JCB MIDI CX BACKHOE LOADER Service Repair Manual Instant Download

Service Manual Midi CX Backhoe Loader Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Publication No. 9803/9400-08 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 Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Section 0 - Service Manual Notes: 0-0 0-0 9803/9400-08

Section 1 General Information Service Manual - Midi CX Backhoe Loader Section 1 - General Information Section 2 - Care and Safety Section 3 - Maintenance Section A - Attachments Section B - Body and Framework Section C - Electrics Section D - Controls Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Publication No. 9803/9400-08 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 Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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Section 1 - General Information Notes: 1-0 1-0 9803/9400-08

Section 1 - General Information Contents Introduction About this Publication ...............................................................................1 - 1 Using the Service Manual ...................................................................1 - 1 Section Numbering ..............................................................................1 - 1 Units of Measurement .........................................................................1 - 1 Left Side, Right Side ............................................................................1 - 2 Cab/Canopy ........................................................................................1 - 2 Cross References ................................................................................1 - 2 Identifying the Machine .............................................................................1 - 3 Machine Identification Plate ................................................................1 - 3 Component Identification Plates ..........................................................1 - 4 Fuel ..........................................................................................................1 - 7 Types of Fuel .......................................................................................1 - 7 Page No. Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................1 - 10 Introduction ........................................................................................1 - 10 Bolts and Screws ...............................................................................1 - 10 Hydraulic Connections ............................................................................1 - 14 'O' Ring Face Seal System ................................................................1 - 14 'Torque Stop' Hose System ...............................................................1 - 17 Service Tools Numerical List .........................................................................................1 - 18 Service Aids Sealing and Retaining Compounds ........................................................1 - 20 Terms and Definitions Colour Coding .........................................................................................1 - 21 Hydraulic Schematic Colour Codes ...................................................1 - 21 1 - i 1 - i

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

Section 1 - General Information Introduction About this Publication Introduction About this Publication Using the Service Manual General Information - includes torque settings and service tools. Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. Maintenance - includes service schedules and recommended lubricants for all the machine. 1 T11-004 This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. 2 3 These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. Attachments Body and Framework, etc. A B General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them. Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. 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. Units of Measurement T1-001_2 In this publication, the S.I. system of units is used. For example, liquid capacities are given in litres. The Imperial units follow in parentheses ( ) eg 28 litres (6 gal). Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication. Finally, please remember above all else safety must come first! Section Numbering T11-005 The manual is compiled in sections, the first three are numbered and contain information as follows: 1-1 1-1 9803/9400-08

Section 1 - General Information Introduction About this Publication Left Side, Right Side P2-1002 In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. This is so whether you are facing the loader (front) or the backhoe (rear). A B A B C003690 Fig 1. Cab/Canopy T1-003_2 This manual frequently makes references to the cab. For instance, 'do not operate the machine without a manual in the cab'. It should be noted that these statements also apply to canopy build machines. Cross References T1-004_2 In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The number of the page upon which the subject begins, is indicated within the brackets. For example: K References ( T T 1-2). K Cross 1-2 1-2 9803/9400-08

Section 1 - General Information Introduction Identifying the Machine Identifying the Machine Machine Identification Plate The machine has an identification plate mounted on the loader tower. The serial numbers of the machine and its major units are stamped on the plate. The serial number of each major unit is also stamped on the unit itself. If a major unit is replaced by a new one, the serial number on the identification plate will be wrong. Either stamp the new number of the unit on the identification plate, or simply stamp out the old number. This will prevent the wrong unit number being quoted when replacement parts are ordered. The machine and engine serial numbers can help identify exactly the type of equipment you have. Typical Vehicle Identification Number (VIN) T025210-1 Fig 2. SLP 1 Midi 2 T 3 S 4 6 5 E 6 972021 7 Typical Product Identification Number (PIN) P2-1006 World Manufacturer Identification (SLP = JCB) 1 Machine Model 2 T016220-8 Steer Type (T= 2WS, F= 4WS) 3 Fig 3. Build Type (S=Sideshift, C=Centremount, L=Loader) 4 World Manufacturer Identification (3 Digits) 1 Year of Manufacture: 5 Machine Model (5 Digits) 2 6 = 2006 Check Letter (1 Digit) 3 7 = 2007 The Check Letter is used to verify the authenticity of a machine's PIN. 8 = 2008 Machine Serial Number (8 Digits) 4 9 = 2009 Each machine has a unique serial number. Manufacturer Location (E = England) 6 Machine Serial Number 7 1-3 1-3 9803/9400-08

Section 1 - General Information Introduction Identifying the Machine Component Identification Plates A Typical Engine Identification Number Perkins TYPE The full engine serial number is stamped on an identification plate A on the right-hand side of the cylinder block. LIST NO SERIAL NO TYPE 404C-22 1 50262 2 U 3 500405 4 N 5 Engine Type = 400 series 1 404C-22 = 4 cylinder, 2.2 litres naturally aspirated 404D-22 = 4 cylinder, 2.2 litres naturally aspirated Build Number 2 Fig 4. Engine Country of Manufacture 3 U = United Kingdom Engine Serial Number 4 Year of Manufacture 5 N = 2006 P = 2007 1-4 1-4 9803/9400-08

Section 1 - General Information Introduction Identifying the Machine Transmission Identification Numbers ROPS/FOPS Certification plate The transmission components have a serial number stamped on a data plate A as shown. A Fig 7. Cab Machines built to ROPS/FOPS standards have an identification label fitted to the inside of the cab. K K Fig 7. ( T T 1-5). Fig 5. Front Axle The FOPS structure provides Level II Impact Protection against falling objects (as defined in ISO 3449:2005). Definition of terms: Roll Over Protection Structure Falling Objects Protection Structure ROPS FOPS A FOPS Data Plate !MWARNING Do not use the machine if the falling objects protection level provided by the structure is not sufficient for the application. Falling objects can cause serious injury. Fig 6. Rear Axle 8-2-8-17 If the machine is used in any application where there is a risk of falling objects then a falling-objects protective structure (FOPS) must be installed. For further information contact your JCB Dealer The falling objects protection structure (FOPS) is fitted with a dataplate. The dataplate indicates what level protection the structure provides. There are two levels of FOPS: 1-5 1-5 9803/9400-08

Section 1 - General Information Introduction Identifying the Machine Level I Impact Protection - impact strength for protection from small falling objects (e.g. bricks, small concrete blocks, hand tools) encountered in operations such as landscaping and other construction site services. Level II Impact Protection - impact strength for protection from heavy falling objects (e.g. trees, rocks) for machines involved in site clearing, overhead demolition or forestry. highway maintenance, 1-6 1-6 9803/9400-08

Section 1 - General Information Introduction Fuel Fuel !MCAUTION Types of Fuel Consult your fuel supplier or JCB distributor about the suitability of any fuel you are unsure of. Acceptable and Unacceptable Fuels T3-048 Important: No warranty liability whatsoever will be accepted for failure of fuel injection equipment where the failure is attributed to the quality and grade of the fuel used. GEN-9-2 Table 1. Fuel Specification EN590 Diesel fuel types - Auto/C0/C1/C2/ C3/C4 BS2869 Class A2 ASTM D975-076 2-D, US DF1, US DF2, US DFA JIS K2204 Grades 1, 2, 3 and Special Grade 3 ASTM D975-076 1-D MIL T38219 JP7 NATO F63 French EN590 (RME5) with 5% maximum Applicable Engines All Service Requirements Obey the maintenance procedures. usual schedules routine and All Obey maintenance procedures. Fuel additives are recommended for use with low sulphur K K Additives ( T T 1-9). Obey the maintenance schedules procedures. Fuel additives must be used(1). K K Additives ( T the usual schedules routine and Important: Engines operated with these fuels may have a reduced service life. fuels(1). AVTURFSII, NATO F34, JP8, MIL T83133, DERD 2463, DEF STAN 91-87 AVCAT FSII, NATO F44, JP5, MIL T5624, DERD 2452, AVTOR NATO F35, JET A1, DEF STAN 91-91, DERD 2494, XF63 AVCAT, NATO F43 (obsolete), JP5 without additives JET A (ASTM D1655) ASTM D3699 Kerosene B5 Biodiesel - RME content blended with mineral derived diesel (5% maximum) - ASTM D6751, DIN 51606, ISO 14214 AVTAG (obsolete) AVTAG FSII (obsolete), NATO F40, JP4, DERD 2454 JET B (ASTM D1655) BS MA100 JIS K2203 No.2 Unmodified vegetable oils All usual routine and Important: Engines operated with these fuels may have a reduced service life. T 1-9). You must obey special routine maintenance schedules procedures. K K Warranty ( T Tier 3 only(2). and T 1-9). These fuels are not acceptable with or without additives. Engines must not be operated with these fuels. 1-7 1-7 9803/9400-08

Section 1 - General Information Introduction Fuel (1) (2) Use a fuel additive (where instructed) to make sure that the fuel meets the minimum lubricity requirement. Refer to Typical Engine Identification Number. 1-8 1-8 9803/9400-08

Section 1 - General Information Introduction Fuel tank (or the storage tank). Water will encourage mico- bacterial growth. Make sure that the fuel pre-filter is drained daily (not every week as currently advised). Only Tier 3 engines (factory filled with CH4 oil) - this is not approved with other manufacturers. Use heater kits in low ambient temperature territories. The biodiesel must meet the following standards: ASTM D6751, DIN 51606, ISO 14214 Additives The additives listed below are advertised as being suitable for bringing the lubricity levels of kerosene/low sulphur fuels up to those of diesel fuels. They must be used as specified by your fuel supplier who will understand the concentration level necessary. Important: The lubricity wear scar diameter must not be more than 460 microns, as tested on a high frequency reciprocating rig at 60 C (140 F). Refer to ISO 12156-1. Note: If necessary use a test kit to confirm the fuel specification. Testing kits are available (not from JCB currently), use the internet as a source for the kits. Elf 2S 1750. Dosage 1000-1500 ppm (0.1 - 0.15%), specifically for Indian Superior Kerosene (SKO) but may be applicable to other fuels. Lubrizol 539N. Dosage (on Swedish low sulphur fuel) 250 ppm. Paradyne 7505 (from Infineum). Dosage 500 ppm (0.05%). Note: If performance related issues are to be reported to JCB Service, and the engine has been run on biodiesel, then the fuel system must be filled with standard diesel (at least 2 x tank fills) to EN590 specification and relevant stall speeds recorded prior to making the report. Note: These products are given as examples only. The information is derived from the manufacturers data. The products are not recommended or endorsed by JCB. Warranty JCB have shown a commitment to support the environment by approving the use of biodiesel blended fuels. Service Requirements for use of B5 Biodiesel The engine oil must be a grade CH4 as minimum specification. Do not leave unused B5 biodiesel in the fuel tank for extended periods (top up each day). Make sure that 1 in 5 fuel tank fills use standard diesel to EN590 specification, this will help to prevent 'gumming'. Make sure regular oil sampling is completed (look for excessive unburnt fuel content, water or wear particles. Change the engine oil and filter more frequently (as a minimum half the recommended intervals), or as indicated by oil sampling. Change the fuel filters more frequently (as a minimum half the recommended intervals), or if there are engine performance related issues. Make sure the fuel is stored correctly, care must be taken to make sure no water enters the machine fuel Using a B5 blend of biodiesel requires caution and additional servicing of the engine is required. K Requirements for use of B5 Biodiesel ( T K Service T 1-9). Failure to follow the additional recommended service requirements may lead to a warranty claim being declined. Failures resulting by the incorrect use of biodiesels or other fuel additives are not defects of the engine workmanship and therefore will not be supported by JCB Warranty. 1-9 1-9 9803/9400-08

Section 1 - General Information Introduction Fuel Sulphur Content Effects of Fuel Contaminates T3-032 T3-033 High sulphur content can cause engine wear. (High sulphur fuel is not normally found in North America, Europe or Australia.) If you have to use high sulphur fuel you must change the engine oil more frequently. K K Table 2. Sulphur Content ( T The effect of dirt, water and other contaminants in diesel can be disastrous for injection equipment: Dirt - A severely damaging contaminant. Finely machined and mated surfaces such as delivery valves and distributor rotors are susceptible to the abrasive nature of dirt particles - increased wear will almost inevitably lead to greater leakage, uneven running and poor fuel delivery. Water - Water can enter fuel through poor storage or careless handling, and will almost inevitably condense in fuel tanks. The smallest amounts of water can result in effects that are just as disastrous to the fuel injection pump as dirt, causing rapid wear, corrosion and in severe cases, even seizure. It is vitally important that water is prevented from reaching the fuel injection equipment. The filter/water trap must be drained regularly. Wax - Wax is precipitated from diesel when the ambient temperature falls below that of the fuel's cloud point, causing a restriction in fuel flow resulting in rough engine running. Special winter fuels may be available for engine operation at temperatures below 0 C (32 F). These fuels have a lower viscosity and limit wax formation. T 1-10). Low sulphur fuels must have the appropriate fuel lubricity additives, these lubricity improvers must not create residual deposits that block the fuel system, e.g. injectors, filters etc. Contact your fuel Supplier. !MCAUTION A combination of water and sulphur will have a corrosive chemical effect on fuel injection equipment. It is essential that water is eradicated from the fuel system when high sulphur fuels are used. ENG-3-2 Table 2. Sulphur Content Percentage of sulphur in the fuel (%) Less than 0.5 0.5 to 1.0 More than 1.0 Oil Change Interval Normal 0.75 of normal 0.50 of normal 1-10 1-10 9803/9400-08

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 1-10). Torque settings are given for the following conditions: K Table 3. Fastener Types Condition 1 Table 3. 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 8. 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. 1-10 1-10 9803/9400-08

Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. 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 5. 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 1-11 1-11 9803/9400-08

Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. 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 7. 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 1-12 1-12 9803/9400-08

Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 8. 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 9. 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 1-13 1-13 9803/9400-08

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 10. 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 11. Torque Settings - SAE Connections Hexagon (A/F) mm 7/16 - 20 15.9 9/16 - 18 19.1 3/4 - 16 22.2 7/8 - 14 27.0 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 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 20.0 - 28.0 46.0 - 54.0 95.0 - 105.0 130.0 - 140.0 190.0 - 210.0 290.0 - 310.0 280.0 - 380.0 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 1-14 1-14 9803/9400-08

Section 1 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 9. Hoses 9-B screwed into adaptors 9-A seal onto an `O' ring 9-C which is compressed into a 45 seat machined into the face of the adaptor port. Note: Dimension 9-D will vary depending upon the torque applied. Table 12. 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 1-15 1-15 9803/9400-08

Section 1 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 13. 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 1-16 1-16 9803/9400-08

Section 1 - General Information Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 10. `Torque Stop' Hoses 10-B screwed into adaptors 10-A seal onto an 'O' ring 10-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 10-D, which acts as a physical stop. Note: Minimum dimension 10-E fixed by shoulder 10-D. Table 14. 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 1-17 1-17 9803/9400-08

Section 1 - General Information Service Tools Numerical List Service Tools Numerical List The tools listed in the table are special tools required for carrying out the procedures described in this manual. These tools are available from JCB Service. details of all tools, including the content of kits and sets, see the relevant section in this manual. 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. Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full Part Number - - - - - - - - - - - - 4104/1310 892/00253 892/00268 892/00334 892/00822 892/00842 892/00843 892/00844 892/00845 892/00846 892/00847 892/00848 892/00849 892/01016 892/01017 892/01018 892/01019 892/01020 892/01021 892/01022 Description Tool Detail Reference - see Section: C E, F E, F E, F E, F E, F E, F E, F E, F E, F E, F B B E, F E, F E F B B B B B B B B E E E E E E E AVO Test Kit - see tool detail reference for content Bonded Washers - see tool detail reference for content Female Cone Blanking Plugs - see tool detail reference for content Female Connectors - see tool detail reference for content Hydraulic Flow Test Equipment - see tool detail reference for content Hydraulic Hand Pump Equipment - see tool detail reference for content Male Adaptors - BSP x BSP - see tool detail reference for content Male Adaptors - BSP x NPT (USA only) - see tool detail reference for content Male Cone Blanking Caps - see tool detail reference for content Pressure Test Points - `T' Adaptors - see tool detail reference for content Pressure Test Points - Adaptors - see tool detail reference for content Rivet Nut Tool - see tool detail reference for content Hand Cleaner Hydraulic Pressure Test Kit - see tool detail reference for content Flow Monitoring Unit - Other components required, see tool detail Ram Seal Fitting Tool Splined Bolt Socket - Propshaft removal Glass Lifter Folding Stand for Holding Glass Long Knife Cartridge Gun Glass Extractor (Handles) Nylon Spatula Wire Starter Braided Cutting Wire Ram Protection Sleeve for 25 mm Rod Diameter Ram Protection Sleeve for 30 mm Rod Diameter Ram Protection Sleeve for 40 mm Rod Diameter Ram Protection Sleeve for 50 mm Rod Diameter Ram Protection Sleeve for 50 mm Rod Diameter Ram Protection Sleeve for 60 mm Rod Diameter Ram Protection Sleeve for 60 mm Rod Diameter 1-18 1-18 9803/9400-08

Section 1 - General Information Service Tools Numerical List Part Number Description Tool Detail Reference - see Section: 892/01023 892/01024 892/01025 892/01026 892/01027 892/01042 892/01237 926/15500 992/04000 992/09300 992/09400 992/12300 992/12400 992/12600 992/12800 992/12801 993/68100 993/85700 Ram Protection Sleeve for 65 mm Rod Diameter Ram Protection Sleeve for 70 mm Rod Diameter Ram Protection Sleeve for 75 mm Rod Diameter Ram Protection Sleeve for 80 mm Rod Diameter Piston Seal Assembly Tool Nitrogen Charging Tool Kit Park Brake Lock-up Tool - Transmission motor removal Rubber Spacer Blocks Torque Multiplier Hexagon Spanner 55mm A/F Hexagon Spanner 65mm A/F 12V Mobile Oven 24V Static Oven (2 Cartridge) 24V Static Oven (6 Cartridge) Cut-Out Knife `L' Blades Slide Hammer Kit - see tool detail reference for content Battery Tester E E E E E E F B F E E B B B B B B, F C 1-19 1-19 9803/9400-08

Section 1 - General Information Service Aids Sealing and Retaining Compounds Service Aids Sealing and Retaining Compounds T11-001_4 Table 15. 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) 4101/0601 4101/0651 4101/0250 4101/0251 10 ml 50 ml 10 ml 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. 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. A medium strength thread sealing compound. A cleaning primer which speeds the curing rate of anaerobic products. JCB Threadlocker and Sealer (High Strength) 4101/0550 4101/0552 10 ml 200 ml JCB Threadseal JCB Activator 4102/1951 4104/0251 4104/0253 4104/1557 50 ml 200 ml (Aerosol) 1 ltr (Bottle) 400 ml (Aerosol) JCB Cleaner/Degreaser For degreasing components prior to use of anaerobic adhesives and sealants. For one pane of glass; comprises of: Direct Glazing Kit 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. For direct glazing. For direct glazing. For direct glazing. To seal butt jointed glass. To seal plastic to metal joints. To finish exposed edges of laminated glass. Ultra Fast Adhesive Active Wipe 205 Black Primer 206J Clear Silicone Sealant Plastic to Metal Bonder Black Polyurethane Sealant 4103/2109 4104/1203 4201/4906 4102/0901 4103/0956 4102/2309 310 ml 250 ml 30 ml 50 g 310 ml 1-20 1-20 9803/9400-08

Section 1 - General Information Terms and Definitions Colour Coding Hydraulic Schematic Colour Codes T11-006 The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications. 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 1-21 1-21 9803/9400-08

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