JCB 2.0D/G, 2.5D/G, 3.0D/G, 4×4 3.0D, 4×4 3.5D Teletruk Service Manual – 9803/3400-16 – PDF DOWNLOAD

General Information Care & Safety Routine Maintenance Attachments

Service Manual

Body & Framework Electrics Controls

Teletruk From M/c No. 788001

Hydraulics Transmission Brakes

PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB AFTERMARKET TRAINING; © WOODSEAT, ROCESTER, STAFFORDSHIRE, ST14 5BW, ENGLAND Tel. ROCESTER (01889) 594700 PRINTED IN ENGLAND Publication No. 9803/3400 Issue 16 Copyright © 2006 JCB AFTERMARKET TRAINING 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.

Steering Engine

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

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Introduction

General This Service Manual is designed for the benefit of JCB Distributor Service Engineers who are receiving or have received, training by JCB Technical Training Department.

These personnel have a sound knowledge of safe workshop practices, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment.

The replacement of oil seals, gaskets and any other components showing obvious signs of wear or damage is expected as a matter of course. Components should be cleaned and lubricated where appropriate, and any open hose or pipe connection must be blanked off to prevent the loss of hydraulic fluid or allow an ingress of dirt. Finally, please remember SAFETY COMES FIRST!

Service Manual Layout This Service manual is compiled in sections, the first three are numbered and contain information as follows: 1 2 3

General Information Care and Safety Routine maintenance

The remaining sections are alphabetically coded and deal with the overhaul and inspection of specific components, for example: A B

Attachments Body and Framework ....etc.

The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new information in later issues of this Service Manual.

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

Read the section contents to locate machine types, machine type identification is not listed on individual pages.

All sections are listed on the front cover; tabbed divider cards align directly with each individual section for quick reference.

Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads. Torque figures for lubricated threads can be reduced by one third.

“Left Hand” and “Right Hand” are as viewed from the rear of the machine facing forwards.

This Service Manual covers the following machine type: Teletruk Product Identification Number (PIN) 0788001

9803/3400

Issue 1

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Section 1

General Information

Section 1

i

i

Contents Identification - Vehicle Identification Number - Unit Identification * - Typical Engine Identification Number

Page No.

1-1 1-1 1-1

Torque Settings * - Introduction - Zinc Plated Fasteners and Dacromet Fasteners 2-1 * - Metric Grade 8.8 Bolts 2-1 UNF Grade “S” Bolts 2 -1 * 2-2 * - Hydraulic Fittings & Torque Settings 2-2 * - ‘O’ Ring Face Seal System Torque Stop Hose System 2 -3 * Service -

Tools Numerical List Body and Framework Electrics Hydaulics

Sealing and Retaining Compounds

9803/3400

3 3 3 3

-

1 2 5 6

4-1

Issue 4*

Section 1

General Information

Section 1

Identification

1-1

Vehicle Identification Number (VIN)

1-1

*

The Product Identification Number (PIN), transmission pump serial number and engine serial number positively identify the type of Teletruk that you have. These numbers are stamped on the machine VIN plate as shown in the following Figure.

A typical VIN is a 17 digit number as follows: 401571

SLP TLT25 V E 0788001 SLP TLT25 V E 0788001

Manufacturer (JCB) Machine Model (Teletruk) Year (1997) Country (England) (PIN)

J.C.BAMFORD EXCAVATORS LTD. ROCESTER, STAFFS, ENGLAND.

R

CONSTRUCTOR

Vehicle Identification No.

Unit Identification To confirm the identity of your machine, check the VIN plate details against the serial numbers of each component.

MADE IN UK

Product Identification No.

ENGINE SERIAL No.

WEIGHT

PUMP SERIAL No.

YEAR OF MANUFACTURE

MODEL

80/1269/EEC POWER KW R.P.M.

MODEL

80/1269/EEC POWER KW R.P.M.

Typical Engine Identification Number This applies to the diesel engines only.

HR A

51245 B

817/16599

U C

A Engine Type KR = 4 cylinder naturally aspirated - up to machine serial number 892816.

HP = 4 cylinder naturally aspirated - low emission stage 2 from machine serial number 892817.

HR = 4 cylinder turbo - low emission stage 2 - 3.5 machines only.

Where the service procedure differ between the engine types, the text and or the illustration will specify.

B Build Number C Country of Origin

9803/3400

Issue 3*

Section 1

General Information Torque Settings

2-1 *

Section 1 2-1

Introduction - Zinc Plated Fasteners and Dacromet Fasteners JCB Teletruks are assembled 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 as follows: Fastener Type Zinc and Yellow Dacromet

Colour Golden finish Mottled silver finish

Part Number ‘Z’ (e.g. 1315/3712Z) ‘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 fasteners.

Note: A Dacromet bolt should not be used in conjunction with a Zinc and Yellow plated nut, as this could change the torque characteristics of the torque settings further. For the same reason, a Dacromet nut should not be used in conjunction with a Zinc and Yellow plated bolt.

Use only where no torque setting is specified in the text. Values are for dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third.

Metric Grade 8.8 Bolts Bolt size Diameter mm

Hexagon (A/F) mm

M6 x 1.0 M8 x 1.25 M10 x 1.5 M12 x 1.75 M14 x 2 M16 x 2 M18 x 2.5 M20 x 2.5 M24 x 3 M30 x 3.5

10 13 17 19 22 24 27 30 36 46

Zinc Plated Fasteners Torque Settings Nm kgf m lbf ft

Dacromet Fasteners Torque Settings Nm kgf m lbf ft

12 28 56 98

1.2 3.0 5.7 10

9 21 42 72

244 350 476 822 1633

25 36 48 84 166

180 258 352 607 1205

9 22.5 47.5 80 133 200 278 392 675 1348

0.9 2.3 4.8 8.2 13.6 20.4 28.4 40 69 138

7 17 35 59 98 148 205 289 498 994

UNF Grade 'S' Bolts Bolt Size in 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8

1 11/4 11/2

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

Hexagon (A/F) in 7/16 1/2 9/16 5/8 3/4 13/16 15/16

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

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

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

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

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

9803/3400

Issue 2*

Section 1

General Information

2-2

Section 1

Hydraulic Fittings & Torque Settings

2-2

‘O’ Ring Face Seal System Adaptors screwed into valve blocks Adaptors screwed into valve blocks, etc. seal onto an 'O' ring which is compressed into a 45o seat machined in the face of the tapped port.

Adaptor Size 1/4” BSP 3/8” BSP 1/2” BSP 5/8” BSP 3/4” BSP 1” BSP 1 1/4” BSP

Common Spanner Size (A/F) mm in.

Tightening Torque Nm lbf ft

19 22 27 30 32 38

18 31 49 60 81 129 206

0.75 0.875 1 1.25 1.5

13 23 36 44 60 95 152

SAE Tube Size

SAE Port Thread Size

Common Spanner Size (A/F) mm in.

Tightening Torque Nm lbf ft

4 6 8 10 12 16 20

7/16 - 20 9/16 - 18 3/4 - 16 7/8 - 14 1.1/16 - 12 1.5/16 - 12 1.5/8 - 12

15.9 19.1 22.2 27.0 31.8 38.1 47.6

20 - 28 46 - 54 95 - 105 130 - 140 190 - 210 290 - 310 280 - 380

0.625 0.750 0.875 1.063 1.250 1.500 1.875

16.5 - 18.5 34 - 40 69 - 77 96 - 104 141 - 155 216 - 230 210 - 280

Hoses Screwed onto Adaptors Hoses B screwed onto adaptors A etc. seal onto an 'O' ring C which is compressed into a 45o seat machined in the face of the adaptor port.

Dimension will vary depending on torque applied.

C B A

Hose Size 1/8” BSP 1/4” BSP 3/8” BSP 1/2” BSP 5/8” BSP 3/4” BSP 1” BSP 1 1/4” BSP 1 1/2” BSP 9803/3400

Common Spanner Size (A/F) mm in.

Tightening Torque Nm lbf ft

14 19 22 27 30 32 38

14 24 33 44 58 84 115 189 244

0.75 0.875 1 1.25 1.5

A438690

10 18 24 33 43 62 85 140 180 Issue 1

Section 1 2-3

General Information

Section 1

Hydraulic Fittings & Torque Settings

2-3

Torque Stop Hose System 'Torque Stop' Hoses B screwed onto adaptors A etc. seal onto an 'O' ring C which is compressed into a 45o seat machined in the face of the adaptor port. To prevent the ‘O’ ring being damaged as a result of over tightening, 'Torque Stop' Hoses have an additional shoulder, which acts as a physical stop.

Minimum dimension fixed by shoulder D.

C

B D A

Hose Size 1/8” BSP 1/4” BSP 3/8” BSP 1/2” BSP 5/8” BSP 3/4” BSP 1” BSP 1 1/4” BSP 1 1/2” BSP

9803/3400

Common Spanner Size (A/F) mm in.

Tightening Torque Nm lbf ft

14 19 22 27 30 32 38

14 27 40 55 65 95 120 189 244

0.75 0.875 1 1.25 1.5

A438700

10 20 30 40 48 70 89 140 180

Issue 1

Section 1

General Information Service Tools

3-1

Numerical List 1406/0011 1406/0018 1406/0021 1406/0029 1604/0003 1604/0004 1604/0006 1606/0003 1606/0004 1606/0007 1606/0008 1606/0009 1612/0006 4101/0251 4101/0451 4101/0552 4101/0651 4102/0551 4102/1201 4104/0251 4104/0253 4104/1310 * 331/27987 * 721/11069 816/00189 816/00190 816/00193 816/00196 816/00197 816/00294 816/15118 816/20008 816/50043 816/55038 816/55040 816/60096 826/01099 826/01101 826/01102 826/01103 826/01104 826/01105 892/00047 892/00048 892/00055 892/00056 892/00057 892/00059 892/00060 892/00074 892/00075 892/00077 892/00137 892/00223 892/00252 892/00253 892/00255 892/00256 892/00257 892/00258 892/00259

9803/3400

Section 1

Page No. Bonded Washer 3-7 Bonded Washer 3-7 Bonded Washer 3 - 6/3 - 7 Bonded Washer 3-7 Adapter 3-7 Adapter 3-7 Adapter 3 - 6/3 - 7 Adapter 3-7 Adapter 3-7 Adapter 3-7 Adapter 3-7 Adapter 3-7 Adapter 3-6 JCB Threadlocker and sealer 4-1 JCB Threadlocker 4-1 JCB Threadlocker and Sealer (HS) 4-1 JCB Retainer (High Strength) 4-1 JCB High Strength Threadlocker 4-1 JCB Multi-Gasket 4-1 JCB Activator (Aerosol) 4-1 JCB Activator (Bottle) 4-1 Hand Cleaner 3-2 Flank Drive Socket 3-5 Speed Sensor Test Lead 3-5 Blanking Cap 3-8 Blanking Cap 3-8 Blanking Cap 3-8 Blanking Cap 3-8 Blanking Cap 3-8 Blanking Cap 3-8 Pressure Test Adapter 3-6 Adapter 3-6 'T' Adapter 3-8 Pressure Test 'T' Adapter 3-6 Pressure Test 'T' Adapter 3-6 'T' Adapter 3-8 M6 x 16mm Rivet Nut 3-2 M6 x 19mm Rivet Nut 3-2 M8 x 21mm Rivet Nut 3-2 M8 x 18mm Rivet Nut 3-2 M10 x 23mm Rivet Nut 3-2 M10 x 26mm Rivet Nut 3-2 'T' Adapter 3-8 'T' Adapter 3-8 Blanking Plug 3-8 Blanking Plug 3-8 Blanking Plug 3-8 Blanking Plug 3-8 Blanking Plug 3-8 Female Connector 3-8 Female Connector 3-8 Female Connector 3-8 Hose 3-7 Hand Pump 3-7 A.R.V Test Block - Husco 3-7 Pressure Test Kit 3-6 Pressure Test Adapter 3-6 Pressure Test Adapter 3-6 Pressure Test Adapter 3-6 Pressure Test Adapter 3-6 Pressure Test Adapter 3-6

892/00260 892/00261 892/00262 892/00263 892/00264 892/00265 892/00268 892/00269 892/00270 892/00271 892/00272 892/00274 892/00275 892/00276 892/00277 892/00278 892/00279 892/00281 892/00282 892/00283 892/00284 892/00285 892/00286 892/00706 892/00842 892/00843 892/00844 892//00845 892/00846 892/00847 892/00848 892/00849 892/00923 * 892/00924 926/15500 992/09300 992/09400 992/09500 992/09600 992/12300 992/12400 992/12600 992/12800 992/12801 993/68100 993/85700

3-1 Page No. Pressure Test Adapter 3-6 Pressure Test Adapter 3-6 Pressure Test 'T' Adapter 3 - 6/3 - 7 Pressure Test 'T' Adapter 3-6 Pressure Test 'T' Adapter 3-6 Pressure Test 'T' Adapter 3-6 Flow Monitoring Unit 3-6 Sensor Head 3-6 Load Valve 3-6 Adapter 3-6 Adapter 3-6 Adapter 3-7 Adapter 3-6 Adapter 3-6 Adapter 3-6 Gauge 3-7 Gauge 3-7 AVO Meter 3-5 Shunt 3-5 Tool Kit Case 3-5 Tachometer 3-5 Hydraulic Oil Temperature Probe 3-5 Surface Temperature Probe 3-5 Test Probe 3-7 Glass Lifter 3-3 Folding Stand for Holding Glass 3-2 Long Knife 3-4 Cartridge Gun 3-2 Glass Extractor (Handles) 3-3 Nylon Spatula 3-4 Wire Starter 3-3 Braided Cutting Wire 3-4 A.R.V Test Block - Commercial Hyd. 3 - 7 Psion Walkabout 3-5 Rubber Spacer Blocks 3-4 Spanner 3-7 Spanner 3-7 Spanner 3-7 Spanner 3-7 12V Mobile Oven 3-2 240V Static Oven -2 Cartridge 3-3 240V Static Oven -6 Cartridge 3-3 Cut-Out Knife 3-3 ‘L’ Blades 3-3 Slide Hammer Kit 3-4 Battery tester 3-5

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

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

3 3 3 3

-

6 6 6 6

Issue 2

Section 1

General Information

3-2

Section 1 3-2

Service Tools

Section B - Body & Framework

826/01099 826/01101 826/01103 826/01102 826/01104 826/01105

M6 x 16mm Rivet Nut M6 x 19mm Rivet Nut M8 x 18mm Rivet Nut M8 x 21mm Rivet Nut M10 x 23mm Rivet Nut M10 x 26mm Rivet Nut

Installation Tool Available from: Bollhoff Fastenings Ltd. Midacre The Willenhall Estate Rose Hill Willenhall West Midlands, WV13 2JW S1261210

Cartridge Gun - hand operated - essential for the application of sealants, polyurethane materials etc.

JCB part 892/00845

number

-

Hand Cleaner - special blend for the removal of polyurethane adhesives.

JCB part number - 4104/1310 (454g; 1 lb tub)

S186240

S186270

Folding Stand for Holding Glass - essential for preparing new glass prior to installation.

12V Mobile Oven - 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 (715/04300).

JCB part number - 992/12300

JCB part 892/00843

number

-

S186280 S186250

9803/3400

Issue 1

Section 1 3-3

General Information

Section 1

Service Tools

3-3

Section B - Body & Framework (cont’d)

240V Static Oven - available with 2 or 6 cartridge capacity - required to pre-heat adhesive prior to use.

No plug supplied. Note: 110V models available upon request - contact JCB Technical Service.

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.

JCB part number: 992/12400 - 2 Cartridge x 240V 992/12600 - 6 Cartridge x 240V

JCB part number - 892/00842

S186300

S186260

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

Cut-Out Knife - used to remove broken glass.

JCB part number - 992/12800 JCB part number - 892/00848

S186310

S186340

'L' Blades - 25 mm (1 in) cut - replacement blades for cut-out knife (above).

JCB part number - 992/12801 (unit quantity = 5 off)

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

JCB part number - 892/00846 S186320

9803/3400

S186350

Issue 1

Section 1

General Information

Section 1

Service Tools

3-4

3-4

Section B - Body & Framework (cont’d)

Long Knife - used to give extended reach for normally inaccessible areas.

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

JCB part number - 892/00844 JCB part number - 892/00849 (approx 25 m length)

S186360

S186330

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

JCB part number - 926/15500 (unit quantity = 500 off) Nylon Spatula - general tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge.

JCB part number - 892/00847 *

S186550

S186470-V1

Slide Hammer Kit - 993/68100 1 :993/68101 Slide Hammer 2 :993/68102 End Stops 3 :993/68103 Adaptor - M20 x 5/8" UNF 4 :993/68104 Adaptor - M20 x 1" UNF 5 :993/68105 Adaptor - M20 x M20

6 7 8 9 * 10 11

:993/68106 :993/68107 :993/68108 :993/68109 :993/68110 :993/68111 2

11

Adaptor - M20 x M24 Bar - M20 x M20 X 800MM Adaptor - M20 x 7/8" UNF Adaptor - M20 x M12 Adaptor - M20 x M16 Adaptor - M20 x 1/2" UNF 2 5

1

3

6

2

4

9 10 8 7

S196910

9803/3400

Issue 3*

Section 1

General Information

3-5

Section 1 3-5

Service Tools

Section C - Electrics

239510

993/85700

Battery Tester

* S188231

AVO Test Kit 1 2 3 4 5 6

892/00283 892/00281 892/00286 892/00284 892/00282 892/00285

Tool Kit Case AVO Meter Surface Temperature Probe Venture Microtach Digital Tachometer 100 Amp Shunt - Open Type Hydraulic Temperature Probe

1

A437530

331/27987

Flank Drive Socket

4

1

3

2

1 2

4 3

2

A437560

1 2

892/00924 892/00931

9803/3400

Psion Walkabout Psion Service Software Lead

721/11069

Speed Sensor Test Lead

Issue 4*

Section 1

General Information

Section 1

Service Tools

3-6

3-6

Section E - Hydraulics

Hydraulic Circuit Pressure Test Kit 892/00253

Pressure Test Kit

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 (0-400 lbf/in2)

892/00254

Replacement Hose

188120

188130

Pressure Test Adapters

Pressure Test 'T' Adapters 892/00262 816/55038 816/55040 892/00263 892/00264 892/00265

200140

1/4 in M BSP x 1/4 in F BSP x Test Point 3/8 in M BSP x 3/8 in F BSP x Test Point 1/2 in M BSP x 1/2 in F BSP x Test Point 5/8 in M BSP x 5/8 in F BSP x Test Point 3/4 in M BSP x 3/4 in F BSP x Test Point 1 in M BSP x 1 in F BSPP x Test Point

892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261

1/4 in BSP x Test Point 3/8 in BSP x Test Point 1/2 in BSP x Test Point 5/8 in BSP x Test Point 3/4 in BSP x Test Point 1 in BSP x Test Point 1.1/4 in BSP x Test Point 5/8 in UNF x Test Point

Flow Test Equipment

188150

9803/3400

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

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

Issue 1

Section 1

General Information

Section 1

Service Tools

3-7

3-7

Section E - Hydraulics

220840

S270650

892/00252 Test Block for A. R. V. - Husco valves 892/00923 Test Block for A. R. V. - Commercial Hydraulic valves

193850

188140

Hand Pump Equipment 892/00223 892/00137 892/00274 892/00262 892/00706 892/00278 892/00279

Hand Pump Micro-bore Hose 1/4 in BSP x 5 metres Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1/4 in M BSP x 1/4 in F BSP x Test Point Test Probe Gauge 0 - 40 bar (0 - 600 lbf/in2) Gauge 0 - 400 bar (0 - 6000 lbf/in2)

Bonded Washers 1406/0011 1406/0018 1406/0021 1406/0029

1/4 in BSP 1/2 in BSP 3/4 in BSP 1.1/4 in BSP

193860 193930

Male Adapters - BSP x BSP 1606/0003 1604/0003 1606/0004 1606/0007 1604/0004 1606/0008 1606/0009 1604/0006

9803/3400

3/8 in x 1/4 in 3/8 in x 3/8 in 1/2 in x 1/4 in 1/2 in x 3/8 in 1/2 in x 1/2 in 3/4 in x 3/8 in 3/4 in x 1/2 in 3/4 in x 3/4 in

Hexagon Spanners for Ram Pistons and End Caps 992/09300 992/09400 992/09500 992/09600

55 mm A/F 65 mm A/F 75 mm A/F 85 mm A/F

Issue 1

Section 1

General Information

Section 1

Service Tools

3-8

3-8

Section E - Hydraulics

193880 193870

Male Cone Blanking Plug Female Cone Blanking Plug 892/00055 892/00056 892/00057 892/00059 892/00060

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

1/4 in BSP 3/8 in BSP 1/2 in BSP 3/4 in BSP 1 in BSP'T'

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

193890

'T' Adapters 892/00047 892/00048 816/50043 816/60096

9803/3400

193900

Female Connectors 3/8 in BSP (A) x 1/4 in BSP (B) 1/2 in BSP (A) x 1/4 in BSP (B) 3/4 in BSP (A) x 1/4 in BSP (B) 3/4 in BSP (A) x 3/4 in BSP (B)

892/00074 892/00075 892/00077

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

Issue 1

Section 1 4-1

General Information

Section 1 4-1

Sealing and Retaining Compounds

Sealing and Retaining Compounds JCB Multi-Gasket

JCB High Strength Threadlocker

JCB Retainer (High Strength)

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

4102/1212

50ml

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

4102/0551

50ml

For all retaining parts which are unlikely to be dismantled.

4101/0651

50ml

JCB Threadlocker and Sealer

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

4101/0250 4101/0251

10ml 50ml

Threadseal

A medium strength thread sealing compound.

4102/1951

50ml

Threadlocker

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

4101/0451

50ml

4104/0251 4104/0253

(1ltr) Bottle

400ml

Activator

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

(200ml)

Cleaner / Degreaser

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

4104/1557

For one pane of glass, comprises items marked † below plus applicator nozzle etc.

993/55700

† Ultra Fast Adhesive

For direct glazing

4103/2109

310 ml

† Active Wipe 205

For direct glazing

4104/1206 4104/1203

30 ml 250 g

† Black Primer 206J

For direct glazing

4201/4906

30 ml

Clear Silicone Sealant

To seal butt jointed glass

4102/0933

Black Polyurethane Sealant

To finish exposed edges of laminated glass

4102/2309

310 ml

JCB Cleaner & Degreaser

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

4104/1538

Aerosol

Direct Glazing Kit

9803/3400

Issue 2

Care & Safety

Section 2

Section 2

i

i

Contents

9803/3400

Page No.

Safety Notices

1-1

General

2-1

General Safety

3-1

Operating Safety

4-1

Maintenance Safety

5-1

Issue 1

Section 2

Care & Safety

1-1

Safety Notices

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In this manual and on the machine there are safety notices. Each notice starts with a signal word The meanings of the signal words are given below.

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

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

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

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! WARNING Study this Service Manual before carrying out any maintenance work on the machine. You must always understand and observe the relevant laws and regulations If you are unsure about anything, ask your JCB Distributor.

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Care & Safety

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General

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Introduction This section of the Manual is intended to REMIND the operator of basic safety requirements when operating industrial machinery. It is not a complete list of hazards that may exist when operating or maintaining the Teletruk.

SPECIFIC HAZARDS RELATING TO MAINTENANCE INSTRUCTIONS ARE DETAILED IN THE RELEVANT SECTIONS OF THIS MANUAL.

Safety First - Yours And Other People’s All industrial equipment can be hazardous. When a machine is properly maintained, it is a safe machine to work with. But when it is poorly maintained it can become a danger to you (the operator) and others.

In this Manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your supervisor or JCB Distributor to explain them.

But safety is not just a matter of responding to the warnings.

All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them.

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

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General Safety

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! WARNING Manual. You and others can be injured if you maintain the machine without first studying this Manual. Read the safety instructions before maintaining the machine. If you do not understand anything, ask your supervisor or JCB Distributor to explain it. Keep this Manual clean and in good condition.

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! WARNING Clothing. You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery.

Wear protective clothing to suit the job. Examples of protective clothing are: a hard hat, safety shoes, safety glasses, a well fitting overall, ear protectors and industrial gloves. Keep cuffs fastened. Do not wear a necktie or scarf. Keep long hair restrained.

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! WARNING Care and Alertness. All the time you are working with or on the machine, take care and stay alert. Always be careful.

Always be alert for hazards.

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! WARNING Fires. If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the correct machine location until you need to use it.

Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an electrical fire. Use carbon dioxide, dry chemical or foam extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use self-contained breathing apparatus.

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! WARNING Alcohol and Drugs. It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or whilst operating the machine or attachments. Be aware of medicines which can cause drowsiness.

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! CAUTION Regulations. Obey all laws, work site and local regulations which affect you and your machine.

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