JCB JS200 JS210 JS220 JS260 TRACKED EXCAVATOR Service Repair Manual Instant Download

Open front screen Service Manual JS200, JS210, JS220, JS240, JS260 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track and Running Gear Section K - Engine Publication No. 9803/6510-03 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

Open front screen Section 1 General Information Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Track and Running Gear Section K - Engine Publication No. 9803/6510-03 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

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Section 1 - General information Contents Introduction About this Publication .............................................................................. 1 - 1 Schematic Codes .................................................................................... 1 - 2 Colour Codes ..................................................................................... 1 - 2 Page No. Identifying your Machine Identifying Your Machine ......................................................................... 1 - 3 Data Plate ........................................................................................... 1 - 3 Typical Product Identification Number (PIN) ...................................... 1 - 3 Typical Engine Identification Number ................................................. 1 - 4 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1 - 5 Introduction ......................................................................................... 1 - 5 Bolts and Screws ................................................................................ 1 - 5 Hydraulic Connections ............................................................................. 1 - 9 'O' Ring Face Seal System ................................................................. 1 - 9 'Torque Stop' Hose System .............................................................. 1 - 12 Service Tools Numerical List Section B - Body and Framework .................................. 1 - 13 Tool Detail Reference Section B - Body and Framework ...................... 1 - 14 Numerical List Section C - Electrics ...................................................... 1 - 17 Tool Detail Reference Section C - Electrics ........................................... 1 - 18 Numerical List Section E- Hydraulics .................................................... 1 - 20 Tool Detail Reference Section E- Hydraulics ......................................... 1 - 22 Inserting seal ring and correction jig ................................................. 1 - 29 Jig for pulling out, press-fitting bushing ............................................ 1 - 30 Jig for press-fitting wiper ring ........................................................... 1 - 30 Jig for inserting cylinder head ........................................................... 1 - 30 Seal Ring and Connector Jig ............................................................ 1 - 30 Bush Removal Jig ............................................................................ 1 - 30 Bush Fitting Jig ................................................................................. 1 - 31 Wiper Ring Fitting Jig ....................................................................... 1 - 31 Wiper Ring Fitting Jig ....................................................................... 1 - 31 Numerical List Section F - Transmission ............................................... 1 - 32 Tool Detail Reference Section F - Transmission .................................... 1 - 33 Service Consumables Sealing and Retaining Compounds ....................................................... 1 - 36 1 - i 1 - i

Section 1 - General information Contents Page No. 1 - ii 1 - ii

Section 1 - General Information Introduction About this Publication This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. All sections are listed on the front cover; tabbed divider cards align directly with individual sections on the front cover for rapid reference. 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. 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. 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! 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards. This Service Manual covers the following machines: JS200, JS210, JS220, JS260 The manual is compiled in sections, the first three are numbered and contain information as follows: General Information - includes torque settings and service tools. 1 Care & Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. 2 Routine Maintenance - includes service schedules and recommended lubricants for all the machine. 3 The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: Attachments Body & Framework...etc. A B 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. 1 - 1 1 - 1 9803/6510-3

Section 1 - General Information Introduction Schematic Codes Schematic Codes Colour Codes The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and MRV operating pressure. Red Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red. Pink Servo: Oil pressure used in controlling a device (servo). Orange Neural: Neutral circuit pressure. Blue Green Exhaust: Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation). Light Green Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up). Yellow 1 - 2 1 - 2 9803/6510-3

Section 1 - General Information Identifying your Machine Identifying Your Machine Data Plate Typical Product Identification Number (PIN) Your machine has a Data Plate, located on the outside of the cab as shown at A. The machine serial number is inscribed at B which is the baseplate of the rear frame and the engine number is at C. 1 2 3 C 4 6 5 JCB JS13C 1018354 World Manufacturer Identification (JCB) 1 Machine Type and Model (JS13C = JS130 Tracked) 2 Randomly generated check letter. 3 Year of Manufacture (1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004, 5 = 2005, 6 = 2006) 4 Machine Serial Number (1018354) 5 Fig 1. Fig 2. 1 - 3 1 - 3 9803/6510-3

Section 1 - General Information Identifying your Machine Identifying Your Machine 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. Fig 3. a b c J d e 2 AB 50316 000001 Engine Type (AB= 4 cylinder turbo) a Engine Parts List b Country of Manufacture c Engine Serial Number d Year of Manufacture e 1 - 4 1 - 4 9803/6510-3

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. Note: Dacromet fasteners are lubricated as part of the plating process, do not lubricate. The two types of fasteners can be readily identified by colour and part number suffix. K ( T T 1-5). Torque settings are given for the following conditions: K Table 1. Fastener Types Condition 1 Table 1. Fastener Types Colour Un-lubricated fasteners Zinc fasteners Yellow plated fasteners Fastener Type Zinc and Yellow Dacromet Part No. Suffix Golden finish 'Z' (e.g. 1315/3712Z) Condition 2 Mottled silver finish 'D' (e.g. 1315/3712D) Zinc flake (Dacromet) fasteners Lubricated zinc and yellow plated fasteners Where there is a natural lubrication. For example, cast iron components 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. 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. Fig 4. 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. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings. 1 - 5 1 - 5 9803/6510-3

Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Hexagon (A/F) in. Nm 7/16 11.2 1/2 22.3 9/16 40.0 5/8 64.0 3/4 98.00 13/16 140.0 15/16 196.0 1 1/8 343.0 1 15/16 547.0 1 1/2 814.0 1 7/8 1181.0 2 1/4 1646.0 Bolt Size Condition 1 kgf m 1.1 2.3 4.1 6.5 10.0 14.3 20.0 35.0 55.8 83.0 120.4 167.8 Condition 2 kgf m 1.0 2.0 3.7 5.8 9.0 12.8 18.0 31.5 50.2 74.6 108.4 151.0 in. 1/4 5/16 3/8 7/16 1/2 9/16 5/8 3/4 7/8 1 1 1/8 1 1/4 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 lbf ft 8.3 16.4 29.5 47.2 72.3 103.2 144.6 253.0 403.4 600.4 871.1 1214.0 Nm 10.0 20.0 36.0 57.0 88.0 126.0 177.0 309.0 492.0 732.0 1063.0 1481.0 lbf ft 7.4 14.7 26.5 42.0 64.9 92.9 130.5 227.9 362.9 539.9 784.0 1092.3 Table 3. Torque Settings - Metric Grade 8.8 Fasteners Hexagon (A/F) Bolt Size Condition 1 Condition 2 ISO Metric Thread M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 mm 5 6 8 10 12 16 20 24 30 36 mm 8 10 13 17 19 24 30 36 46 55 Nm 5.8 9.9 24.0 47.0 83.0 205.0 400.0 690.0 1372.0 2399.0 kgf m 0.6 1.0 2.4 4.8 8.5 20.9 40.8 70.4 139.9 244.6 lbf ft 4.3 7.3 17.7 34.7 61.2 151.2 295.0 508.9 1011.9 1769.4 Nm 5.2 9.0 22.0 43.0 74.0 184.0 360.0 621.0 1235.0 2159.0 kgf m 0.5 0.9 2.2 4.4 7.5 18.8 36.7 63.3 125.9 220.0 lbf ft 3.8 6.6 16.2 31.7 54.6 135.7 265.5 458.0 910.9 1592.4 1 - 6 1 - 6 9803/6510-3

Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Hexagon (A/F) Bolt Size Condition 1 Condition 2 ISO Metric Thread M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 mm 5 6 8 10 12 16 20 24 30 36 mm 8 10 13 17 19 24 30 36 46 55 Nm 8.1 13.9 34.0 67.0 116.0 288.0 562.0 971.0 1930.0 3374.0 kgf m 0.8 1.4 3.5 6.8 11.8 29.4 57.3 99.0 196.8 344.0 lbf ft 6.0 10.2 25.0 49.4 85.5 212.4 414.5 716.9 1423.5 2488.5 Nm 7.3 12.5 30.0 60.0 104.0 259.0 506.0 874.0 1737.0 3036.0 kgf m 0.7 1.3 3.0 6.1 10.6 26.4 51.6 89.1 177.1 309.6 lbf ft 5.4 9.2 22.1 44.2 76.7 191.0 373.2 644.6 1281.1 2239.2 Table 5. Metric Grade 12.9 Fasteners Hexagon (A/F) Bolt Size Condition 1 Condition 2 ISO Metric Thread M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 mm 5 6 8 10 12 16 20 24 30 36 mm 8 10 13 17 19 24 30 36 46 55 Nm 9.8 16.6 40.0 80.0 139.0 345.0 674.0 1165.0 2316.0 4049.0 kgf m 1.0 1.7 4.1 8.1 14.2 35.2 68.7 118.8 236.2 412.9 lbf ft 7.2 12.2 29.5 59.0 102.5 254.4 497.1 859.2 1708.2 2986.4 Nm 8.8 15.0 36.0 72.0 125.0 311.0 607.0 1048.0 2084.0 3644.0 kgf m 0.9 1.5 3.7 7.3 12.7 31.7 61.9 106.9 212.5 371.6 lbf ft 6.5 11.1 26.5 53.1 92.2 229.4 447.7 773.0 1537.1 2687.7 1 - 7 1 - 7 9803/6510-3

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 M3 3 M4 4 M5 5 M6 6 M8 8 M10 10 M12 12 Nm 1.2 3.0 6.0 10.0 24.0 48.0 82.0 kgf m 0.1 0.3 0.6 1.0 2.5 4.9 8.4 lbf ft 0.9 2.0 4.5 7.5 18.0 35.5 60.5 Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size ISO Metric Thread M3 2.0 M4 6.0 M5 11.0 M6 19.0 M8 46.0 M10 91.0 M12 159.0 M16 395.0 M18 550.0 M20 770.0 M24 1332.0 Nm kgf m 0.2 0.6 1.1 1.9 4.7 9.3 16.2 40.0 56.0 79.0 136.0 lbf ft 1.5 4.5 8.0 14.0 34.0 67.0 117.0 292.0 406.0 568.0 983.0 1 - 8 1 - 8 9803/6510-3

Section 1 - General Information Torque Settings Hydraulic Connections Hydraulic Connections T11-003 '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. Table 8. Torque Settings - BSP Adaptors BSP Adaptor Size in. mm 1/4 19.0 3/8 22.0 1/2 27.0 5/8 30.0 3/4 32.0 1 38.0 1 1/4 50.0 Hexagon (A/F) Nm 18.0 31.0 49.0 60.0 81.0 129.0 206.0 kgf m 1.8 3.2 5.0 6.1 8.2 13.1 21.0 lbf ft 13.0 23.0 36.0 44.0 60.0 95.0 152.0 Table 9. Torque Settings - SAE Connections Hexagon (A/F) mm 15.9 20.0 - 28.0 19.1 46.0 - 54.0 22.2 95.0 - 105.0 27.0 130.0 - 140.0 1 1/16 - 12 31.8 1 5/16 - 12 38.1 1 5/8 47.6 SAE Tube Size 4 6 8 10 12 16 20 SAE Port Thread Size 7/16 - 20 9/16 - 18 3/4 - 16 7/8 - 14 Nm kgf m 2.0 - 2.8 4.7 - 5.5 9.7 - 10.7 13.2 - 14.3 19.4 - 21.4 29.6 - 31.6 28.5 - 38.7 lbf ft 16.5 - 18.5 34.0 - 40.0 69.0 - 77.0 96.0 - 104.0 141.0 - 155.0 216.0 - 230.0 210.0 - 280.0 190.0 - 210.0 290.0 - 310.0 280.0 - 380.0 1 - 9 1 - 9 9803/6510-3

Section 1 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 5. Hoses 5-B screwed into adaptors 5-A seal onto an `O' ring 5-C which is compressed into a 45 seat machined into the face of the adaptor port. Note: Dimension 5-D will vary depending upon the torque applied. Table 10. BSP Hose - Torque Settings Hexagon (A/F) mm 14.0 14.0 - 16.00 19.0 24.0 - 27.0 22.0 33.0 - 40.0 27.0 44.0 - 50.0 30.0 58.0 - 65.0 32.0 84.0 - 92.0 38.0 115.0 - 126.0 50.0 189.0 - 200.0 55.0 244.0 - 260.0 BSP Hose Size in. 1/8 1/4 3/8 1/2 5/8 3/4 1 1 1/4 1 1/2 Nm kgf m 1.4 - 1.6 2.4 - 2.7 3.4 - 4.1 4.5 - 5.1 5.9 - 6.6 8.6 - 9.4 11.7 - 12.8 19.3 - 20.4 24.9 - 26.5 lbf ft 10.3 - 11.8 17.7 - 19.9 24.3 - 29.5 32.4 - 36.9 42.8 - 47.9 61.9 - 67.8 84.8 - 92.9 139.4 - 147.5 180.0 - 191.8 1 - 10 1 - 10 9803/6510-3

Section 1 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size Nm in. 1/8 20.0 1/4 34.0 3/8 75.0 1/2 102.0 5/8 122.0 3/4 183.0 1 203.0 1 1/4 305.0 1 1/2 305.0 kgf m 2.1 3.4 7.6 10.3 12.4 18.7 20.7 31.0 31.0 lbf ft 15.0 25.0 55.0 75.0 90.0 135.0 150.0 225.0 225.0 1 - 11 1 - 11 9803/6510-3

Section 1 - General Information Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 6. `Torque Stop' Hoses 6-B screwed into adaptors 6-A seal onto an 'O' ring 6-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 6-D, which acts as a physical stop. Note: Minimum dimension 6-E fixed by shoulder 6-D. Table 12. BSP `Torque Stop' Hose - Torque Settings BSP Hose Size Hexagon (A/F) in. mm 1/8 14.0 1/4 19.0 3/8 22.0 1/2 27.0 5/8 30.0 3/4 32.0 1 38.0 1 1/4 50.0 1 1/2 55.0 Nm 14.0 27.0 40.0 55.0 65.0 95.0 120.0 189.0 244.0 kgf m 1.4 2.7 4.1 5.6 6.6 9.7 12.2 19.3 24.9 lbf ft 10.0 20.0 30.0 40.0 48.0 70.0 89.0 140.0 180.0 1 - 12 1 - 12 9803/6510-3

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 4104/1310 826/01099 826/01101 826/01102 826/01103 826/01104 826/01105 892/00842 892/00843 892/00844 892/00845 892/00846 892/00847 892/00848 892/00849 926/15500 992/12300 992/12400 992/12600 992/12800 992/12801 Description Tool Detail Reference K Fig 7. ( T K Fig 8. ( T K Fig 8. ( T K Fig 8. ( T K Fig 8. ( T K Fig 8. ( T K Fig 8. ( T K Fig 9. ( T K Fig 10. ( T K Fig 11. ( T K Fig 12. ( T K Fig 13. ( T K Fig 14. ( T K Fig 15. ( T K Fig 16. ( T K Fig 17. ( T K Fig 18. ( T K Fig 19. ( T K Fig 19. ( T K Fig 20. ( T K Fig 21. ( T Hand Cleaner M6 x 16mm Rivet Nut M6 x 19mm Rivet Nut M8 x 21mm Rivet Nut M8 x 18mm Rivet Nut M10 x 23mm Rivet Nut M10 x 26mm Rivet Nut Glass Lifter Folding Stand for Holding Glass Long Knife Cartride Gun Glass Extractor (Handles) Nylon Spatula Wire Starter Braided Cutting Wire Rubber Spacer Blocks 12V Oven 240V Oven 2 Cartridge 240V Oven 6 Cartridge Cut-Out Knife L Blades T 1-14) T 1-14) T 1-14) T 1-14) T 1-14) T 1-14) T 1-14) T 1-14) T 1-14) T 1-15) T 1-15) T 1-15) T 1-15) T 1-15) T 1-15) T 1-16) T 1-16) T 1-16) T 1-16) T 1-16) T 1-16) K K K K K K K K K K K K K K K K K K K K K 1 - 13 1 - 13 9803/6510-3

Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework Tool Detail Reference Section B - Body and Framework Note: Not all service tools are illustrated. Illustrations are shown in tool number order. Fig 9. 892/00842 Note: minimum 2 off - essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage. Fig 7. 410/1310 Note: Special blend for the removal of polyurethane adhesives Fig 10. 892/00483 Fig 8. Note: - essential for preparing new glass prior to installation.. Installation Tool Available from: Bollhoff Fastenings Ltd. Midacre The Willenhall Estate Rose Hill Willenhall West Midlands, WV13 2JW 1 - 14 1 - 14 9803/6510-3

Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework Fig 11. 892/00844 Fig 14. 892/0847 Note: - used to give extended reach for normally inaccessible areas. Note: - general tool used for smoothing sealants - also used to re-install glass in rubber glazing because metal tools will chip the glass edge. Fig 12. 892/00845 Note: - hand operated - essential for the application of sealants, polyurethane materials etc. Fig 15. 892/00848 Note: - used to access braided cutting wire through original polyurethane seal. Fig 16. 892/00849 Fig 13. 892/00846 Note: - (approx 25 m length) consumable heavy duty cut-out wire used with the glass extraction tool. Note: - used with braided cutting wire (below) to cut out broken glass. 1 - 15 1 - 15 9803/6510-3

Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework Fig 17. 926/15500 Note: - (unit quantity = 500 off) used to provide the correct set clearance between glass edge and cab frame. Fig 20. 992/12800 Note: - used to remove broken glass. Fig 21. 992/12801 Fig 18. 992/12300 Note: - (unit quantity = 5 off) 25 mm (1 in) cut - replacement blades for cut-out knife (above).. Note: - 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). Fig 19. Note: -available with 2 or 6 cartridge capacity ( 992/ 12400 - 2 Cartridge x 240V, 992/12600 - 6 Cartridge x 240V) - required to pre-heat adhesive prior to use. No plug supplied. 110V models available upon request - contact JCB Technical Service. 1 - 16 1 - 16 9803/6510-3

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 892/00283 892/00281 892/00286 892/00284 892/00282 892/00285 892/00298 993/85700 892/01174 Description Tool Detail Reference K Fig 22. ( T K Fig 22. ( T K Fig 22. ( T K Fig 22. ( T K Fig 22. ( T K Fig 22. ( T K Fig 22. ( T K Fig 23. ( T K Fig 24. ( T Tool Kit Case AVO Meter Surface Temperature Microtach Digital Tachometer Shunt - open type Hydraulic Oil Temperature Probe Fluke 85 Multimeter Battery Tester Electronic Service Tool Kit T 1-18) T 1-18) T 1-18) T 1-18) T 1-18) T 1-18) T 1-18) T 1-18) T 1-19) K K K K K K K K K 1 - 17 1 - 17 9803/6510-3

Section 1 - General Information Service Tools Tool Detail Reference Section C - Electrics Tool Detail Reference Section C - Electrics Note: Not all service tools are illustrated. Illustrations are shown in tool number order. Fig 23. 993/85700 Fig 22. 1 2 3 4 5 6 7 892/00283 Tool Kit Case 892/00281 AVO Meter 892/00286 Surface Temperature 892/00284 Microtach Digital Tachometer 892/00282 Shunt - open type 892/00285 Hydraulic Oil Temperature Probe 892/00298 Fluke 85 Multimeter 1 - 18 1 - 18 9803/6510-3

Section 1 - General Information Service Tools Tool Detail Reference Section C - Electrics 1 2 D C B E A J F G H 3 5 4 6 Fig 24. 892/01174 1 Interconnecting cable, DLA to machine ECU diagnostics socket. Interconnecting cable, DLA to machine ECU diagnostics socket. Kit carrying case. Interconnecting cable, DLA to laptop PC. Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable diagnostics software. Interconnecting cable, DLA to laptop PC. 2 3 4 5 6 1 - 19 1 - 19 9803/6510-3

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 545/18000 556/43400 811/50232 816/00018 816/00189 816/00190 816/00193 816/00196 816/00197 816/00294 816/15118 816/50005 816/55038 816/55040 816/60096 892/00055 892/00056 892/00057 892/00058 892/00059 892/00060 892/00223 892/00254 892/00255 892/00256 892/00257 892/00258 892/00259 892/00260 892/00261 892/00262 Description Tool Detail Reference K Fig 25. ( T K Fig 25. ( T K Fig 25. ( T K Fig 26. ( T K Fig 27. ( T K Fig 27. ( T K Fig 27. ( T K Fig 27. ( T K Fig 27. ( T K Fig 27. ( T K Fig 28. ( T K Fig 26. ( T K Fig 29. ( T K Fig 29. ( T K Fig 26. ( T K Fig 30. ( T K Fig 30. ( T K Fig 30. ( T K Fig 30. ( T K Fig 30. ( T K Fig 30. ( T K Fig 31. ( T K Fig 32. ( T K Fig 28. ( T K Fig 28. ( T K Fig 28. ( T K Fig 28. ( T K Fig 28. ( T K Fig 28. ( T K Fig 28. ( T K Fig 29. ( T Lynch Pin Lift Ram 1,1/4 Pivot Pin 1 in BSP (A) x 1 in BSP (B) Male Cone Blanking Plug 3/8 in BSP Male Cone Blanking Plug 1/2 in BSP Male Cone Blanking Plug 1 in BSP Male Cone Blanking Plug 3/4 in BSP Male Cone Blanking Plug 5/8 in BSP Male Cone Blanking Plug 1/4 in BSP Pressure Test Adapter 3/4 in BSP x Test Point 1/2 in BSP (A) x 1/2 in BSP (B) Pressure Test T Adapter 3/8 in BSP x 3/8 in F BSP x Test Point Pressure Test T Adapter 1/2 in BSP x 1/2 in F BSP x Test Point 3/4 in BSP (A) x 3/4 in BSP (B) Female Cone Blanking Plug 1/4 in BSP Female Cone Blanking Plug 3/8 in BSP Female Cone Blanking Plug 1/2 in BSP Female Cone Blanking Plug Female Cone Blanking Plug 5/8 in BSP Female Cone Blanking Plug 3/4 in BSP Female Cone Blanking Plug 1 in BSP Hand Pump Hose Pressure Test Adapter 1/4 in BSP x Test Point Pressure Test Adapter 3/8 in BSP x Test Point Pressure Test Adapter 1/2 in BSP x Test Point Pressure Test Adapter 5/8 in BSP x Test Point Pressure Test Adapter 1 in BSP x Test Point Pressure Test Adapter 1,1/4 in BSP x Test Point Pressure Test Adapter 5/8 in UNF x Test Point Pressure Test T Adapter 1/4 in BSP x 1/4 in F BSP x Test Point T 1-22) T 1-22) T 1-22) T 1-22) T 1-22) T 1-22) T 1-22) T 1-22) T 1-22) T 1-22) T 1-23) T 1-22) T 1-23) T 1-23) T 1-22) T 1-23) T 1-23) T 1-23) T 1-23) T 1-23) T 1-23) T 1-23) T 1-24) T 1-23) T 1-23) T 1-23) T 1-23) T 1-23) T 1-23) T 1-23) T 1-23) K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K K 1 - 20 1 - 20 9803/6510-3

Section 1 - General Information Service Tools Numerical List Section E- Hydraulics Part Number Description Tool Detail Reference 892/00263 892/00264 892/00265 892/00266 892/00267 892/00279 Pressure Test T Adapter 5/8 in BSP x 5/8 in F BSP x Test Point Pressure Test T Adapter 3/4 in BSP x 3/4 in F BSP x Test Point Pressure Test T Adapter 1 in M BSP x 1 in F BSP x Test Point Pressure Test T Adapters1,1/4 in M BSP x 1,1/4 in F BSP x Test Point Pressure Test T Adapter 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point K K Fig 29. ( T K Fig 29. ( T K Fig 29. ( T K Fig 29. ( T K Fig 29. ( T K Fig 32. ( T T 1-23) T 1-23) T 1-23) T 1-23) T 1-23) T 1-24) K K K K Pressure Gauge 0-400 bar (0-6000 lbf/in2) K 892/00346 K K Fig 32. ( T T 1-24) Pressure Gauge 0-70 bar (0-1000 lbf/in2) 829/00280 K K Fig 32. ( T T 1-24) Pressure Gauge 0-600 bar (0-9000 lbf/in2 Connector Spanner 55 mm A/F Spanner 60 mm A/F Spanner 65 mm A/F Spanner 70 mm A/F Spanner 75 mm A/F Spanner 85 mm A/F Spanner 90 mm A/F Spanner 100 mm A/F Spanner 110 mm A/F Spanner 115 mm A/F Anchor Side Plate (supplied loose unwelded) Anchor Cross Member (supplied loose unwelded) Ram Eye End Modification Plate Assembly Rig Assembly (not including spanners and ram) Spanner 80 mm A/F Spanner 95 mm A/F Socket Box Wrench Nut Adapter Seal Ring Tool Stopper Bearing Rig 892/00347 993/99512 993/99513 993/99514 993/99515 993/99516 993/99517 993/99518 993/99519 993/99520 993/99521 993/99522 993/99523 993/99524 993/99525 SSP0046 SSP0047 K K Fig 32. ( T K Fig 33. ( T K Fig 33. ( T K Fig 33. ( T K Fig 33. ( T K Fig 33. ( T K Fig 33. ( T K Fig 33. ( T K Fig 33. ( T K Fig 33. ( T K Fig 33. ( T K Fig 25. ( T K Fig 25. ( T K Fig 25. ( T K Fig 25. ( T K Fig 33. ( T K Fig 33. ( T K Fig 34. ( T K Fig 35. ( T K Fig 36. ( T K Fig 37. ( T K Fig 38. ( T T 1-24) T 1-24) T 1-24) T 1-24) T 1-24) T 1-24) T 1-24) T 1-24) T 1-24) T 1-24) T 1-24) T 1-22) T 1-22) T 1-22) T 1-22) T 1-24) T 1-24) T 1-25) T 1-26) T 1-27) T 1-28) T 1-29) K K K K K K K K K K K K K K K K K K K K K 1 - 21 1 - 21 9803/6510-3

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics Tool Detail Reference Section E- Hydraulics Note: Not all service tools are illustrated. Illustrations are shown in tool number order. Fig 26. T Adapter 816/50005 T adapter 1/2 in BSP (A) x 1/2 in BSP (B) 816/60096 T adapter 3/4 in BSP (A) x 3/4 in BSP (B) 816/00018 T adapter 1 in BSP (A) x 1 in BSP (B) Fig 25. Ram Piston Nut Removal/Fitting Rig 993/99525 Rig Assembly (not including spanners and ram) 993/99522 Anchor Side Plate (supplied loose unwelded) 993/99523 Anchor Cross Member (supplied loose unwelded) 993/99524 Ram Eye End Modification Plate Assembly 556/43400 Lift Ram 545/18000 Lynch Pin 811/50232 1,1/4 Pivot Pin Fig 27. Male Cone Blanking Plug 816/00294 - 1/4 in BSP 816/00189 - 3/8 in BSP 816/00190 - 1/2 in BSP 816/00197 - 5/8 in BSP 816/00196 - 3/4 in BSP 816/00193 - 1 in BSP 1 - 22 1 - 22 9803/6510-3

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics 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 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 30. Female Cone Blanking Plug 892/00055 - 1/4 in BSP 892/00056 - 3/8 in BSP 892/00057 - 1/2 in BSP 892/00058 - 5/8 in BSP 892/00059 - 3/4 in BSP 892/00060 - 1 in BSP Fig 31. 892/00223 Note: Components listed below also required Item Description 1 892/00137 Micro-bore Hose 1/4 in BSP x 5 metres 2 892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper 3 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 4 892/00706 Test Probe 5 892/00278 Gauge 0 - 40 bar (0 - 600 lb/in2) 6 892/00279 Gauge 0 - 400 bar (0 - 6000 lb/in2) 7 892/00280 Gauge 0 - 600 bar (0 - 8500 lb/in2) Fig 29. Pressure Test T Adapters 892/00262 1/4 in BSP x 1/4 in F BSP x Test Point 816/55040 1/2 in 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 892/00266 1,1/4 in M BSP x 1,1/4 in F BSP x Test Point 892/00267 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point 1 - 23 1 - 23 9803/6510-3

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics Fig 32. Hydraulic Pressure Test Gauges and Connections 1 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2) 2 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2) 892/00347 Connector 892/00254 Hose 3 4 5 892/00280 Pressure Gauge 0-600 bar (0-9000 lbf/in2) 993/99517 Spanner 85 mm A/F 993/99518 Spanner 90 mm A/F 993/99519 Spanner 100 mm A/F 993/99520 Spanner 110 mm A/F 993/99521 Spanner 115 mm A/F SSP0046 Spanner 80 mm A/F SSP0047 Spanner 95 mm A/F JS07050 Fig 33. Ram Piston Nut Removal/Fitting Spanner 993/99512 Spanner 55 mm A/F 993/99513 Spanner 60 mm A/F 993/99514 Spanner 65 mm A/F 993/99515 Spanner 70 mm A/F 993/99516 Spanner 75 mm A/F 1 - 24 1 - 24 9803/6510-3

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408900 Fig 34. Socket Box Wrench Note: For disassembly and assembly of slew motor gearbox. 1 - 25 1 - 25 9803/6510-3

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408860 Fig 35. Nut Adapter Note: For disassembly and assembly of slew motor gearbox. 1 - 26 1 - 26 9803/6510-3

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408880-C1 Fig 36. Seal Ring Tool Note: For assembly and disassembly of slew motor gearbox seal. 1 - 27 1 - 27 9803/6510-3

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Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408890 Fig 37. Stopper Note: For assembly of slew motor gearbox. 1 - 28 1 - 28 9803/6510-3

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408870-C1 Fig 38. Bearing Rig Note: For removal of slew motor bearing. Inserting seal ring and correction jig WDB 2052 WDB 2054 WDB 2164 WDB 2056 Bucket Boom Boom Arm 120mm Cylinder inner diameter 125mm Cylinder inner diameter 130mm Cylinder inner diameter 150mm Cylinder inner diameter 1 - 29 1 - 29 9803/6510-3

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