JCB JZ140 TIER2 TRACKED EXCAVATOR Service Repair Manual Instant Download

Open front screen Service Manual JZ140 ZTS Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmissions Section J - Track and Running Gear Section K - Engine Publication No. 9803/6530-1 World Class Customer Support Copyright 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377

Open front screen Section 1 General Information Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmissions Section J - Track and Running Gear Section K - Engine Publication No. 9803/6530-1 World Class Customer Support Copyright 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377

Section 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: JZ140 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 B Attachments 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. 1 - 1 1 - 1 9803-6530

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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 Pink Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red. Orange Servo: Oil pressure used in controlling a device (servo). Blue Neural: Neutral circuit pressure. Green Exhaust: Light Green Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation). Yellow Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up). 1 - 2 1 - 2 9803-6530

Section 1 - General Information Identifying your Machine Identification Plates Data Plate Typical Vehicle Identification Number (VIN) Your machine has a Data Plate, located on the outside 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 4 C 5 4 6 E 7 SLP JZ 14 1137000 1 World Manufacturer Identification (SLP = JCB) 2 Machine Type ( JZ = Tracked) 3 Machine Model (14 = 140) 4 Generation B A 5 Year of Manufacture (1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004, 5 = 2005, 6 = 2006) 6 Manufacturers Location (E = England) 7 Machine Serial Number (1137001) Fig 1. 732820 Fig 2. 1 - 3 1 - 3 9803-6530

Section 1 - General Information Identifying your Machine Identification Plates 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. C Fig 3. a b c J d e 2 AB 50316 000001 a Engine Type (AB= 4 cylinder turbo) b Engine Parts List c Country of Manufacture d Engine Serial Number e Year of Manufacture 1 - 4 1 - 4 9803-6530

Section 1 - General Information Torque Settings Introduction - Zinc Plated Fasteners and Dacromet Fasteners Some external fasteners on machines 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 Colour Golden finish Part Number Z (e.g. 1315/3712Z) Dacromet Mottled 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 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. 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 areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in application such as gearbox and engine joint seams or internal applications. 1 - 5 1 - 5 9803-6530

Section 1 - General Information Torque Settings Zinc Plated Fasteners (golden finish) Zinc Plated Fasteners (golden finish) Metric Grade 8.8 Bolts 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. Bolt size (mm) Torque Settings Nm kgf m Dia. Hexagon lbf ft UNF Grade S Bolts (A/F) mm M5 (5) 8 7 0.7 5 Bolt size (mm) Torque Settings Nm kgf m M6 (6) 10 12 1.2 9 Dia. Hexagon lbf ft M8 (8) 13 28 3.0 21 (A/F) mm M10 (10) 17 56 5.7 42 1/4 6.3 7/16 14 1.4 10 M12 (12) 19 98 10 72 5/16 7.9 1/2 28 2.8 20 M16 (16) 24 244 25 180 3/8 9.5 9/16 49 5.0 36 M18 (18) 27 350 36 258 7/16 11.1 5/8 78 8.0 58 M20 (20) 30 476 48 352 1/2 12.7 3/4 117 12.0 87 M24 (24) 36 822 84 607 9/16 14.3 13/16 170 17.3 125 M30 (30) 46 1633 166 1205 5/8 15.9 15/16 238 24.3 175 M36 (36) 55 2854 291 2105 3/4 19 1 1/8 407 41.5 300 Metric Grade 10.9 Bolts 7/8 22.2 1 5/16 650 66.3 480 1 25.4 1 1/2 970 99.0 715 Bolt size (mm) Torque Settings Nm kgf m 1 1/4 31.7 1 7/8 1940 198.0 1430 Dia. Hexagon lbf ft 1 1/2 38.1 2 1/4 3390 345.0 2500 (A/F) mm Rivet Nut Bolts/Screws M6 (6) 10 16 1.6 12 M8 (8) 13 39 4 29 Bolt size Dia. Torque Settings Nm kgf m M10 (10) 17 78 8 57 (mm) lbf ft M12 (12) 19 137 14 101 M16 (16) 24 343 35 253 M3 3 1.2 0.12 0.9 M20 (20) 30 657 67 485 M4 4 3.0 0.3 2.0 M24 (24) 36 1157 118 853 M5 5 6.0 0.6 4.5 M6 6 10.0 1.0 7.5 M8 8 24.0 2.5 18.0 M10 10 48.0 4.9 35.5 M12 12 82.0 8.4 60.5 1 - 6 1 - 6 9803-6530

Section 1 - General Information Torque Settings Zinc Plated Fasteners (golden finish) Metric - All Internal Hexagon Headed Cap Screws Hydraulic Hose to Adapter Connections Diameter mm Torque Settings kgf m BSP Size Nm kgf m lbf ft Nm lbf ft (inches) M3 2 0.2 1.5 1/8 14 1.4 10 M4 6 0.6 4.5 1/4 24 2.5 18 M5 11 1.1 8 3/8 33 3.3 24 M6 19 1.9 14 1/2 44 4.8 35 M8 46 4.7 34 5/8 58 6.0 43 M10 91 9.3 67 3/4 84 8.6 62 M12 159 16.2 117 1 115 11.8 85 M16 395 40 292 1 1/2 244 24.9 180 M18 550 56 406 Hydraulic Adapter into Component Connections with bonded washers M20 770 79 568 M24 1332 136 983 Verbs Ripp Bolts BSP Size Nm kgf m lbf ft (inches) 1/8 20 2.1 15 1/4 34 3.4 25 3/8 75 7.6 55 1/2 102 10.3 75 A343780 5/8 122 12.4 90 Fig 1. 3/4 183 18.7 135 1 203 20.7 150 Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings. 1 1/2 305 31 225 1 - 7 1 - 7 9803-6530

Dacromet Fasteners (mottled silver finish) Dacromet Fasteners (mottled silver finish) Metric Grade 12.9 Bolts Use only where no torque setting is specified in the text. plating process: do not lubricate. Bolt Size Dia Torque Settings kgf m Nm lbf ft Metric Grade 8.8 Bolts M6 x 1.0 15 1.5 11 M8 x 1.25 40 4.1 29 Bolt Size Dia Torque Settings kgf m M10 x 1.5 80 8.2 59 Nm lbf ft M12 x 1.75 133 13.6 98 M6 x 1.0 9 0.9 7 M14 x 2 225 23 166 M8 x 1.25 22.5 2.3 17 M16 x 2 350 35.7 258 M10 x 1.5 47.5 4.8 35 M18 x 2.5 463 47 342 M12 x 1.75 80 8.2 59 M20 x 2.5 654 67 482 M14 x 2 133 13.6 98 M24 x 3 1125 115 830 M16 x 2 200 20.4 148 M30 x 3.5 2247 229 1657 M18 x 2.5 278 28.4 205 M20 x 2.5 392 40 289 M24 x 3 675 69 498 M30 x 3.5 1348 138 994 Metric Grade 10.9 Bolts Bolt Size Dia Torque Settings kgf m Nm lbf ft M6 x 1.0 13.5 1.4 10 M8 x 1.25 35 3.6 26 M10 x 1.5 62.5 6.4 46 M12 x 1.75 115 11.7 85 M14 x 2 175 17.9 129 M16 x 2 300 30.6 221 M18 x 2.5 395 40 291 M20 x 2.5 559 57 412 M24 x 3 962 98 710 M30 x 3.5 1920 196 1416 9803-6530

Section 1 - General Information Service Tools Numerical List Section B - Body and Framework 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. 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. Part Number 4104/1310 Description Tool Detail Reference Fig 1. (X X 1-10) Fig 2. (X X 1-10) Fig 2. (X X 1-10) Fig 2. (X X 1-10) Fig 2. (X X 1-10) Fig 2. (X X 1-10) Fig 2. (X X 1-10) Fig 3. (X X 1-10) Fig 4. (X X 1-10) Fig 5. (X X 1-11) Fig 6. (X X 1-11) Fig 7. (X X 1-11) Fig 8. (X X 1-11) Fig 9. (X X 1-11) Fig 10. (X X 1-11) Fig 11. (X X 1-12) Fig 12. (X X 1-12) Fig 13. (X X 1-12) Fig 13. (X X 1-12) Fig 14. (X X 1-12) Fig 15. (X X 1-12) Hand Cleaner 826/01099 M6 x 16mm Rivet Nut 826/01101 M6 x 19mm Rivet Nut 826/01102 M8 x 21mm Rivet Nut 826/01103 M8 x 18mm Rivet Nut 826/01104 M10 x 23mm Rivet Nut 826/01105 M10 x 26mm Rivet Nut 892/00842 Glass Lifter 892/00843 Folding Stand for Holding Glass 892/00844 Long Knife 892/00845 Cartride Gun 892/00846 Glass Extractor (Handles) 892/00847 Nylon Spatula 892/00848 Wire Starter 892/00849 Braided Cutting Wire 926/15500 Rubber Spacer Blocks 992/12300 12V Oven 992/12400 240V Oven 2 Cartridge 992/12600 240V Oven 6 Cartridge 992/12800 Cut-Out Knife 992/12801 L Blades 1 - 9 1 - 9 9803-6530

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 3. 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 1. 410/1310 Note: Special blend for the removal of polyurethane adhesives Fig 4. 892/00483 Fig 2. 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 - 10 1 - 10 9803-6530

Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework Fig 5. 892/00844 Fig 8. 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 6. 892/00845 Note: - hand operated - essential for the application of sealants, polyurethane materials etc. Fig 9. 892/00848 Note: - used to access braided cutting wire through original polyurethane seal. Fig 10. 892/00849 Fig 7. 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 - 11 1 - 11 9803-6530

Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework Fig 11. 926/15500 Note: - (unit quantity = 500 off) used to provide the correct set clearance between glass edge and cab frame. Fig 14. 992/12800 Note: - used to remove broken glass. Fig 15. 992/12801 Fig 12. 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 13. 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 - 12 1 - 12 9803-6530

Section 1 - General Information Service Tools Numerical List Section C - Electrics Numerical List Section C - Electrics 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. The tools listed in the table are special tools required for testing electrics. These tools are available from JCB Service . Part Number 892/00283 Description Tool Detail Reference Fig 16. (X X 1-14) Fig 16. (X X 1-14) Fig 16. (X X 1-14) Fig 16. (X X 1-14) Fig 16. (X X 1-14) Fig 16. (X X 1-14) Fig 16. (X X 1-14) Fig 17. (X X 1-14) Fig 18. (X X 1-14) Fig 19. (X X 1-15) 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 718/20237 Interconnecting cable 892/01033 Electronic Service Tool Kit 892/01174 Electronic Service Tool Kit 1 - 13 1 - 13 9803-6530

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. 1 2 3 4 5 Fig 16. Fig 18. 892/01033 1 892/00283 Tool Kit Case 1 Parallel Interconnecting cable, DLA to laptop PC. 2 2 892/00281 AVO Meter Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable diagnostics software. 3 892/00286 Surface Temperature 4 892/00284 Microtach Digital Tachometer 5 892/00282 Shunt - open type 6 892/00285 Hydraulic Oil Temperature Probe 3 Kit carrying case. 7 892/00298 Fluke 85 Multimeter 4 Serial Interconnecting cable, DLA to laptop PC. 5 Interconnecting cable, DLA to machine ECU diagnostics socket. D C B E A J F G H A408030 Fig 17. 718/20237 Interconnecting cable, DLA to machine ECU diagnostics socket. 1 - 14 1 - 14 9803-6530

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 19. 892/01174 1 Interconnecting cable, DLA to machine ECU diagnostics socket. 2 Interconnecting cable, DLA to machine ECU diagnostics socket. 3 Kit carrying case. 4 USB Interconnecting cable, DLA to laptop PC. 5 USB Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable diagnostics software. 6 Serial Interconnecting cable, DLA to laptop PC. 1 - 15 1 - 15 9803-6530

Section 1 - General Information Service Tools Numerical List Section E- Hydraulics Numerical List Section E- Hydraulics 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. The tools listed in the table are special tools required for testing, removing and replacing hydraulics. These tools are available from JCB Service . Part Number 545/18000 Description Tool Detail Reference Fig 20. (X X 1-18) Fig 20. (X X 1-18) Fig 20. (X X 1-18) Fig 21. (X X 1-18) Fig 22. (X X 1-18) Fig 22. (X X 1-18) Fig 22. (X X 1-18) Fig 22. (X X 1-18) Fig 22. (X X 1-18) Fig 22. (X X 1-18) Fig 23. (X X 1-19) Fig 21. (X X 1-18) Fig 24. (X X 1-19) Fig 24. (X X 1-19) Fig 21. (X X 1-18) Fig 25. (X X 1-19) Fig 25. (X X 1-19) Fig 25. (X X 1-19) Fig 25. (X X 1-19) Fig 25. (X X 1-19) Fig 25. (X X 1-19) Fig 26. (X X 1-19) Fig 27. (X X 1-20) Fig 23. (X X 1-19) Fig 23. (X X 1-19) Fig 23. (X X 1-19) Fig 23. (X X 1-19) Fig 23. (X X 1-19) Fig 23. (X X 1-19) Fig 23. (X X 1-19) Fig 24. (X X 1-19) Lynch Pin 556/43400 Lift Ram 811/50232 1,1/4 Pivot Pin 816/00018 1 in BSP (A) x 1 in BSP (B) 816/00189 Male Cone Blanking Plug 3/8 in BSP 816/00190 Male Cone Blanking Plug 1/2 in BSP 816/00193 Male Cone Blanking Plug 1 in BSP 816/00196 Male Cone Blanking Plug 3/4 in BSP 816/00197 Male Cone Blanking Plug 5/8 in BSP 816/00294 Male Cone Blanking Plug 1/4 in BSP 816/15118 Pressure Test Adapter 3/4 in BSP x Test Point 816/50005 1/2 in BSP (A) x 1/2 in BSP (B) 816/55038 Pressure Test T Adapter 3/8 in BSP x 3/8 in F BSP x Test Point 816/55040 Pressure Test T Adapter 1/2 in BSP x 1/2 in F BSP x Test Point 816/60096 3/4 in BSP (A) x 3/4 in BSP (B) 892/00055 Female Cone Blanking Plug 1/4 in BSP 892/00056 Female Cone Blanking Plug 3/8 in BSP 892/00057 Female Cone Blanking Plug 1/2 in BSP 892/00058 Female Cone Blanking Plug Female Cone Blanking Plug 5/8 in BSP 892/00059 Female Cone Blanking Plug 3/4 in BSP 892/00060 Female Cone Blanking Plug 1 in BSP 892/00223 Hand Pump 892/00254 Hose 892/00255 Pressure Test Adapter 1/4 in BSP x Test Point 892/00256 Pressure Test Adapter 3/8 in BSP x Test Point 892/00257 Pressure Test Adapter 1/2 in BSP x Test Point 892/00258 Pressure Test Adapter 5/8 in BSP x Test Point 892/00259 Pressure Test Adapter 1 in BSP x Test Point 892/00260 Pressure Test Adapter 1,1/4 in BSP x Test Point 892/00261 Pressure Test Adapter 5/8 in UNF x Test Point 892/00262 Pressure Test T Adapter 1/4 in BSP x 1/4 in F BSP x Test Point 1 - 16 1 - 16 9803-6530

Section 1 - General Information Service Tools Numerical List Section E- Hydraulics Part Number Description Tool Detail Reference Fig 24. (X X 1-19) Fig 24. (X X 1-19) Fig 24. (X X 1-19) Fig 24. (X X 1-19) Fig 24. (X X 1-19) Fig 27. (X X 1-20) Fig 27. (X X 1-20) Fig 27. (X X 1-20) Fig 28. (X X 1-20) Fig 28. (X X 1-20) Fig 28. (X X 1-20) Fig 28. (X X 1-20) Fig 28. (X X 1-20) Fig 28. (X X 1-20) Fig 28. (X X 1-20) Fig 28. (X X 1-20) Fig 28. (X X 1-20) Fig 28. (X X 1-20) Fig 20. (X X 1-18) Fig 20. (X X 1-18) Fig 20. (X X 1-18) Fig 20. (X X 1-18) Fig 28. (X X 1-20) Fig 28. (X X 1-20) Fig 29. (X X 1-21) Fig 30. (X X 1-22) Fig 31. (X X 1-23) Fig 32. (X X 1-24) Fig 33. (X X 1-25) 892/00263 Pressure Test T Adapter 5/8 in BSP x 5/8 in F BSP x Test Point 892/00264 Pressure Test T Adapter 3/4 in BSP x 3/4 in F BSP x Test Point 892/00265 Pressure Test T Adapter 1 in M BSP x 1 in F BSP x Test Point 892/00266 Pressure Test T Adapters1,1/4 in M BSP x 1,1/4 in F BSP x Test Point 892/00267 Pressure Test T Adapter 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2) 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2) 892/00347 Connector 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 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 993/99522 Anchor Side Plate (supplied loose unwelded) 993/99523 Anchor Cross Member (supplied loose unwelded) 993/99524 Ram Eye End Modification Plate Assembly 993/99525 Rig Assembly (not including spanners and ram) SSP0046 Spanner 80 mm A/F SSP0047 Spanner 95 mm A/F Socket Box Wrench Nut Adapter Seal Ring Tool Stopper Bearing Rig 1 - 17 1 - 17 9803-6530

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 21. 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 20. 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 Fig 22. Male Cone Blanking Plug 816/00294 - 1/4 in BSP 556/43400 Lift Ram 545/18000 Lynch Pin 816/00189 - 3/8 in BSP 811/50232 1,1/4 Pivot Pin 816/00190 - 1/2 in BSP 816/00197 - 5/8 in BSP 816/00196 - 3/4 in BSP 816/00193 - 1 in BSP 1 - 18 1 - 18 9803-6530

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics Fig 23. Pressure Test Adapters 892/00255 1/4 in BSP x Test Point Fig 25. Female Cone Blanking Plug 892/00055 - 1/4 in BSP 892/00256 3/8 in BSP x Test Point 892/00056 - 3/8 in BSP 892/00257 1/2 in BSP x Test Point 892/00057 - 1/2 in BSP 892/00258 5/8 in BSP x Test Point 892/00058 - 5/8 in BSP 816/15118 3/4 in BSP x Test Point 892/00059 - 3/4 in BSP 892/00259 1 in BSP x Test Point 892/00060 - 1 in BSP 892/00260 1,1/4 in BSP x Test Point 892/00261 5/8 in UNF x Test Point Fig 26. 892/00223 Note: Components listed below also required Item Description Fig 24. Pressure Test T Adapters 892/00262 1/4 in BSP x 1/4 in F BSP x Test Point 1 892/00137 Micro-bore Hose 1/4 in BSP x 5 metres 816/55040 1/2 in BSP x 1/2 in F BSP x Test Point 2 892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper 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 3 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 892/00265 1 in M BSP x 1 in F BSP x Test Point 4 892/00706 Test Probe 892/00266 1,1/4 in M BSP x 1,1/4 in F BSP x Test Point 5 892/00278 Gauge 0 - 40 bar (0 - 600 lb/in2) 892/00267 1,1/2 in M BSP x 1,1/2 in F BSP x Test Point 6 892/00279 Gauge 0 - 400 bar (0 - 6000 lb/in2) 7 892/00280 Gauge 0 - 600 bar (0 - 8500 lb/in2) 1 - 19 1 - 19 9803-6530

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics Fig 27. Hydraulic Pressure Test Gauges and Connections 892/00279 Pressure Gauge 0-400 bar (0-6000 lbf/in2) 1 2 892/00346 Pressure Gauge 0-70 bar (0-1000 lbf/in2) 3 892/00347 Connector 4 892/00254 Hose JS07050 Fig 28. Ram Piston Nut Removal/Fitting Spanner 993/99512Spanner 55 mm A/F 993/99513Spanner 60 mm A/F 993/99514Spanner 65 mm A/F 993/99515Spanner 70 mm A/F 993/99516Spanner 75 mm A/F 993/99517Spanner 85 mm A/F 993/99518Spanner 90 mm A/F 993/99519Spanner 100 mm A/F 993/99520Spanner 110 mm A/F 993/99521Spanner 115 mm A/F SSP0046Spanner 80 mm A/F SSP0047Spanner 95 mm A/F 1 - 20 1 - 20 9803-6530

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408900 Fig 29. Socket Box Wrench Note: For disassembly and assembly of slew motor gearbox. 1 - 21 1 - 21 9803-6530

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408860 Fig 30. Nut Adapter Note: For disassembly and assembly of slew motor gearbox. 1 - 22 1 - 22 9803-6530

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408880-C1 Fig 31. Seal Ring Tool Note: For assembly and disassembly of slew motor gearbox seal. 1 - 23 1 - 23 9803-6530

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408890 Fig 32. Stopper Note: For assembly of slew motor gearbox. 1 - 24 1 - 24 9803-6530

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics A408870-C1 Fig 33. Bearing Rig Note: For removal of slew motor bearing. 1 - 25 1 - 25 9803-6530

Section 1 - General Information Service Tools Numerical List Section F - Transmission Numerical List Section F - Transmission 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. The tools listed in the table are special tools required for testing, removing and replacing hydraulics. These tools are available from JCB Service . Part Number SST0037 Description Tool Detail Reference Fig 34. (X X 1-27) Fig 35. (X X 1-27) Fig 36. (X X 1-28) Re-sealing Tool Stopper Puller 1 - 26 1 - 26 9803-6530

Section 1 - General Information Service Tools Tool Detail Reference Section F - Transmission Tool Detail Reference Section F - Transmission Note: Not all service tools are illustrated. Illustrations are shown in tool number order. Fig 34. SST0037 Re-sealing Tool Note: All dimensions are in mm. A409010-C1 Fig 35. Stopper Note: for the assembly of Hydraulic motor on track gearbox. 1 - 27 1 - 27 9803-6530

Section 1 - General Information Service Tools Tool Detail Reference Section F - Transmission Fig 36. Puller Note: For the removal of Track motor Bushes. (All dimensions in mm). 1 Handle 2 Sliding Hammer 3 Bar 4 Nut M12 5 Washer 13 x 24 6 Bush 7 Bolt M10 x 35 1 - 28 1 - 28 9803-6530

Section 1 - General Information Service Consumables Sealing and Retaining Compounds T11-001_2 Table 1. Type JCB Multi-Gasket Description A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter. A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important. For all retaining parts which are unlikely to be dismantled. Part No. 4102/1212 Quantity 50 ml JCB High Strength Threadlocker 4102/0551 50 ml JCB Retainer (High Strength) 4101/0651 50 ml JCB Threadlocker and Sealer A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. 4101/0250 10 ml 4101/0251 50 ml JCB Threadlocker and Sealer (High Strength) A high strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. 4101/0550 10 ml 4101/0552 200 ml JCB Threadseal A medium strength thread sealing compound. 4102/1951 50 ml JCB Activator A cleaning primer which speeds the curing rate of anaerobic products. 4104/0251 200 ml (Aerosol) 4104/0253 1 ltr (Bottle) JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic adhesives and sealants. 4104/1557 400 ml (Aerosol) Anti-Seize Paste A compound used for assembly and prevention of parts seizure. 4003/0211 Direct Glazing Kit For one pane of glass; comprises of: 993/55700 1 x Ultra Fast Adhesive (310 ml) 1 x Active Wipe 205 (30 ml) 1 x Black Primer 206J (30 ml) plus applicator nozzle etc. Ultra Fast Adhesive For direct glazing. 4103/2109 310 ml Active Wipe 205 For direct glazing. 4104/1206 30 ml 4104/1203 250 ml Black Primer 206J For direct glazing. 4201/4906 30 ml Clear Silicone Sealant To seal butt jointed glass. 4102/0901 Plastic to Metal Bonder To seal plastic to metal joints. 4103/0955 Black Polyurethane Sealant To finish exposed edges of laminated glass. 4102/2309 310 ml 1 - 29 1 - 29 9803-6530

Section 2 Care and Safety Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmissions Section J - Track and Running Gear Section K - Engine Publication No. 9803/6530-1 World Class Customer Support Copyright 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. Issued by JCB Technical Publications, JCB Service, World Parts Centre, Beamhurst, Uttoxeter, Staffordshire, ST14 5PA, England. Tel +44 1889 590312 Fax +44 1889 593377

Section 2 - Care and Safety Safety Check List Safety Notices In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. !MDANGER 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. INT-1-2-1 !MWARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-2 !MCAUTION 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. INT-1-2-3 2 - 1 2 - 1 9803-6530

Section 2 - Care and Safety Safety Check List Safety - Yours and Others Safety - Yours and Others All construction and agricultural equipment can be hazardous. When a JCB machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. Do not work with the machine until you are sure that 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. Remember BE CAREFUL BE ALERT BE SAFE GEN-1-6 As well as the warnings in the following pages, specific warnings are given throughout the book. This section is designed to give a safety code for use of the machine generally and for operation and maintenance practices. Note: This section includes a certain amount of operating safety information. But remember that whenever you drive the machine or operate its controls, you are in effect a machine operator. Therefore you should read and understand the information given in the Operator Handbook before driving the machine or operating its controls. 2 - 2 2 - 2 9803-6530

Section 2 - Care and Safety Safety Check List General Safety General Safety !MWARNING Handbook !MWARNING Clothing You and others can be injured if you operate or maintain the machine without first studying this handbook. Read the safety instructions before operating the machine. If you do not understand anything, ask your employer or JCB dealer to explain it. Keep this handbook clean and in good condition. Do not operate the machine without a handbook in the cab, or if there is anything on the machine you do not understand. 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. INT-1-3-6 INT-1-3-2 !MWARNING Lifting Equipment !MWARNING Decals You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that lifting tackle complies with all local regulations and is suitable for the job. Make sure that lifting equipment is strong enough for the job. Decals on the machine warn you of particular hazards. You can be injured if you do not obey the decal safety instructions. Each decal is attached close to a part of the machine where there is a possible hazard. Make sure replacement parts include warning decals where necessary. INT-1-3-7 !MWARNING Raised Equipment Keep all decals clean and readable. Replace lost or damaged decals. Each decal has a part number printed on it, use this number to order a new decal from your JCB distributor. Raised equipment can fall and injure you. Do not walk or work under raised equipment unless safely supported. 13-1-1-6 INT-3-3-3_1 !MDANGER !MWARNING Care and Alertness Before removing the boom from the machine, ensure that the counterweight is adequately supported as in certain ground conditions the machine could tip backwards. Never travel or transport the machine with the boom removed. All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards. INT-1-3-5 BF-6-2 !MWARNING 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. INT-1-3-9 2 - 3 2 - 3 9803-6530

Section 2 - Care and Safety Safety Check List Operating Safety Operating Safety !MWARNING Practice !MWARNING Visibility You or others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practise away from the work site on a clear area. Keep other people away. Do not perform new operations until you are sure you can do them safely. Accidents can be caused by working in poor visibility. Use your lights to improve visibility. Keep the road lights, windows and mirrors clean. Do not operate the machine if you cannot see clearly. INT-2-1-1 5-1-4-7 !MWARNING Machine Condition !MWARNING Machine Limits A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this handbook are completed before using the machine Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications. INT-2-1-2 INT-2-1-4 !MCAUTION !MWARNING Exhaust Gases If you have an attachment which is not covered in this handbook do not install it, use it or remove it until you have obtained, read and understood the pertinent information. Install attachments only on the machines for which they were designed. Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making sure there is good ventilation. If possible, fit an exhaust extension. If you begin to feel drowsy, stop the machine at once. Get out of the cab into fresh air. 5-5-1-1 !MWARNING Entering/Leaving INT-2-1-10 !MDANGER Sparks Entering or leaving the cab or canopy must only be made where steps and handrails are provided. Always face the machine when entering and leaving. Make sure the step(s), handrails and your boot soles are clean and dry. Do not jump from the machine. Do not use the machine controls as handholds, use the handrails. Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust. INT-2-1-7_1 INT-2-2-10 !MWARNING Controls !MWARNING Engine You or others can be killed or seriously injured if you operate the control levers from outside the cab. Operate the control levers only when you are correctly seated inside the cab. The engine has exposed rotating parts. Do not open the engine cover while the engine is running. Do not use the machine with the cover open. INT-2-1-6_1 INT-2-1-3 2 - 4 2 - 4 9803-6530

Section 2 - Care and Safety Safety Check List Operating Safety !MCAUTION Passengers !MWARNING Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate within the engine compartment or in the propshaft guards (when fitted). Please inspect these areas frequently and clean at the beginning of each work shift or more often if required. Before opening the engine cover, ensure that the top is clear of debris. Passengers in or on the machine can cause accidents. Do not carry passengers. INT-2-2-2_1 !MWARNING Safe Working Loads Overloading the machine can damage it and make it unstable. Study the specifications in this handbook before using the machine. 5-3-1-12_2 !MWARNING Electrical Power Cables 7-1-1-8 !MWARNING You could be electrocuted or badly burned if you get the machine or its attachments too close to electrical power cables. The Long Reach is larger and higher than a normal excavating rig. You must take extra care when you are working in dangerous or restricted height locations such as under power lines, bridges, etc. You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near electric power lines. 8-2-8-10 !MWARNING Before you start using the machine, check with your electricity supplier if thee are any buried power cables on the site. When using Quick Hitch Type 2, the attachment can become unexpectedly disengaged from the Quick Hitch, when any of the following occurs: There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier. Power failure to the Electronic Control Unit (ECU). 2-2-5-4 When the redundancy switch is engaged. !MCAUTION If an electrical component in the Quick Hitch system should fail. With certain combinations of bucket or attachment and boom/dipper configuration, it is possible for the bucket teeth or attachment extremities to contact ad cause damage to the structure of the machine. Check the limit of free movement as the dipper is brought in towards the machine. 0178 !MCAUTION Because of the extra length and height of the Long Reach boom and dipper, you must be very careful when slewing. Do not slew quickly and strike the dipper against obstacles. You may cause severe damage to the rig structure. 8-2-5-2 !MWARNING Hazardous Atmospheres 8-2-8-11 This machine is designed for use in normal out door atmospheric conditions. It should not be used in an enclosed area without adequate ventilation. Do not use the machine in atmosphere, i.e. combustible vapours, gas or dust, without first consulting your JCB Distributor. a potentially explosive INT-2-1-14 2 - 5 2 - 5 9803-6530

Section 2 - Care and Safety Safety Check List Maintenance Safety Maintenance Safety !MWARNING Repairs !MWARNING Diesel Fuel Do not try to do repairs or any other type of maintenance work you do not understand. To avoid injury and/or damage get the work done by a specialist engineer. Diesel fuel is flammable; keep naked flames away from the machine. Do not smoke while refuelling the machine or working on the engine. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions. GEN-1-5 INT-3-2-2 !MWARNING Metal Splinters !MWARNING Oil You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or drift to remove and fit metal pins. Always wear safety glasses. Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants which can cause skin cancer. Do not handle used engine oil more than necessary. Always use barrier cream or wear gloves to prevent skin contact. Wash skin contaminated with oil thoroughly in warm soapy water. Do not use petrol, diesel fuel or paraffin to clean your skin. INT-3-1-3 !MWARNING Petrol Do not use petrol in this machine. Do not mix petrol with the diesel fuel; in storage tanks the petrol will rise to the top and form flammable vapours. INT-3-2-3 !MWARNING Hydraulic Fluid INT-3-1-6 !MWARNING Modifications and Welding Fine jets of hydraulic fluid at high pressure can penetrate the skin. Do not use your fingers to check for hydraulic fluid leaks. Do not put your face close to suspected leaks. Hold a piece of cardboard close to suspected leaks and then inspect the cardboard for signs of hydraulic fluid. If hydraulic fluid penetrates your skin, get medical help immediately. Non-approved modifications can cause injury and damage. Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Contact your JCB dealer for advice before modifying the machine. INT-3-1-10_1 INT-3-1-2_1 !MWARNING Fires !MWARNING Electrical Circuits If your machine is equipped with a fire extinguisher, make sure it is checked regularly. Keep it in the operator's cab until you need to use it. Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. Do not use water to put out a machine fire, you could spread an oil fire or get a shock from an elecrical fire. Use carbon dioxide, dry extinguishers. Contact your nearest fire department as quickly as possible. Firefighters should use self- contained breathing apparatus. INT-3-1-4 chemical or foam INT-3-2-7_1 2 - 6 2 - 6 9803-6530

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Section 2 - Care and Safety Safety Check List Maintenance Safety !MWARNING Hydraulic Pressure !MCAUTION Rams Hydraulic fluid at system pressure can injure you. Before disconnecting or connecting hydraulic hoses, stop the engine and operate the controls to release pressure trapped in the hoses. Make sure the engine cannot be started while the hoses are open. The efficiency of the rams will be affected if they are not kept free of solidified dirt. Clean dirt from around the rams regularly. When leaving or parking the machine, close all rams if possible to reduce the risk of weather corrosion. INT-3-1-11_1 INT-3-2-10 !MWARNING Hot Coolant !MCAUTION 'O' rings, Seals and Gaskets Badly fitted, damaged or rotted 'O' rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed instructed. Do not use Triochloroethane or paint thinners near 'O' rings and seals. The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the filler cap. Let the system cool before removing the filler cap. To remove the cap; turn it to the first notch and let the system pressure escape, then remove the cap. unless otherwise INT-3-2-12 INT-3-2-9_1 !MWARNING !MCAUTION Cleaning If you try to charge a frozen battery, or jump start and run the engine, the battery could explode. Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge. Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents. INT-3-2-11 0125 !MWARNING Hydraulic Hoses !MWARNING Battery Gases Damaged hoses can cause fatal accidents. Inspect the hoses regularly for: Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure there is good ventilation in closed areas where batteries are being used or charged. Do not check the battery charge by shorting the terminals with metal; use a hydrometer or voltmeter. Damaged hose ends Chafed outer covers Balloned outer covers Kinked or crushed hoses Embedded armouring in outer covers Displaced end fittings. INT-3-1-8 !MWARNING Battery Terminals INT-3-3-2 The machine is negatively earthed. Always connect the negative pole of the battery to earth. !MWARNING Soft Ground When connecting the battery, connect the earth (-) lead last. A machine can sink into soft ground. Never work under a machine on soft ground. INT-3-2-4 When disconnecting the battery, disconnect the earth (-) lead first. INT-3-1-9 2 - 7 2 - 7 9803-6530

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