Introduction
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.
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. Finally, please remember above all else SAFETY MUST COME FIRST!
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 & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc.
3 = Routine 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 & Framework ...etc.
The page numbering in each alphabetically coded section is not continuous. This allows for the insertion of new items in later issues of the manual.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.
All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid 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, hence for lubricated threads may be reduced by one third.
'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards.
Colour Codes
The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications
Red
Pink Orange
Blue Green
Light Green
Yellow
Full Presssure
Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and M.R.V. operating pressure.
Pressure
Pressure that is above neutral circuit pressure but lower than that denoted by red.
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).
A390940
Black & White Codes
The following black and white coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications
Neutral Circuit Pressure.
Pressure generated by the operation of a service. Depending on application this may be anything between Neutral Circuit Pressure and M.R.V. Operation Pressure.
Pressure that is above Neutral Circuit Pressure but lower than that denoted above. Exhaust.
A276340
Oil subjected to a partial vacuum due to a drop in pressure (cavitation).
Oil trapped within a chamber or line preventing movement of componenets (lock-up).
Oil pressure used in a controlling device (servo).
MachineIdentificationPlate1-1
TypicalVehicleIdentificationNumber(VIN)1-1
TypicalEngineIdentificationNumber1-1
SerialPlates1-2
TorqueSettings1-3
JCBStandardTorqueSettings
B.S.P.PortConnection(ColourCoded)1-4
HoseEndsandFlangeFittings(ColourCoded)1-5
ServiceToolsNumericalList3-1
ServiceTools
BodyandFramework4-1
Electrics5-1
Hydraulics6-1
Transmission7-1
Steering8-1
Engine8-1
SealingandRetainingCompounds9-1
Machine Identification Plate
Yourmachinehasanidentificationplatemountedasshown. Theserialnumbersofthemachineanditsmajorunitsare stampedontheplate.
Typical Vehicle Identification Number (VIN)
SLP 270 A T V E 0787034 ABCDEFG
A WorldManufacturerIdentification
B MachineModel
C SteerType(A=Articulated)
D BuildType(T=TelescopicHandler)
E YearofManufacture:
R=19941=2001
S=19952=2002
T=19963=2003
V=19974=2004
W=19985=2005
X=19996=2006
Y=20007=2007
F ManufacturerLocation(E=England)
G ProductIdentificationNumber(PIN)
Theserialnumberofeachmajorunitisalsostampedonthe unititself.Ifamajorunitisreplacedbyanewone,theserial numberontheidentificationplatewillbewrong.Eitherstamp thenewnumberoftheunitontheidentificationplate,orsimplystampouttheoldnumber.Thiswillpreventthewrongunit numberbeingquotedwhenreplacementpartsareordered.
Themachineandengineserialnumberscanhelpidentify exactlythetypeofequipmentyouhave.
Typical Engine Identification Number
AB 50262 U 500405 P ABCDE
A EngineType
AB=4cylinderturbo
B BuildNumber
C CountryofOrigin
D EngineSequenceNumber
E YearofManufacture
U.K. and
1-3
TORQUE SETTINGS
Useonlywherenotorquesettingisspecifiedinthetext.Valuesarefordrythreadsandmaybewithinthreepercentofthe figuresstated.ForlubricatedthreadsthevaluesshouldbeREDUCEDbyonethird.
Note: AllboltsusedonJCBmachinesarehightensileandmustnotbereplacedbyboltsofalessertensilespecification.
JCBStandardTorqueSettingsB.S.P.PortConnection(ColourCoded)
Note: Alladapters,elbowsandhosesshouldbetightenedtoJCBstandardtorquesettingsunlessstatedotherwise.
JCBStandardTorqueSettingsforHoseEndsandFlangedFittings(ColourCoded)
Note: Alladapters,elbowsandhosesshouldbetightenedtoJCBstandardtorquesettingsunlessstatedotherwise.
HOSEENDFITTINGS
SPLITFLANGEand FLANGEDPIPEFITTINGS
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1406/0011BondedWasher6-2
1406/0018BondedWasher6-2
1406/0021BondedWasher6-1,6-2
1406/0029BondedWasher6-2
1604/0002MaleAdaptor6-2
1604/0003MaleAdaptor6-2
1604/0004MaleAdaptor6-2
1604/0006MaleAdaptor6-1,6-2
1604/0008MaleAdaptor6-1
1606/0003MaleAdaptor6-2
1606/0004MaleAdaptor6-2
1606/0007MaleAdaptor6-2
1606/0008MaleAdaptor6-2
1606/0009MaleAdaptor6-2
4101/0251JCBThreadlockerandSealer5-1
4101/0451JCBThreadlocker5-1
4101/0550JCBThreadlockerandSealer
(highstrength)10ml5-1
4101/0552JCBThreadlockerandSealer
(highstrength)200ml5-1
4101/0651JCBRetainer(highstrength)5-1
4102/0551JCBHighStrengthThreadlocker5-1
4102/0933ClearSiliconeSealant5-1
4102/1212JCBMulti-gasket5-1
4102/1951JCBThreadseal5-1
4102/2309BlackPolyuretheneSealant5-1
4103/2109UltraFastAdhesive5-1
4104/0251JCBActivator(aerosol)5-1
4104/0253JCBActivator(bottle)5-1
4104/1203ActiveWipe205(250g)5-1
4104/1206ActiveWipe205(30ml)5-1
4104/1310HandCleaner(454g)4-1
41041557JCBCleanerandDegreaser5-1
4201/4906BlackPrimer206J(30ml)5-1
816/00189BlankingCap6-3
816/00190BlankingCap6-3
816/00196BlankingCap6-3
816/00294BlankingCap6-3
825/00410CrowfootWrench5-1
825/99833Adaptorfor825/004105-1
826/01099RivetNut4-1
826/01101RivetNut4-1
826/01102RivetNut4-1
826/01103RivetNut4-1
826/01104RivetNut4-1
826/01105RivetNut4-1
892/00041De-glazingTool8-1
892/00047Adaptor6-3
892/00048Adaptor6-3
892/00055BlankingPlug6-3
892/00056BlankingPlug6-3
892/00057BlankingPlug6-3
892/00059BlankingPlug6-3
892/00074FemaleConnector6-3
892/00075FemaleConnector6-3