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 9803-9490-1 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual JCB 403 Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section K - Engine
Section 0 - Service Manual 0-0 0-0 9803-9490-1
Notes:
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 9803-9490-1 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 Information Service Manual - JCB 403 Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section K - Engine
Notes:
Section 1 - 1 1-2 1-2 9803-9490-1
Section 1 - General Information Contents 1-i 1-i Page No. Contents About this Manual Introduction ................................................................................................ 1-1 Using the Service Manual .....................................................................1-1 Units of Measurement ...........................................................................1-1 Section Numbering ................................................................................1-1 Cross References ..................................................................................1-1 Using the Machine .................................................................................1-1 Hydraulic Schematic Colour Codes .......................................................1-2 Identifying the Machine Serial Numbers .......................................................................................... 1-3 Machine Model and Serial Number .......................................................1-3 Data Plate ..............................................................................................1-3 Typical Vehicle Identification Number (VIN) ..........................................1-3 Typical Engine Identification Number ....................................................1-3 Standard Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-4 Introduction ............................................................................................1-4 Bolts and Screws ...................................................................................1-4 Hydraulic Connections ............................................................................... 1-8 'O' Ring Face Seal System ....................................................................1-8 'Torque Stop' Hose System .................................................................1-11 Service Tools Numerical List .......................................................................................... 1-12 Tool Detail Reference .............................................................................. 1-16 Section B - Body and Framework ........................................................1-16 Section C - Electrics ............................................................................1-17 Section E - Hydraulics .........................................................................1-18 Moving a Disabled Machine Towing or Winching ................................................................................. 1-22 Service Consumables Sealing and Retaining Compounds ......................................................... 1-24
Using the Service Manual
About this Manual
Introduction
Section Numbering
T11-004
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department.
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment.
The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify.
General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt.
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third.
The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication.
Finally, please remember above all else safety must come first!
Units of Measurement
T1-001_2
In this publication, the S.I. system of units is used. For example, liquid capacities are given in litres. The Imperial units follow in parentheses ( ) eg 28 litres (6 gal).
T11-005
The manual is compiled in sections, the first three are numbered and contain information as follows:
1 General Information - includes torque settings and service tools.
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.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:
A Attachments
B Body and Framework, etc.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.
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 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)
Using the Machine
T1-002_2
To use the machine efficiently and safely 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. This manual instructs you on the machine, its controls and its safe operation; it is not a training manual. If you are a new operator, get yourself trained in the skills of using a machine before trying to work with it. If you don't, you will not do your job well, and you will be a danger to yourself and others.
Section 1 - General Information 1-1 1-1
9803-9490-1
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.
PinkPressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red.
OrangeServo: Oil pressure used in controlling a device (servo).
BlueNeural: Neutral circuit pressure.
GreenExhaust
Light GreenCavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).
YellowLock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).
9803-9490-1
Section 1 - General Information About this Manual Introduction 1-2 1-2
Identifying the Machine
Serial Numbers
Machine Model and Serial Number
This manual provides information for the following machines :
403 from machine serial number 1070000 to 1070499
Data Plate
Your machine has a Data Plate. The serial numbers of the machine, engine and transmission unit are stamped on the plate.
Typical Vehicle Identification Number (VIN)
1 World Manufacturer Identification (SLP = JCB)
2 Machine Type (403)
3 Year of Manufacture (1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004, 5 = 2005, 6 = 2006, 7=2007)
4 Manufacturers Location (E = England)
5 Machine Serial Number (1070000)
Typical Engine Identification Number
If the engine is replaced by a new one, the data plate serial number will be wrong. Either stamp the new number on the plate or stamp out the old one. This will prevent the wrong number being quoted when you order replacement parts.
a Engine Type (AB= 4 cylinder turbo)
b Engine Parts List
c Country of Manufacture
d Engine Serial Number
e Year of Manufacture
Section 1 - General Information 1-3 1-3
9803/9490-1
Fig 1.
JCB EARTHMOVERS LIMITED LAKESIDE WORKS, ROCESTER, UTTOXETER, UNITED KINGDOM REGISTERED VIN Vehicle Identification Number PIN Product Identification Number ENGINE SERIAL NUMBER FRONT AXLE SERIAL NUMBER REAR AXLE SERIAL NUMBER TRANSMISSION SERIAL NUMBER WEIGHT (Kg) YEAR OF CONST. ENGINE POWER Kw @ RPM MACHINE TYPE HOMOLOGATION No. P406AL5E1163000 1163000 01009749 20325164 4600 2005 44 / 2500 FITA 522 635 FITA 522 634 BSI SL 12345 SLP4037E1070000 abcde AB50316J0000012
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
T11-002
Introduction
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.
The two types of fasteners can be readily identified by colour and part number suffix. K Table 1. Fastener Types ( T 1-4)
Fastener Type ColourPart No. Suffix
Zinc and Yellow Golden finish'Z' (e.g. 1315/3712Z)
DacrometMottled silver finish'D' (e.g. 1315/3712D)
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.
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.
Bolts and Screws
Use the following torque setting tables only where no torque setting is specified in the text.
Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate.
Torque settings are given for the following conditions:
Condition 1
–Un-lubricated fasteners
–Zinc fasteners
–Yellow plated fasteners
Condition 2
–Zinc flake (Dacromet) fasteners
–Lubricated zinc and yellow plated fasteners
–Where there is a natural lubrication. For example, cast iron components
Verbus Ripp Bolts
Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.
9803-9490-1
Section 1 - General Information
1-4 1-4
Table 1. Fastener Types
Fig 2.
Section 1 - General Information
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Bolt SizeHexagon (A/F)Condition 1Condition 2
1-5 1-5
9803-9490-1
Table 2. Torque Settings - UNF Grade 'S' Fasteners
Bolt SizeHexagon (A/F)Condition 1Condition 2 in.mmin.Nmkgf mlbf ftNmkgf mlbf ft 1/46.37/1611.21.18.310.01.07.4 5/167.91/222.32.316.420.02.014.7 3/89.59/1640.04.129.536.03.726.5 7/1611.15/864.06.547.257.05.842.0 1/212.73/498.0010.072.388.09.064.9 9/1614.313/16140.014.3103.2126.012.892.9 5/815.915/16196.020.0144.6177.018.0130.5 3/419.01 1/8343.035.0253.0309.031.5227.9 7/822.21 15/16547.055.8403.4492.050.2362.9 125.41 1/2814.083.0600.4732.074.6539.9 1 1/831.71 7/81181.0120.4871.11063.0108.4784.0 1 1/438.12 1/41646.0167.81214.01481.0151.01092.3
Table 3. Torque Settings - Metric Grade 8.8 Fasteners
ISO Metric ThreadmmmmNmkgf mlbf ftNmkgf mlbf ft M5585.80.64.35.20.53.8 M66109.91.07.39.00.96.6 M881324.02.417.722.02.216.2 M10101747.04.834.743.04.431.7 M12121983.08.561.274.07.554.6 M161624205.020.9151.2184.018.8135.7 M202030400.040.8295.0360.036.7265.5 M242436690.070.4508.9621.063.3458.0 M3030461372.0139.91011.91235.0125.9910.9 M3636552399.0244.61769.42159.0220.01592.4
Section 1 - General Information
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
1-6 1-6
9803-9490-1
Table 4. Metric Grade 10.9 Fasteners
SizeHexagon (A/F)Condition 1Condition 2 ISO Metric ThreadmmmmNmkgf mlbf ftNmkgf mlbf ft M5588.10.86.07.30.75.4 M661013.91.410.212.51.39.2 M881334.03.525.030.03.022.1 M10101767.06.849.460.06.144.2 M121219116.011.885.5104.010.676.7 M161624288.029.4212.4259.026.4191.0 M202030562.057.3414.5506.051.6373.2 M242436971.099.0716.9874.089.1644.6 M3030461930.0196.81423.51737.0177.11281.1 M3636553374.0344.02488.53036.0309.62239.2 Bolt SizeHexagon (A/F)Condition 1Condition 2 ISO Metric ThreadmmmmNmkgf mlbf ftNmkgf mlbf ft M5589.81.07.28.80.96.5 M661016.61.712.215.01.511.1 M881340.04.129.536.03.726.5 M10101780.08.159.072.07.353.1 M121219139.014.2102.5125.012.792.2 M161624345.035.2254.4311.031.7229.4 M202030674.068.7497.1607.061.9447.7 M2424361165.0118.8859.21048.0106.9773.0 M3030462316.0236.21708.22084.0212.51537.1 M3636554049.0412.92986.43644.0371.62687.7
Table 5. Metric Grade 12.9 Fasteners
Bolt
Section 1 - General Information
Standard Torque Settings
Zinc Plated Fasteners and Dacromet
Fasteners 1-7 1-7 9803-9490-1
Table 6. Torque Settings - Rivet Nut Bolts/Screws
Bolt Size
mlbf ft ISO Metric Threadmm M331.20.10.9 M443.00.32.0 M556.00.64.5 M6610.01.07.5 M8824.02.518.0 M101048.04.935.5 M121282.08.460.5 Bolt Size Nmkgf mlbf ft ISO Metric Thread M32.00.21.5 M46.00.64.5 M511.01.18.0 M619.01.914.0 M846.04.734.0 M1091.09.367.0 M12159.016.2117.0 M16395.040.0292.0 M18550.056.0406.0 M20770.079.0568.0 M241332.0136.0983.0
Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc)
Nmkgf
Hydraulic Connections
'O' Ring Face Seal System
Adaptors Screwed into Valve Blocks
Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.
General Information
1-8 1-8 9803-9490-1
Section 1 -
Standard Torque Settings Hydraulic Connections
T11-003
Table 8. Torque Settings - BSP Adaptors
BSP Adaptor Size Hexagon (A/F) Nmkgf mlbf ft in.mm 1/419.018.01.813.0 3/822.031.03.223.0 1/227.049.05.036.0 5/830.060.06.144.0 3/432.081.08.260.0 138.0129.013.195.0 1 1/450.0206.021.0152.0 SAE Tube Size SAE Port Thread Size Hexagon (A/F) Nmkgf mlbf ft mm 47/16 - 2015.920.0 - 28.02.0 - 2.816.5 - 18.5 69/16 - 1819.146.0 - 54.04.7 - 5.534.0 - 40.0 83/4 - 1622.295.0 - 105.09.7 - 10.769.0 - 77.0 107/8 - 1427.0130.0 - 140.013.2 - 14.396.0 - 104.0 121 1/16 - 1231.8190.0 - 210.019.4 - 21.4141.0 - 155.0 161 5/16 - 1238.1290.0 - 310.029.6 - 31.6216.0 - 230.0 201 5/847.6280.0 - 380.028.5 - 38.7210.0 - 280.0
Table 9. Torque Settings - SAE Connections
Hoses Screwed into Adaptors
1-9 1-9
Section 1 - General Information Standard Torque Settings Hydraulic Connections
9803-9490-1
Fig 3.
Hoses 3-B screwed into adaptors 3-A seal onto an `O' ring 3-C which is compressed into a 45° seat machined into the face of the adaptor port.
Note: Dimension 3-D will vary depending upon the torque applied.
BSP Hose SizeHexagon (A/F) Nmkgf mlbf ft in.mm 1/814.014.0 - 16.001.4 - 1.610.3 - 11.8 1/419.024.0 - 27.02.4 - 2.717.7 - 19.9 3/822.033.0 - 40.03.4 - 4.124.3 - 29.5 1/227.044.0 - 50.04.5 - 5.132.4 - 36.9 5/830.058.0 - 65.05.9 - 6.642.8 - 47.9 3/432.084.0 - 92.08.6 - 9.461.9 - 67.8 138.0115.0 - 126.011.7 - 12.884.8 - 92.9 1 1/450.0189.0 - 200.019.3 - 20.4139.4 - 147.5 1 1/255.0244.0 - 260.024.9 - 26.5180.0 - 191.8
Table 10. BSP Hose - Torque Settings
Adaptors into Component Connections with Bonded Washers
General
Standard Torque Settings Hydraulic Connections 1-10 1-10
Section 1 -
Information
9803-9490-1
BSP Size Nmkgf mlbf ft in. 1/820.02.115.0 1/434.03.425.0 3/875.07.655.0 1/2102.010.375.0 5/8122.012.490.0 3/4183.018.7135.0 1203.020.7150.0 1 1/4305.031.0225.0 1 1/2305.031.0225.0
Table 11. BSP Adaptors with Bonded Washers - Torque Settings
'Torque Stop' Hose System
`Torque Stop' Hoses 4-B screwed into adaptors 4-A seal onto an 'O' ring 4-C which is compressed into a 45° seat machined in the face of the adaptor port. To prevent the 'O' ring being damages as a result of over tightening, 'Torque
Stop' Hoses have an additional shoulder 4-D, which acts as a physical stop.
Note: Minimum dimension 4-E fixed by shoulder 4-D
General
1-11 1-11 9803-9490-1
Section 1 -
Information Standard Torque Settings Hydraulic Connections
Fig 4.
BSP Hose SizeHexagon (A/F) Nmkgf mlbf ft in.mm 1/814.014.01.410.0 1/419.027.02.720.0 3/822.040.04.130.0 1/227.055.05.640.0 5/830.065.06.648.0 3/432.095.09.770.0 138.0120.012.289.0 1 1/450.0189.019.3140.0 1 1/255.0244.024.9180.0
Table 12. BSP `Torque Stop' Hose - Torque Settings
Service Tools
Numerical List
The tools listed in the table are special tools required for removal and replacement of Body and Framework parts. These tools are available from JCB Service.
Note: Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.
Section 1 - General Information 1-12 1-12
9803-9490-1
Part Number DescriptionTool Detail Reference 1406/0011Bonded Washer K Fig 17. ( T 1-19) 1406/0014Bonded Washer K Fig 17. ( T 1-19) 1406/0018Bonded Washer K Fig 17. ( T 1-19) 1406/0021Bonded Washer K Fig 17. ( T 1-19) 1406/0029Bonded Washer K Fig 17. ( T 1-19) 1604/0003AAdapter K Fig 10. ( T 1-18) 1604/0004AAdapter K Fig 10. ( T 1-18) 1604/0006AAdapter K Fig 18. ( T 1-20) 1604/2055Adapter K Fig 10. ( T 1-18) 1606/0004Adapter K Fig 10. ( T 1-18) 1606/0007AAdapter K Fig 10. ( T 1-18) 1606/0008Adapter K Fig 10. ( T 1-18) 1606/0009Adapter K Fig 10. ( T 1-18) 1606/0012Adapter K Fig 10. ( T 1-18) 1606/0014Adapter K Fig 10. ( T 1-18) 1606/0015Adapter K Fig 10. ( T 1-18) 1606/0016Adapter K Fig 10. ( T 1-18) 1606/0017Adapter K Fig 10. ( T 1-18) 1606/2052Adapter K Fig 10. ( T 1-18) 1612/2054Adapter K Fig 18. ( T 1-20) 816/00017Adapter K Fig 13. ( T 1-19) 816/00189ABlanking Cap K Fig 15. ( T 1-19) 816/00190ABlanking Cap K Fig 15. ( T 1-19) 816/00439Adapter K Fig 10. ( T 1-18) 816/00440Adapter K Fig 10. ( T 1-18) 816/15007AAdapter K Fig 10. ( T 1-18) 816/15008Adapter K Fig 10. ( T 1-18) 816/15118Adapter K Fig 11. ( T 1-18)
Numerical List 1-13 1-13 9803-9490-1 816/20008Adapter K Fig 18. ( T 1-20) 816/20013Adapter K Fig 18. ( T 1-20) 816/50005Adapter K Fig 13. ( T 1-19) 816/50043Adapter K Fig 13. ( T 1-19) 816/55038Adapter K Fig 12. ( T 1-18) 816/55040Adapter K Fig 12. ( T 1-18) 816/55045Adapter K Fig 12. ( T 1-18) 816/60096Adapter K Fig 13. ( T 1-19) 816/90022Blanking Cap K Fig 15. ( T 1-19) 816/90045Blanking Cap K Fig 15. ( T 1-19) 816/90205Blanking Cap K Fig 15. ( T 1-19) 816/90274Blanking Cap K Fig 15. ( T 1-19) 826/01099Rivet Nut K Fig 6. ( T 1-16) 826/01101Rivet Nut K Fig 6. ( T 1-16) 826/01102Rivet Nut K Fig 6. ( T 1-16) 826/01103Rivet Nut K Fig 6. ( T 1-16) 826/01104Rivet Nut K Fig 6. ( T 1-16) 826/01105ARivet Nut K Fig 6. ( T 1-16) 892/00047Adapter K Fig 13. ( T 1-19) 892/00048Adapter K Fig 13. ( T 1-19) 892/00049Adapter K Fig 13. ( T 1-19) 892/00055ABlanking Cap K Fig 14. ( T 1-19) 892/00056ABlanking Cap K Fig 14. ( T 1-19) 892/00057Blanking Cap K Fig 14. ( T 1-19) 892/00058ABlanking Cap K Fig 14. ( T 1-19) 892/00059ABlanking Cap K Fig 14. ( T 1-19) 892/00060Blanking Cap K Fig 14. ( T 1-19) 892/00051Adapter K Fig 13. ( T 1-19) 892/00074Connector K Fig 16. ( T 1-19) 892/00075Connector K Fig 16. ( T 1-19) 892/00076Connector K Fig 16. ( T 1-19) 892/00077Connector K Fig 16. ( T 1-19) 892/00078Connector K Fig 18. ( T 1-20) 892/00137Hose K Fig 21. ( T 1-21) 892/00201Replacement Gauge K Fig 19. ( T 1-20) 892/00202Replacement Gauge K Fig 19. ( T 1-20) 892/00203Replacement Gauge K Fig 19. ( T 1-20)
Section 1 - General Information Service Tools
Part Number DescriptionTool Detail Reference
Numerical
1-14 1-14 9803-9490-1 892/00223Hand Pump K Fig 21. ( T 1-21) 892/00254Replacement Hose K Fig 20. ( T 1-21) 892/00255Adapter K Fig 11. ( T 1-18) 892/00256Adapter K Fig 11. ( T 1-18) 892/00257Adapter K Fig 11. ( T 1-18) 892/00258Adapter K Fig 11. ( T 1-18) 892/00259Adapter K Fig 11. ( T 1-18) 892/00260Adapter K Fig 11. ( T 1-18) 892/00261Adapter K Fig 11. ( T 1-18) 892/00263Adapter K Fig 12. ( T 1-18) 892/00264Adapter K Fig 12. ( T 1-18) 892/00265Adapter K Fig 12. ( T 1-18) 892/00266Adapter K Fig 12. ( T 1-18) 892/00267Adapter K Fig 12. ( T 1-18) 892/00268Flow Monitoring Unit K Fig 18. ( T 1-20) 892/00269Sensor Head K Fig 18. ( T 1-20) 892/00270Load Valve K Fig 18. ( T 1-20) 892/00271Adapter K Fig 18. ( T 1-20) 892/00272Adapter K Fig 18. ( T 1-20) 892/00273Sensor Head K Fig 18. ( T 1-20) 892/00274Adapter K Fig 15. ( T 1-19) 892/00275Adapter K Fig 18. ( T 1-20) 892/00276Adapter K Fig 18. ( T 1-20) 892/00277Adapter K Fig 18. ( T 1-20) 892/00278Gauge K Fig 21. ( T 1-21) 892/00279Gauge K Fig 21. ( T 1-21) 892/00280Gauge K Fig 20. ( T 1-21) 892/00284Tachometer K Fig 9. ( T 1-17) 892/00285Hydraulic Oil Temperature Probe K Fig 8. ( T 1-17) 892/00293Connector Pipe K Fig 18. ( T 1-20) 892/00298Fluke Meter K Fig 7. ( T 1-17) 892/00347Connector K Fig 19. ( T 1-20) 892/00706Test Probe K Fig 19. ( T 1-20) 993/68101Slide Hammer K Fig 5. ( T 1-16) 993/68102End Stops K Fig 5. ( T 1-16) 993/68103Adapter K Fig 5. ( T 1-16) 993/68104Adapter K Fig 5. ( T 1-16) Part Number
Detail
Section 1 - General Information Service Tools
List
DescriptionTool
Reference
Service
Numerical List 1-15 1-15 9803-9490-1 993/68105Adapter K Fig 5. ( T 1-16) 993/68106Adapter K Fig 5. ( T 1-16) 993/68107Bar K Fig 5. ( T 1-16) 993/68108Adapter K Fig 5. ( T 1-16) 993/68109Adapter K Fig 5. ( T 1-16) 993/68110Adapter K Fig 5. ( T 1-16) 993/68111Adapter K Fig 5. ( T 1-16) Part Number DescriptionTool Detail Reference
Section 1 - General Information
Tools
Tool Detail Reference
Section B - Body and Framework
Note: Not all service tools are illustrated. Fig
1 826/01099M6 x 16 mm Rivet Nut
826/01101M6 x 19 mm Rivet Nut
826/01102M8 x 18 mm Rivet Nut
826/01103M8 x 21 mm Rivet Nut
826/01104M10 x 23 mm Rivet Nut
826/01105AM10 x 26 mm Rivet Nut
2 -Installation Tool available from: Bollhoff Fastenings Ltd (www.bollhof.com)
Service
Tool Detail Reference 1-16 1-16
Section 1 - General Information
Tools
9803-9490-1
1 993/68101Slide Hammer 7 993/68107 Bar - M20 x M20 X 800 mm 2 993/68102 End Stops 8 993/68108Adaptor - M20 x 7/8" UNF 3 993/68103Adaptor - M20 x 5/8" UNF 9 993/68109Adaptor - M20 x M12 4 993/68104Adaptor - M20 x 1" UNF 10 993/68110Adaptor - M20 x 5/8" UNF (Shoulder)
993/68105Adaptor - M20 x M20
993/68111Adaptor - M20 x
993/68106Adaptor - M20 x M24
5. 993/68100 Slide Hammer Kit
5
11
1/2" UNF 6
Fig 6. Rivet Nut Tool
Tool Detail Reference
Section C - Electrics
Section 1 - General Information Service Tools
1-17 1-17
9803-9490-1
Fig 7. 892/00298 Fluke Meter
Fig 8. 892/00285 Hydraulic Temperature Probe
Fig 9. 892/00284 Venture Microtach Digital Tachometer
Section E - Hydraulics
Tool Detail Reference
Male Adapters - BSP x BSP
1606/20523/8 in. x 1/4 in.
1604/0003A3/8 in. x 3/8 in.
892/000713/8 in. x 3/8 in. taper
1606/00041/2 in. x 1/4 in.
1606/0007A1/2 in. x 3/8 in.
1604/0004A1/2 in. x 1/2 in.
1606/00175/8 in. x 1/2 in.
1606/00083/4 in. x 3/8 in.
Male Adapters - BSP x NPT (USA only)1606/00093/4 in. x 1/2 in.
816/004393/8 in. x 1/4 in.1604/20553/4 in. x 3/4 in.
816/004401/2 in. x 1/4 in.1606/00123/4 in. x 1 in.
816/15007A3/8 in. x 3/8 in.1606/00143/4 in. x 1.1/4 in.
816/150081/2 in. x 3/8 in.1606/00151 in. x 1.1/4 in.
892/002551/4 in. BSP x Test Point
in. BSP x Test Point
in. BSP x Test Point
in. BSP x Test Point
9803-9490-1
Service
Section 1 - General Information
Tools
1-18 1-18
Fig 10. Male Adaptors
892/002563/8
892/002571/2
892/002585/8
816/151183/4
892/002591
892/002601.1/4
892/002615/8
x Test Point
Fig 11. Pressure Test Adapters
in. BSP x Test Point
in BSP x Test Point
in. BSP x Test Point
in. UNF
816/550451/4 in. M BSP x 1/4 in. F BSP x Test Point 816/550383/8 in. M BSP x 3/8 in. F BSP x Test Point 816/550401/2 in. M BSP x 1/2 in. F BSP x Test Point 892/002635/8 in. M BSP x 5/8 in. F BSP x Test Point 892/002643/4 in. M BSP x 3/4 in. F BSP x Test Point 892/002651 in. M BSP x 1 in. F BSP x Test Point 892/002661.1/4 in. M BSP x 1.1/4 in. F BSP x Test Point 892/002671.1/4 in. M BSP x 1.1/2 in. F BSP x Test Point
Fig 12. Pressure Test 'T' Adapters
Tool Detail Reference
892/000473/8 in. BSP (A) x 1/4 in. BSP (B)
892/000481/2 in. BSP (A) x 1/4 in. BSP (B)
892/000495/8 in. BSP (A) x 1/4 in. BSP (B)
816/500433/4 in. BSP (A) x 1/4 in. BSP (B)
892/000511 in. BSP (A) x 1/4 in. BSP (B)
816/500051/2 in. BSP (A) x 1/2 in. BSP (B)
816/600963/4 in. BSP (A) x 3/4 in. BSP (B)
816/000171 in. BSP (A) x 1 in. BSP (B)
892/00055A1/4 in. BSP
892/00056A3/8 in. BSP
892/000571/2 in. BSP
892/00058A5/8 in. BSP
892/00059A3/4 in. BSP
892/000601 in. BSP
816/900451/4 in. BSP
816/00189A3/8 in. BSP
816/00190A1/2 in. BSP
816/900225/8 in. BSP
816/902743/4 in. BSP
816/902051 in. BSP
892/000743/8 in. BSP x 3/8 in. BSP
892/000751/2 in. BSP x 1/2 in. BSP
892/000765/8 in. BSP x 5/8 in. BSP
892/000773/4 in. BSP x 3/4 in. BSP
1406/00111/4 in. BSP
1406/00181/2 in. BSP
1406/00145/8 in. BSP
1406/00213/4 in. BSP
1406/00291.1/4 in. BSP
9803-9490-1
Section 1 - General Information Service Tools
1-19 1-19
Fig 13. 'T' Adapters
Fig 14. Female Blanking Caps
Fig 15. Male Cone Blanking Caps
Fig 16. Female Connectors
Fig 17. Bonded Washers
Section 1 - General Information
Service Tools
Tool Detail Reference
892/00268Flow Monitoring Unit
892/00269Sensor Head 0 - 100 l/min (0 - 22 UK gal/min)
892/00273Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min)
892/00293Connector Pipe
892/00270Load Valve
1406/0021Bonded Washer
1604/0006AAdapter 3/4 in M x 3/4 in M BSP
1612/2054Adapter 3/4 in F x 3/4 in M BSP
892/00271Adapter 3/4 in F x 5/8 in M BSP
892/00272Adapter 5/8 in F x 3/4 in M BSP
816/20008Adapter 3/4 in F x 1/2 in M BSP
892/00275Adapter 1/2 in F x 3/4 in M BSP
892/00276Adapter 3/4 in F x 3/8 in M BSP
892/00277Adapter 3/8 in F x 3/4 in M BSP
1606/0015Adapter 1.1/4 in M BSP x 1 in M BSP
892/00078Connector 1 in F x 1 in F BSP
1604/0008Adapter 1 in M x 1 in M BSP
1604/0008Adapter 1 in M x 3/4 in M BSP
816/20013Adapter 3/4 in F x 1 in M BSP
892/00201 Replacement Gauge 0-20 bar (0-300 lbf/in2)
892/00202 Replacement Gauge 0-40 bar (0-600 lbf/in2)
892/00203 Replacement Gauge 0-400 bar (0-6000 lbf/in2)
892/00254Replacement Hose
993/69800Seal Kit for 892/00254 (can also be used with probe 892/00706)
892/00706Test Probe
892/00347Connector - Hose to gauge
9803-9490-1
1-20 1-20
Fig 18. Flow Test Equipment
Fig 19. 892/ 00253 Hydraulic Circuit Pressure Test Kit
3 2 1
Section 1 - General Information
Service Tools
Tool Detail Reference
892/00280 Pressure Gauge 0-600 bar (0-9000 lbf/in2)
892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2)
892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2)
892/00347Connector
892/00254Hose
892/00223Hand Pump
892/00137Micro-bore Hose 1/4 in BSP x 3 metres
892/00274Adapter 1/4 in M BSP x 3/8 in M BSP Taper
892/002621/4 in M BSP x 1/4 in F BSP x Test Point
892/00706Test Probe
892/00278 Gauge 0 - 40 bar (0 - 600 lbf/in2)
892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in2)
9803-9490-1
1-21 1-21
Fig 20. Hydraulic Circuit Test Gauges and Connections
Fig 21. Hand Pump Equipment
Moving a Disabled Machine
Towing or Winching
It is only possible to tow or winch the machine very slowly for a short distance. If at all possible repair the disabled machine where it stands.
If the machine needs to be returned to the workshop for repair, it must be winched or lifted onto a trailer.
The machine is normally prevented from moving by hydraulic oil locked up in the transmission circuit. The procedure in Section E of this manual must be carried out before attempting to move the machine. See Preparation for Towing or Winching (Section E)
Section 1 - General Information 1-22 1-22 9803-9490-1
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Moving a Disabled Machine Towing or Winching 1-23 1-23
Section 1 - General Information
9803-9490-1
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Sealing and Retaining Compounds
Service Consumables
Sealing and Retaining Compounds
T11-001_3
Table 13. TypeDescriptionPart
JCB Multi-GasketA medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter.
JCB High Strength ThreadlockerA high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important.
JCB Retainer (High Strength) For all retaining parts which are unlikely to be dismantled.
JCB Threadlocker and SealerA 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.
JCB Threadlocker and 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.
ml
ml
ml
ml
ml
JCB ThreadsealA medium strength thread sealing compound.4102/195150 ml
JCB ActivatorA cleaning primer which speeds the curing rate of anaerobic products.
4104/0251200 ml (Aerosol)
4104/02531 ltr (Bottle)
JCB Cleaner/DegreaserFor degreasing components prior to use of anaerobic adhesives and sealants. 4104/1557400 ml (Aerosol)
Direct Glazing KitFor one pane of glass; comprises of:
–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.
993/55700
Ultra Fast AdhesiveFor direct glazing.4103/2109310 ml Active Wipe 205For direct glazing.4104/1203250 ml Black Primer 206JFor direct glazing.4201/490630 ml
Clear Silicone SealantTo seal butt jointed glass. 4102/0901
Plastic to Metal BonderTo seal plastic to metal joints.4103/095650 g
Black Polyurethane SealantTo finish exposed edges of laminated glass.4102/2309310 ml
Section 1 - General Information Service Consumables
1-24 1-24
9803-9490-1
No.Quantity
4102/121250
ml
4102/055150
ml
4101/065150
4101/025010
4101/025150
4101/055010
4101/0552200
