor

K Fig 24. ( T 1-17)

892/00263

Pressure Test Adaptor

K Fig 24. ( T 1-17)

892/00264

Pressure Test Adaptor

K Fig 24. ( T 1-17)

892/00265

Pressure Test Adaptor

K Fig 24. ( T 1-17)

892/00279

Gauge

K Fig 31. ( T 1-18)

892/00334

Ram Seal Fitting Tool

K Fig 30. ( T 1-18)

892/00706

Test Probe

K Fig 31. ( T 1-18)

892/01016

Ram Protection Sleeve

K Fig 34. ( T 1-19)

892/01017

Ram Protection Sleeve

K Fig 34. ( T 1-19)

892/01018

Ram Protection Sleeve

K Fig 34. ( T 1-19)

892/01019

Ram Protection Sleeve

K Fig 34. ( T 1-19)

892/01021

Ram Protection Sleeve

K Fig 34. ( T 1-19)

892/01023

Ram Protection Sleeve

K Fig 34. ( T 1-19)

892/01024

Ram Protection Sleeve

K Fig 34. ( T 1-19)

892/01025

Ram Protection Sleeve

K Fig 34. ( T 1-19)

892/01026

Ram Protection Sleeve

K Fig 34. ( T 1-19)

992/09300

55mm A/F Hexagon Spanner for Ram Pistons and End Caps

K Fig 29. ( T 1-18)

992/09400

65mm A/F Hexagon Spanner for Ram Pistons and End Caps

K Fig 29. ( T 1-18)

992/09500

75mm A/F Hexagon Spanner for Ram Pistons and End Caps

K Fig 29. ( T 1-18)

992/09600

85mm A/F Hexagon Spanner for Ram Pistons and End Caps

K Fig 29. ( T 1-18)

992/09700

95mm A/F Hexagon Spanner for Ram Pistons and End Caps

K Fig 29. ( T 1-18)

992/09900

115mm A/F Hexagon Spanner for Ram Pistons and End Caps

K Fig 29. ( T 1-18)

992/10000

125mm A/F Hexagon Spanner for Ram Pistons and End Caps

K Fig 29. ( T 1-18)

The following parts are replacement items for kits and would normally be included in the kit numbers above.

Replacement items for kit no. 892/00253

Part Number

Description

Tool Detail Reference

892/00201

Replacement Gauge

K Fig 23. ( T 1-17)

892/00202

Replacement Gauge

K Fig 23. ( T 1-17)

892/00203

Replacement Gauge

K Fig 23. ( T 1-17)

892/00254

Replacement Hose

K Fig 23. ( T 1-17)

1 - 16

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1 - 16


Section 1 - General Information Service Tools Section E - Hydraulics

Section E - Hydraulics 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 Test Point 892/00264 3/4 in BSP x 3/4 in F BSP x Test Point 892/00265 1 in M BSP x 1 in F BSP x Test Point

Fig 23. Hydraulic Circuit Pressure Test Kit

Fig 25. Female Cone Blanking Cap

892/00253 Pressure Test Kit

892/00055 1/4 in BSP

892/00201 Replacement gauge 0-20 bar (0-300 lbf/in2)

892/00056 3/8 in BSP

892/00202 Replacement gauge 0-40 bar (0-600 lbf/in2)

892/00057 1/2 in BSP

892/00203 Replacement gauge 0-400 bar (0-6000 lbf/ in2)

892/00058 5/8 in BSP

892/00254 Replacement Hose

892/00059 3/4 in BSP 892/00060 1 in BSP

Fig 26. Bonded Washers 1406/0011 1/4 in BSP 1406/0018 1/2 in BSP 1406/0014 5/8 in BSP 1406/0021 3/4 in BSP 1406/0029 1.1/4 in BSP Fig 24. Pressure Test `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

1 - 17

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1 - 17


Section 1 - General Information Service Tools Section E - Hydraulics

Fig 27. Male Cone Blanking Cap 816/00294 1/4 in BSP

Fig 29. Hexagon Spanners

816/00189 3/8 in BSP

992/09300 55mm A/F

816/00190 1/2 in BSP

992/09400 65mm A/F

816/00197 5/8 in BSP

992/09500 75mm A/F

816/00196 3/4 in BSP

992/09600 85mm A/F

816/00193 1 in BSP

992/09700 95mm A/F 992/09900 115mm A/F 992/10000 125mm A/F

Fig 28. 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

Fig 30. Ram Seal Fitting Tool 892/00334

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 31. Hand Pump Equipment 892/00223 Hand Pump 892/00137 Micro-bore Hose 1/4 in BSP x 5 metres

1 - 18

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1 - 18


Section 1 - General Information Service Tools Section E - Hydraulics 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 892/00706 Test Probe 892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in2)

Fig 34. Ram Seal Protection Sleeves 892/01016 For 25mm Rod Diameter 892/01017 For 30mm Rod Diameter Fig 32.

892/01018 For 40mm Rod Diameter

892/00180 Seal Fitting Tool for fitting O-ring and King Ring to Steer Valve

892/01019 For 50mm Rod Diameter 892/01021 For 60mm Rod Diameter

892/00181 Replacement Plastic Boss

892/01023 For 65mm Rod Diameter 892/01024 For 70mm Rod Diameter 892/01025 For 75mm Rod Diameter 892/01026 For 80mm Rod Diameter 7mm

892/00167 For 90mm Rod Diameter

11o 20mm

10mm

5mm R

m 3m

110mm 175mm 3o R

1.4

mm

Fig 33. Piston Seal Assembly Tool 892/01027

1 - 19

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1 - 19


Section 1 - General Information Service Tools Numerical List Section F - Transmission

Numerical List Section F - Transmission 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

892/00245

Gauge Ring

K Fig 50. ( T 1-23)

892/00817

Heavy Duty Socket

K Fig 35. ( T 1-21)

892/00818

Heavy Duty Socket

K Fig 35. ( T 1-21)

892/00819

Heavy Duty Socket

K Fig 35. ( T 1-21)

892/00860

Bearing Remover Shim

K Fig 49. ( T 1-23)

892/00861

Bearing Remover Base Tool

K Fig 49. ( T 1-23)

892/00862

Tab Washer Fitting Tool

K Fig 37. ( T 1-21)

892/00863

Blanking Plate Fitting Tool

K Fig 40. ( T 1-21)

892/00891

Seal Fitting Tool Assembly

K Fig 38. ( T 1-21)

892/00909

Puller

K Fig 39. ( T 1-21)

892/01000

Bearing Puller

K Fig 42. ( T 1-22)

892/01001

Bearing Tool

K Fig 43. ( T 1-22)

892/01002

Spring Compressor

K Fig 46. ( T 1-22)

892/01004

Bearing Tool

K Fig 43. ( T 1-22)

892/01005

Bearing Tool

K Fig 43. ( T 1-22)

892/01006

110 Volt Heater

K Fig 44. ( T 1-22)

892/01007

Pipe Swagging Tool

K Fig 47. ( T 1-23)

892/01008

Pipe Swagging Tool

K Fig 47. ( T 1-23)

892/01009

Pipe Swagging Tool

K Fig 47. ( T 1-23)

892/01010

Pipe Swagging Tool

K Fig 47. ( T 1-23)

892/01013

Lift Eye

K Fig 45. ( T 1-22)

892/01014

Retainer

K Fig 48. ( T 1-23)

892/01015

Lift Eye

K Fig 45. ( T 1-22)

892/01034

Transmission Diagnostic Kit

992/04000

Torque Multiplier

K Fig 36. ( T 1-21)

992/07603

Replacer - Bearing Cup

K Fig 41. ( T 1-22)

1 - 20

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1 - 20


Section 1 - General Information Service Tools Section F - Transmission

Section F - Transmission

Fig 35. Heavy Duty Socket for Durlock Bolts 892/00817 17 mm A/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 38. 892/00891

Fig 36. 992/04000 Note: Use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts etc.

Fig 39. 892/00909

Fig 37. 892/00862

Fig 40. 892/00863

1 - 21

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Section 1 - General Information Service Tools Section F - Transmission

Fig 44. 892/01006 Fig 41. 992/07603

Fig 42. 892/01000 Bearing Puller Fig 45. 892/01013 Lifting Eye

Fig 43. 892/01001 Bearing Tool 892/01004 Bearing Tool 892/01005 Bearing Tool

1 - 22

Fig 46. 892/01002

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1 - 22


Section 1 - General Information Service Tools Section F - Transmission

Fig 47. 892/01007 Pipe Swaging Tool 892/01008 Pipe Swaging Tool 892/01009 Pipe Swaging Tool Fig 50. 892/00245

892/01010 Pipe Swaging Tool Gauge Ring

Fig 48. 892/01014

Fig 49. 1 892/00860 Bearing Remover Shin 2 892/00861 Bearing Remover Base Tool

1 - 23

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Section 1 - General Information Service Tools Numerical List Section K - Transmission

Numerical List Section K - Transmission 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

892/00041

De-glazing Tool for Cylinder Bores

K Fig 51. ( T 1-25)

1 - 24

9813-0550-1

1 - 24


Section 1 - General Information Service Tools Section K - Engine

Section K - Engine

Fig 51. 892/00041 De-glazing Tool for Cylinder Bores (to assist the bedding-in of new piston rings)

1 - 25

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Section 1 - General Information Service Tools Section K - Engine Page left intentionally blank

1 - 26

9813-0550-1

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Section 1 - General Information Service Consumables Sealing and Retaining Compounds

Service Consumables Sealing and Retaining Compounds T11-001_3

Table 8. Type

Description

Part No.

Quantity

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.

4101/0651

50 ml

JCB Threadlocker and Sealer

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

4101/0250

10 ml

4101/0251

50 ml

JCB Threadlocker and Sealer (High Strength)

A high strength locking fluid for sealing and retaining 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

– 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 - 27

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Section 1 - General Information Service Consumables Sealing and Retaining Compounds Page left intentionally blank

1 - 28

9813-0550-1

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Section 1 - General Information

Terms and Definitions Colour Coding Hydraulic Schematic Colour Codes T11-006

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

Red

Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and MRV operating pressure.

Pink

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

Orange

Blue

Green

Light Green

Yellow

1 - 29

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

Neutral: Neutral circuit pressure.

Exhaust

Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).

Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).

9813-0550-1

1 - 29


Section 1 - General Information Terms and Definitions Colour Coding Page left intentionally blank

1 - 30

9813-0550-1

1 - 30


Section 1 - General Information

Hydraulic Hoses Connecting/Disconnecting Hydraulic Hoses T4-004

Introduction

Connecting the Hydraulic Hoses

!MWARNING Fluid Under Pressure Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear protective glasses and gloves. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of fluid. If fluid penetrates your skin, get medical help immediately.

1

Make the machine safe. Refer to Routine Maintenance, Prepare the Machine for Maintenance.

2

Vent the hydraulic system. Refer to Routine Maintenance, Releasing the Hydraulic Pressure.

3

If necessary, remove the blanking caps.

4

Check the hoses and adaptors for damage. Refer to Routine Maintenance, Checking for Damage.

5

Connect the hoses.

INT-3-1-10_3

!MWARNING Hydraulic Pressure Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses. Make sure the engine cannot be started while the hoses are open.

If the hoses have quick releases couplings, refer to Quick Release Couplings. a

Make sure that the hose is not twisted. Pressure applied to a twisted hose can cause the hose to fail or the connections to loosen.

INT-3-1-11_2

Some attachments are hydraulically powered. The following procedures show how to connect and disconnect the hydraulic hoses safely.

T037400

Fig 52. b Make sure that the hose does not touch hot parts. High ambient temperatures can cause the hose to fail. c

Make sure that the hose does not touch parts which can rub or cause abrasion.

d Use the hose clamps (where possible) to support long hose runs and keep the hoses away from moving parts, etc.

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Section 1 - General Information Hydraulic Hoses Connecting/Disconnecting Hydraulic Hoses

Disconnecting the Hydraulic Hoses 1

Make the machine safe. Refer to Routine Maintenance, Prepare the Machine for Maintenance.

2

Vent the hydraulic system. Refer to Routine Maintenance, Releasing the Hydraulic Pressure.

3

Disconnect the hoses.

T037420

Fig 53. To allow for length changes when the hose is pressurised, do not clamp at the bend. The curve absorbs the change.

If the hoses have quick releases couplings, then refer to Quick Release Couplings. 4

Check the hoses and adaptors for damage. Refer to Routine Maintenance, Checking for Damage.

5

If necessary, install the blanking caps

6

Check for leaks. a

Start the engine.

b Operate the related control to increase the pressure in the hydraulic system. c

T037410

Fig 54. 6

Stop the engine then remove the starter key.

d Check for indications of leakage at the hose connections. Correct, as necessary.

Check for leaks. a

Start the engine.

b Operate the related control to increase the pressure in the hydraulic system. c

Stop the engine then remove the starter key.

d Check for indications of leakage at the hose connections. Correct, as necessary.

1 - 32

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Section 1 - General Information Hydraulic Hoses Connecting/Disconnecting Hydraulic Hoses

Quick Release Couplings

wedge underneath the sleeve and destroy the coupling.

Flat face quick release couplings allow the operator to remove and install attachments swiftly and efficiently. Generally, your machine pipework will be fitted with a female coupling A and a male coupling B. The optional attachment hoses will also be fitted with a female coupling A and a male coupling B. K Fig 55. ( T 1-34). The quick release couplings should be trouble free and relatively easy to connect and disconnect, provided they are kept clean and used correctly. The recommendations listed below should always apply when using flat face quick release couplings. Finally, please read the correct fitting and releasing procedures before you install or remove any optional attachment fitted with quick release couplings.

Quick Release Couplings - Do's and Don'ts – Do wipe the two faces of the coupling and make sure they are clean before connecting.

– Don't damage the faces of the couplings - this can prevent connection and disconnection, or damage seals and cause leakage. – Don't try to dismantle the couplings - they are non serviceable parts. If a coupling is damaged it should be replaced with a new one.

!MWARNING The external surfaces of the couplings must be clean before connecting or disconnecting. Ingress of dirt will cause fluid leaks and difficulty in connecting or disconnecting. You could be killed or seriously injured by faulty Quick Release Couplings. 2-4-1-15

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.

– Do make sure the outside sleeve (female coupling) is pulled back when disconnecting. – Do connect and disconnect a new coupling two or three times to 'work' the PTFE seals - sometimes a new coupling will stick if the seals have not been 'worked'. – Do use a spanner on the hexagon flats of the coupling when fitting adaptors. – Do use a rubber or hide hammer to disconnect a coupling if it sticks - sticking may occur if there is dirt present in the coupling. – Don't attempt to re-connect a damaged half coupling - this will destroy the seals and necessitate replacing both half couplings. – Don't leave the coupling where it may be run over by a machine or otherwise crushed - this will distort the coupling sleeve and prevent correct connection and disconnection. – Don't clamp on the smooth diameter of the coupling when fitting adaptors - always use the hexagon. – Don't try to turn the sleeve (female coupling) when the coupling has been disconnected - the locking ball will

1 - 33

9813-0550-1

1 - 33


Section 1 - General Information Hydraulic Hoses Connecting/Disconnecting Hydraulic Hoses Connecting Quick Release Couplings 1

Remove any residual hydraulic pressure trapped in the service line hose.

2

Wipe the two faces of the male and female couplings and make sure they are clean.

3

Make sure that ball C in the female coupling is located in one of its slots.

4

Fit the male coupling into the female coupling.

5

Where applicable, rotate sleeve E half a turn and make sure that the locking ball C does not align with the slot D.

Disconnecting Quick Release Couplings 1

Remove any residual hydraulic pressure trapped in the service line hose.

2

Where applicable, align the slot D with ball C.

3

Pull back sleeve E to release the coupling.

C007100-1

Fig 55.

1 - 34

9813-0550-1

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Section 1 - General Information

Disabled Machine Moving a Disabled Machine Introduction

5 P4-2025

The machine can be lifted onto a trailer for transportation. However, you must contact the nearest JCB Dealer before you try to tow, winch or push the machine. Towing, winching or pushing the machine without following the correct procedure can damage the transmission. If possible, repair the disabled machine where it stands.

When the body is fully down, tighten the releasescrew B, then replace the cab floor.

B

A

It is not recommended to tow a disabled machine. If the machine becomes disabled, the machine must be made safe, lifted onto a transporter and moved to a location where maintenance can be carried out. If towing the machine to a safe location is unavoidable, do the procedure that follows before you try to move the machine. 221229

Fig 1.

Emergency Lowering of the Body The body raise/lower function is controlled hydraulically. If the engine power and electrical power fail, there will be no hydraulic pressure to operate the tipping valve. If the body is in the raised position and there is no hydraulic power to lower the body: 1

Remove the cab floor to get access to the tipping valve A. K Fig 1. ( T 1-35).

2

Locate the release-screw B on the rear face of the tipping valve A.

3

Turn the release-screw B approximately four times to lower the body.

4

If the body does not lower under its own weight, to help it lower: a

797600-1

Fig 2.

Position the attachment of an excavator or loading shovel under the rear edge of the body, as shown. K Fig 2. ( T 1-35).

b Raise the attachment until the body begins to lower. c

1 - 35

Adjust the release-screw B to control the rate of speed that the body lowers.

9813-0550-1

1 - 35


Section 1 - General Information Disabled Machine Moving a Disabled Machine

Lifting the Machine B A

Do not lift a laden machine. Install the articulation Lock ( T 1-40).

2

Make sure the doors are closed and the body is in the fully lowered position.

3

Attach the lifting chains to the machines sling-points, which can be the same as the tie-down points. K Fig 3. ( T 1-36).

A

lock.

K Articulation

1

C

B

B A 817-01803-6

Fig 3. Tie-down and sling-point labels 4

Attach the lifting chains to the lifting beam A, which is attached to the crane B.

Note: There must a distance of at least 3000mm (118in.) at position C. The front lifting chains can be replaced by a nylon sling to prevent damage to the bodywork. The lifting beam A must be able to carry the total machine weight and be longer than the machine. a

344950-2

Fig 4.

714: 10932kg (24100lb) dependant on the tyre fitment

b 718: 12960kg (28572lb) dependant on the tyre fitment 5

Lift the machine onto a trailer for transportation.

6

When the operation is complete and the machine is safely on the ground, remove the articulation lock before use.

1 - 36

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Section 1 - General Information Disabled Machine Moving a Disabled Machine

Prepare the Machine for Towing

seen between the brake pad G and the brake disc H.

!MCAUTION

c

Towing a machine too far or too fast can damage the transmission. Do not tow the machine further than 10 Km (6 miles). Use a trailer for greater distances. When towing do not travel faster than 16 km/h (10 mph). Use a rigid towbar. If you must use towing chains, then use two vehicles, One towing vehicle should be coupled to the front of the disabled machine. The other towing vehicle should be couple to the rear of the disabled machine, to provide braking power. The towing vehicle(s) must have enough pulling and braking power to move and stop the machine. 4-2-5-4_2

Note: This procedure depends on the condition of the machine and its hydraulic circuits. For this reason, you should consult your JCB Dealer for help and advice before attempting this work. Towing must be restricted to emergencies only and over the shortest possible distance to a suitable parking position. Note: If possible during the recovery procedure, the engine should be running to provide the braking and steering functions. 1

Make sure the park brake is engaged.

2

Put blocks at the front and the rear of all the tyres.

3

Use the drawbar (or chain) to attach the towing machine to the front chassis towing points A. K Fig 5. ( T 1-38).

4

Attach the second towing machine by a chain to the rear towing points B (if using chains). K Fig 6. ( T 1-38)

5

Release the park brake. If the disabled machines engine is not running, release the park brake manually as follows: a

Tighten the locknut E.

d Put the brake cover D in position, then install the two screws C. 6

Make sure the gear lever is in the neutral position.

7

Make sure the transmission is in the 2-wheel drive mode.

8

If the engine and the hydraulic systems are not damaged, put the body in the fully lowered position.

Important: If the engine or the hydraulic system is damaged and the body can not be lowered, you must contact your JCB Dealer. 9

The machine is now ready to be towed. Make sure you understand what the towing driver will be doing. Obey his instructions and all relevant regulations.

10

The highest travelling speed for a disabled machine should not exceed 2 kph (1.2 mph).

Note: When towing is complete, adjust the park brake so that it is engaged before the towing machine is disconnected. Refer to Routine Maintenance, Adjusting the Park Brake.

Working below the front axle, remove the two screws C and the brake cover D. K Fig 7. ( T 1-38).

b Release the locknut E. Use a screwdriver to turn the centre pin F anti-clockwise until clearance is

1 - 37

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Section 1 - General Information Disabled Machine Moving a Disabled Machine

A 341000

Fig 5.

C E

G

D F B

H 341100

Fig 6. 345280

Fig 7.

1 - 38

9813-0550-1

1 - 38


Section 1 - General Information Disabled Machine Transporting the Machine

Transporting the Machine

!MWARNING

!MWARNING

The safe transit of the load is the responsibility of the transport contractor and driver. Any machine, attachments or parts that may move during transit must be adequately secured. 5-2-5-9

Make sure the articulation lock is in the transport position before you transport the machine. The articulation lock must also be in the transport position if you are carrying out daily checks or doing any maintenance work in the articulation danger zone.

Note: Before transporting the machine make sure that you will be obeying the rules and laws of all the areas that the machine will be carried through.

If the articulation lock is not in the transport position you could be crushed between the two parts of the chassis. 4-3-5-7

Make sure that the transporting machine is suitable. See Static Dimensions (Specifications Section) for the dimensions of your machine.

8

Secure the cab in position.

9

Put blocks at the front and rear of all the machine tyres.

10

Attach the machine to the trailer with chains. Use the front towing points A and rear towing points B.

11

Measure the maximum height of the machine from the ground. Make sure the driver knows the clearance height before he drives away.

9813-0550-1

1 - 39

!MWARNING Before moving the machine onto the trailer, make sure that the trailer and ramp are free from oil, grease and ice. Remove oil, grease and ice from the machine tyres. Make sure the machine will not foul on the ramp angle. See Static Dimensions in SPECIFICATION section for the minimum ground clearance of your machine. 2-2-7-5_1

1

Put blocks at the front and rear of the trailer wheels.

2

Make sure the ramps onto the trailer are in the correct position and are attached securely.

3

Make sure that the body is in the fully lowered position.

4

Carefully move the machine onto the trailer.

5

Engage the park brake and set the transmission to the neutral position, then stop the engine.

6

Make sure that the overall height of the load is within the regulations, adjust the height if necessary.

7

Install the articulation lock. Refer to Articulation Lock.

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Section 1 - General Information Disabled Machine Transporting the Machine

Articulation Lock Transport Position

!MWARNING Make sure the articulation lock is in the transport position before you transport the machine. The articulation lock must also be in the transport position if you are carrying out daily checks or doing any maintenance work in the articulation danger zone. If the articulation lock is not in the transport position you could be crushed between the two parts of the chassis.

7

Install one pin in position and put the second pin partially through its hole.

8

Start the engine.

9

Turn the steering wheel slightly to let the pin drop into position.

10

Stop the engine and examine the articulation lock to make sure the pin has fell into position.

11

If the pin is not fully in position, do steps 7 to 10 again.

Drive Position

!MWARNING

4-3-5-7

!MDANGER Make sure the engine is switched off before fitting or stowing the articulation lock, or you might get crushed between the two parts of the chassis. 7-3-2-2

Note: The location of the drive controls and switches and their operation are shown in this manual, refer to Cab Layout. The articulation lock must be installed with the machine in the 'straight-ahead' position. A second person must assist you when you do this procedure. 1

Steer the machine to put the front and rear wheels in a straight line.

2

Set the transmission to the neutral position.

3

Run the engine at low idle for four minutes, then stop the engine.

4

Remove the pins A and B which secure the articulation lock C to the chassis.

5

Move the articulation lock C to the transport position.

6

Put the pins A and B through the chassis and the articulation lock (as shown) to lock the machine in the transport position.

Always make sure the articulation lock has been removed before attempting to drive the machine. The machine cannot be steered with the articulation lock fitted. 16-3-1-4_2

A second person must assist you when you do this procedure. 1

Remove the pins A and B.

2

Put the articulation lock C in the drive position.

3

Install the pins A and B to secure the articulation lock C in position.

Note: The articulation lock is on the inside of the chassis, it is shown in this position to help identify the components. K Fig 8. ( T 1-41).

If the machine is out of alignment it will not be possible to fully install both of the pins. In this condition, do steps 7 to 10.

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Section 1 - General Information Disabled Machine Transporting the Machine

A

C

B

344980

Fig 8.

A

C

B

341110

Fig 9.

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Section 2 - Care and Safety

Notes:

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Section 2 - 1 Contents Page No. Safety Notices Important Information .............................................................................. 2 - 1 The Operator Manual ......................................................................... 2 - 1 Safety Warnings ................................................................................. 2 - 1 Safety Check List ..................................................................................... 2 - 2 Safety - Yours and Others .................................................................. 2 - 2 General Safety ................................................................................... 2 - 2 Operating Safety ................................................................................ 2 - 4 Maintenance Safety ............................................................................ 2 - 7 Safety Labels ......................................................................................... 2 - 12 Introduction ....................................................................................... 2 - 12 Safety Label Identification ................................................................ 2 - 13 Part Numbers and Descriptions ....................................................... 2 - 14

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Jcb 718 tier3 fastrac service repair manual sn:01304600 01304699  
Jcb 718 tier3 fastrac service repair manual sn:01304600 01304699  
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