JCB TM310 FARM MASTER LOADER Service Repair Manual Instant Download

Open front screen Service Manual TM310 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems Publication No. 9803/9520-06 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 9803/9520-06

Open front screen Section 1 General Information Service Manual - TM310 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Network Systems Publication No. 9803/9520-03 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 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 9803/9520-03

Section 1 - General Information Contents Introduction About this Publication ...............................................................................1 - 1 Schematic Codes .....................................................................................1 - 2 Colour Codes ......................................................................................1 - 2 Page No. Machine Identification Machine Identification Plate ......................................................................1 - 3 Data Plate ............................................................................................1 - 3 Typical Vehicle Identification Number (VIN) ........................................1 - 3 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ......................................1 - 6 Introduction ..........................................................................................1 - 6 Bolts and Screws .................................................................................1 - 6 Hydraulic Connections ............................................................................1 - 10 'O' Ring Face Seal System ................................................................1 - 10 'Torque Stop' Hose System ...............................................................1 - 13 Service Tools Numerical List .........................................................................................1 - 14 Tool Detail Reference .............................................................................1 - 17 Service Aids Sealing and Retaining Compounds ........................................................1 - 35 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. 'Left Hand' and 'Right Hand' are as viewed from the rear of the machine facing forwards. These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt. Finally, please remember above all else SAFETY MUST COME FIRST! The manual is compiled in sections, the first three are numbered and contain information as follows: 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 and Framework...etc. A B Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section. All sections are listed on the front cover. 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. 1-1 1-1 9803/9520-03

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 9803/9520-03

Section 1 - General Information Machine Identification Machine Identification Plate Data Plate Typical Vehicle Identification Number (VIN) Your machine has a Data Plate, located as shown at T. The serial numbers of the machine, engine and transmission unit are stamped on the plate. 1 2 3 3 4 E 5 SLP TM310 1314700 World Manufacturer Identification (SLP = JCB) 1 Machine Type (TM310, TM-W) 2 Year of Manufacture (1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004, 5 = 2005, 6 = 2006, 7 = 2007) 3 Manufacturers Location (E = England) 4 Machine Serial Number (1314700) 5 A272440 Typical Engine Identification Number Fig 1. T1-005_2 Engine data labels A are located on the cylinder block at position C and rocker cover D (if fitted). K The data label contains important engine information and includes the engine identification number E. K Fig 3. ( T T 1-4). A typical engine identification number is explained as follows: SA 1 320/40001 2 U 3 00001 4 04 5 Engine Type 1 S = 4.4 litre series. Fig 2. A = Naturally aspirated. B = Turbocharged. C = Turbocharged and intercooled. E = Electronic common rail fuel injection. Engine part number 2 1-3 1-3 9803/9520-03

Section 1 - General Information Machine Identification Machine Identification Plate Country of manufacture 3 U = United Kingdom Engine Serial Number 4 Year of Manufacture 5 The last three parts of the engine identification number are stamped on the cylinder block at position B. U 00001 04 E D B C B Fig 3. Engine 1-4 1-4 9803/9520-03

Section 1 - General Information Machine Identification Machine Identification Plate Transmission Identification Numbers The transmission serial number is stamped on label A which is mounted on the front face. The drop box serial number is stamped on plate B mounted on the drop box. The axle serial number is stamped on plate C mounted on the axle. B Fig 5. Fig 4. C Fig 6. 1-5 1-5 9803/9520-03

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 1-6). 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 7. 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. 1-6 1-6 9803/9520-03

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 1-7 1-7 9803/9520-03

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 1-8 1-8 9803/9520-03

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 1-9 1-9 9803/9520-03

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 1-10 1-10 9803/9520-03

Section 1 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 8. Hoses 8-B screwed into adaptors 8-A seal onto an `O' ring 8-C which is compressed into a 45 seat machined into the face of the adaptor port. Note: Dimension 8-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 1-11 1-11 9803/9520-03

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 1-12 1-12 9803/9520-03

Section 1 - General Information Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 9. `Torque Stop' Hoses 9-B screwed into adaptors 9-A seal onto an 'O' ring 9-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 9-D, which acts as a physical stop. Note: Minimum dimension 9-E fixed by shoulder 9-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 1-13 1-13 9803/9520-03

Section 1 - General Information 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 or, in some instances, can be manufactured locally from the specifications given in this section. Some tools are supplied as kits or sets. Cross references are given to tables showing the kit contents. 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: - - - - - - - - - - - - - 320/20050 460/15708 721/10885 892/00011 892/00167 892/00180 892/00181 892/00253 892/00268 892/00334 892/00812 892/00822 892/00842 Description: Tool Detail Reference: K Fig 27. ( T K Fig 41. ( T K Fig 30. ( T K Fig 61. ( T K Fig 42. ( T K Fig 45. ( T K Fig 46. ( T K Fig 40. ( T K Fig 40. ( T K Fig 44. ( T K Fig 36. ( T K Fig 37. ( T K Fig 10. ( T K Fig 60. ( T K Fig 47. ( T K Fig 32. ( T K Fig 53. ( T K Fig 52. ( T K Fig 55. ( T K Fig 55. ( T K Fig 35. ( T K Fig 34. ( T K Fig 51. ( T K Fig 58. ( T K Fig 57. ( T K Fig 13. ( T AVO Test Kit - see tool detail reference for content Bonded Washers - see tool detail reference for content Electrical Repair Kit - see tool detail reference for content Engine and Transmission Lifting Frame Female Cone Blanking Plugs - see tool detail reference for content Female Connectors - 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 Point `T' Adaptors - see tool detail reference for content Pressure Test Point Adaptors - see tool detail reference for content Rivet Nut Tool - see tool detail reference for content Engine Lifting Bracket Kit Flow Test Adaptor (Powershift) - Other components required, see tool detail Interconnecting Cable - use with 892/01033 Spool Clamp Ram Protection Sleeve for 90 mm Rod Diameter Seal Fitting Tool - Hydraulic Steer Unit Replacement Plastic Boss for 892/00180 Hydraulic Pressure Test Kit - see tool detail reference for content Flow Monitoring Unit - Other components required, see tool detail Ram Seal Fitting Tool Drive Coupling Spanner Splined Bolt Socket Glass Lifter T 1-21) T 1-26) T 1-22) T 1-34) T 1-26) T 1-27) T 1-27) T 1-26) T 1-26) T 1-26) T 1-25) T 1-25) T 1-17) T 1-33) T 1-28) T 1-23) T 1-30) T 1-29) T 1-30) T 1-30) T 1-24) T 1-24) T 1-29) T 1-31) T 1-31) T 1-18) 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 1-14 1-14 9803/9520-03

Section 1 - General Information Service Tools Numerical List Part Number: Description: Tool Detail Reference: 892/00843 892/00844 892/00845 892/00846 892/00847 892/00848 892/00849 892/00881 892/00905 892/00913 Folding Stand for Holding Glass Long Knife Cartridge Gun Glass Extractor (Handles) Nylon Spatula Wire Starter Braided Cutting Wire Valve Spool Seal Fitting Tool LMI Test Box Grease gun attachment - Use where access to the grease nipple is restricted E.g. Axle driveshaft universal joints Nitrogen Charging Kit (without gauge) Gauge K 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 20. ( T K Fig 54. ( T K Fig 29. ( T K Fig 12. ( T T 1-18) T 1-18) T 1-18) T 1-18) T 1-19) T 1-19) T 1-19) T 1-30) T 1-21) T 1-18) K K K K K K K K K 892/00948 892/00949 892/00964 K K Fig 48. ( T K Fig 48. ( T K Fig 38. ( T T 1-28) T 1-28) T 1-25) K Test Point 1/8 BSP (Powershift) Test Point 3/8 BSP (Powershift) 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 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 Electronic Service Tool Kit - also requires 721/10885 Speed Sensor Test Harness (Powershift) Torque Converter Alignment Tool Rubber Spacer Blocks Torque Multiplier Spool Clamp Hexagon Spanner 55 mm A/F Hexagon Spanner 65 mm A/F Hexagon Spanner 75 mm A/F Hexagon Spanner 85 mm A/F K 892/00965 K K Fig 39. ( T T 1-25) 892/01016 892/01017 892/01018 892/01019 892/01020 892/01021 892/01022 892/01023 892/01024 892/01025 892/01026 892/01027 892/01033 892/01096 892/01110 926/15500 992/04000 992/09100 992/09300 992/09400 992/09500 992/09600 K K Fig 52. ( T K Fig 52. ( T K Fig 52. ( T K Fig 52. ( T K Fig 52. ( T K Fig 52. ( T K Fig 52. ( T K Fig 52. ( T K Fig 52. ( T K Fig 52. ( T K Fig 52. ( T K Fig 50. ( T K Fig 31. ( T K Fig 33. ( T K Fig 59. ( T K Fig 21. ( T K Fig 56. ( T K Fig 53. ( T K Fig 49. ( T K Fig 49. ( T K Fig 49. ( T K Fig 49. ( T T 1-29) T 1-29) T 1-29) T 1-29) T 1-29) T 1-29) T 1-29) T 1-29) T 1-29) T 1-29) T 1-29) T 1-29) T 1-23) T 1-23) T 1-32) T 1-19) T 1-31) T 1-30) T 1-29) T 1-29) T 1-29) T 1-29) K K K K K K K K K K K K K K K K K K K K K 1-15 1-15 9803/9520-03

Section 1 - General Information Service Tools Numerical List Part Number: Description: Tool Detail Reference: 992/09700 992/09800 992/09900 992/10000 992/12300 992/12400 992/12600 992/12800 992/12801 993/68100 993/85700 4104/1310 Hexagon Spanner 95 mm A/F Hexagon Spanner 105 mm A/F Hexagon Spanner 115 mm A/F Hexagon Spanner 125 mm 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 Hand Cleaner K K Fig 49. ( T K Fig 49. ( T K Fig 49. ( T K Fig 49. ( T K Fig 22. ( T K Fig 23. ( T K Fig 23. ( T K Fig 24. ( T K Fig 25. ( T K Fig 11. ( T K Fig 28. ( T K Fig 26. ( T T 1-29) T 1-29) T 1-29) T 1-29) T 1-19) T 1-19) T 1-19) T 1-20) T 1-20) T 1-17) T 1-21) T 1-20) K K K K K K K K K K K 1-16 1-16 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference Tool Detail Reference 826/01099 826/01101 826/01102 826/01103 826/01104 826/01105 Installation Tool Available from: Bollhoff Fastenings Ltd. Midacre The Willenhall Estate Rose Hill Willenhall West Midlands, WV13 2JW M6 x 16 mm Rivet Nut M6 x 19 mm Rivet Nut M8 x 18 mm Rivet Nut M8 x 21 mm Rivet Nut M10 x 23 mm Rivet Nut M10 x 26 mm Rivet Nut Fig 10. Rivet Nut Tool 993/68101 Slide Hammer 993/68102 End Stops 993/68103 Adaptor - M20 x 5/8" UNF 993/68104 Adaptor - M20 x 1" UNF 993/68105 Adaptor - M20 x M20 993/68106 Adaptor - M20 x M24 993/68107 Bar - M20 x M20 X 800 mm 993/68108 Adaptor - M20 x 7/8" UNF 993/68109 Adaptor - M20 x M12 993/68110 Adaptor - M20 x M16 (Shoulder) 1 2 3 4 5 6 7 8 9 10 11 993/68111 Adaptor - M20 x 1/2" UNF Fig 11. 993/68100 Slide Hammer Kit 1-17 1-17 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference Fig 12. 892/00913 Grease Gun Attachment Fig 15. 892/00844 Long Knife Used to give extended reach for normally inaccessible areas. Fig 13. 892/00842 Glass Lifter Minimum 2 off - Essential for glass installation, 2 required to handle large panes of glass. Ensure suction cups are protected from damage during storage. Fig 16. 892/00845 Cartridge Gun Hand operated. Essential for the application of sealants, polyurethane materials etc. Fig 14. 892/00843 Folding Stand Essential for preparing new glass prior to installation. Fig 17. 892/00846 Glass Extractor (Handles) Used with braided cutting wire K out broken glass. K Fig 20. ( T T 1-19) to cut 1-18 1-18 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference Fig 18. 892/00847 Nylon Spatula General tool used for smoothing sealants - also used to re- install glass in rubber glazing because metal tools will chip the glass edge. Fig 21. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off. Fig 22. 992/12300 Mobile Oven 12V 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. 892/00848 Wire Starter Used to access braided cutting wire K through original polyurethane seal. K Fig 20. ( T T 1-19) Fig 23. 992/12400, 992/12600 Static Oven 240V Available with 2 or 6 cartridge capacity. Required to pre- heat adhesive prior to use. No plug supplied. Note: 110V models available upon request - contact JCB Technical Service. Fig 20. 892/00849 Braided Cutting Wire Consumable heavy duty cut-out wire used with the glass extraction tool K K Fig 17. ( T T 1-18), approx. 25 m length. 1-19 1-19 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference Fig 24. 992/12800 Cut-Out Knife Used to remove broken glass Fig 25. 992/12801 `L' Blades 25 mm (1 in) cut. Replacement blades for cut-out knife K K Fig 24. ( T T 1-20). Unit quantity = 5 off. Fig 26. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub). 1-20 1-20 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference AVO Test Kit: 1 892/00283 Tool Kit Case 2 892/00298 Fluke Meter 85 3 892/00286 Surface Temperature Probe 4 892/00284 Venture Microtach Digital Tachometer 5 892/00282 100 amp Shunt - open type 6 892/00285 Hydraulic Temperature Probe Fig 27. AVO Test Kit Fig 28. 993/85700 Battery Tester Fig 29. 892/00905 LMI Test Box For testing load moment indicator system 1-21 1-21 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference K K Electrical Repair Kit ( T 1 2A 7212/0002 2B 7212/0004 2C 7212/0003 2D 7212/0001 3A 7213/0002 3B 7213/0004 3C 7213/0003 3D 7213/0001 4A 7213/0006 4B 7213/0008 4C 7213/0007 4D 7213/0005 5A 7214/0002 5B 7214/0004 5C 7214/0003 5D 7214/0001 6A 7216/0002 6B 7216/0004 6C 7216/0003 6D 7216/0001 7A 7218/0002 7B 7218/0004 7C 7218/0003 7D 7218/0001 8A 7219/0002 8B 7219/0004 8C 7219/0003 8D 7219/0001 9A 7219/0006 9B 7219/0008 9C 7219/0007 9D 7219/0005 10 7210/0001 11 7210/0002 12 7210/0003 T 1-22) Electrical Repair Kit 2 Way Pin Housing 2 Way Pin Retainer 2 Way Socket Retainer 2 Way Socket Connector 3 Way Pin Housing 3 Way Pin Retainer 3 Way Socket Retainer 3 Way Socket Connector 3 Way Pin Housing (DT) 3 Way Pin Retainer (DT) 3 Way Socket Retainer (DT) 3 Way Socket Connector (DT) 4 Way Pin Housing 4 Way Pin Retainer 4 Way Socket Retainer 4 Way Socket Connector 6 Way Pin Housing 6 Way Pin Retainer 6 Way Socket Retainer 6 Way Socket Connector 8 Way Pin Housing 8 Way Pin Retainer 8 Way Socket Retainer 8 Way Socket Connector 10 Way Pin Housing 10 Way Pin Retainer 10 Way Socket Retainer 10 Way Socket Connector 14 Way Pin Housing Fig 30. Electrical Repair Kit 14 Way Pin Retainer 14 Way Socket Retainer 14 Way Socket Connector Dummy Plug Wire Seal (1.4 - 2.2 mm dia.) Wire Seal (2.2 - 2.9 mm dia.) 1-22 1-22 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference 711300-C1 Fig 33. 892/01096 Speed Sensor Test Harness A406130-C1 Fig 31. 892/01033 Electronic Test Kit Note: Also requires 721/10885 interconnecting cable Item Description 1 Data Link Adaptor (DLA), enables data exchange between the machine ECUs (Electronic Control Units) and laptop PC loaded with the applicable ServiceMaster diagnostics software 2 Interconnecting cable, DLA to laptop PC. Several cables are included to enable compatibility with different PC port types 3 Kit carrying case D C B E A J F G H A406130-C2 Fig 32. 721/10885 Interconnecting Cable Use with 892/01033 1-23 1-23 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference Fig 34. 892/00268 Flow Monitoring Unit Note: Components listed as follows also required 1406/0021 Sealing washer 1604/0006 Adaptor 3/4 in M x 3/4 in M BSP 1604/0008 Adaptor 1 in M x 1 in M BSP 1606/0012 Adaptor 1 in M x 3/4 in M BSP 1606/0015 Adaptor 11/4 in M x 1 in M BSP 1612/0006 Adaptor 3/4 in F x 3/4 in M BSP 816/20008 Adaptor 3/4in F x 1/2 in M BSP 816/20013 Adaptor 3/4 in F x 1 in M BSP 892/00078 Connector 1 in F x 1 in F BSP 892/00269 Sensor head 0 - 100 l /min. (0 - 22 UK gal / min.) 892/00270 Load valve 892/00271 Adaptor 3/4 in F x 5/8 in M BSP 892/00272 Adaptor 5/8 in F x 3/4 in M BSP 892/00273 Sensor head 0 - 380 l per min. 892/00275 Adaptor 1/2 in F x 3/4 in M BSP 892/00276 Adaptor 3/4 in F x 3/8 in M BSP 892/00277 Adaptor 3/8 in F x 3/4 in M BSP 892/00293 Connector pipe 892/00294 Connector pipe Fig 35. 892/00253 Hydraulic Pressure Test Kit Item Description 1 892/00201 Replacement gauge 0 -20 bar (0-300 lbf/in2 2 892/00202 Replacement gauge 0 -40 bar (0-600 lbf/in2 3 892/00203 Replacement gauge 0 -400 bar (0- 6000 lbf/in2 4 892/00254 Replacement hose Note: Components listed as follows also required 993/69800 Seal kit for 892/00254 (can also be used with probe 892/00706) 892/00706 Test probe 892/00347 Connector - hose to gauge 1-24 1-24 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference Fig 38. 892/00964 Test Point 1/8 BSP Fig 36. Pressure Test `T' Adaptors 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point 816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point 892/00263 5/8 in M BSP x 5/8 in F BSP x Test Point 892/00264 3/4 in M BSP x 3/4 in F BSP x Test Point 892/00265 1 in M BSP x 1 in F BSP x Test Point Fig 39. 892/00965 Test Point 3/8 BSP Fig 37. Pressure Test Adaptors 1/4 in BSP x Test Point 3/8 in BSP x Test Point 1/2 in BSP x Test Point 5/8 in BSP x Test Point 3/4 in BSP x Test Point 1 in BSP x Test Point 1.1/4 in BSP x Test Point 5/8 in UNF x Test Point 892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261 1-25 1-25 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference Fig 42. Female Blanking Caps 1/4 in. BSP 3/8 in. BSP 1/2 in. BSP 5/8 in. BSP 3/4 in. BSP 1 in. BSP 892/00055 892/00056 892/00057 892/00058 892/00059 892/00060 Fig 40. Male Adaptors Male Adapters - BSP x NPT (USA only) 816/00439 3/8 in. x 1/4 in. 816/00440 1/2 in. x 1/4 in. 816/15007 3/8 in. x 3/8 in. 816/15008 1/2 in. x 3/8 in. Male Adapters - BSP x BSP 1606/0003 3/8 in. x 1/4 in. 1604/0003 3/8 in. x 3/8 in. 892/00071 3/8 in. x 3/8 in. taper 1606/0004 1/2 in. x 1/4 in. 1606/0007 1/2 in. x 3/8 in. 1604/0004 1/2 in. x 1/2 in. 1606/0017 5/8 in. x 1/2 in. 1606/0008 3/4 in. x 3/8 in. 1606/0009 3/4 in. x 1/2 in. 1604/0006 3/4 in. x 3/4 in. 1606/0012 3/4 in. x 1 in. 1606/0014 3/4 in. x 1.1/4 in. 1606/0015 1 in. x 1.1/4 in. Fig 43. T Adaptors 3/8 in. BSP (A) x 1/4 in. BSP (B) 1/2 in. BSP (A) x 1/4 in. BSP (B) 5/8 in. BSP (A) x 1/4 in. BSP (B) 3/4 in. BSP (A) x 1/4 in. BSP (B) 1 in. BSP (A) x 1/4 in. BSP (B) 1/2 in. BSP (A) x 1/2 in. BSP (B) 3/4 in. BSP (A) x 3/4 in. BSP (B) 1 in. BSP (A) x 1 in. BSP (B) 892/00047 892/00048 892/00049 816/50043 892/00051 816/50005 816/60096 816/00017 816/00294 816/00189 816/00190 816/00197 816/00196 816/00193 1/4 in. BSP 3/8 in. BSP 1/2 in. BSP 5/8 in. BSP 3/4 in. BSP 1 in. BSP Fig 41. Bonded Washers 1/4 in. BSP 1/2 in. BSP 5/8 in. BSP 3/4 in. BSP 1.1/4 in. BSP 1406/0011 1406/0018 1406/0014 1406/0021 1406/0029 Fig 44. Male Cone Blanking Caps 1-26 1-26 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference Fig 45. Female Connectors 3/8 in. BSP x 3/8 in. BSP 1/2 in. BSP x 1/2 in. BSP 5/8 in. BSP x 5/8 in. BSP 3/4 in. BSP x 3/4 in. BSP 892/00074 892/00075 892/00076 892/00077 Fig 46. Hand Pump Equipment Hand Pump Micro-bore Hose 1/4 in BSP x 3 metres Adapter 1/4 in M BSP x 3/8 in M BSP Taper 1/4 in M BSP x 1/4 in F BSP x Test Point Test Probe 892/00223 892/00137 892/00274 892/00262 892/00706 892/00278 Gauge 0 - 40 bar (0 - 600 lbf/in2) 892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in2) 1-27 1-27 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference 1 3 4 6 5 Fig 48. Nitrogen Charging Kit Charging Kit (without gauge) Gauge 892/00948 892/00949 2 A313250-C1 Fig 47. 460/15708 Flow Test Adaptor Note: Components listed below also required Item Description 1 460/15707 Banjo bolt 2 2401/0222 O-ring 3 2403/0110 O-ring 4 2403/0108 O-ring 5 1604/0004 Adaptor - 2 off 6 1406/0018 Sealing washer - 2 off 1-28 1-28 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference Fig 51. 892/00334 Ram Seal Fitting Tool Fig 49. Hexagon Spanners for Ram Pistons and End Caps 992/09300 55 mm A/F 992/09400 65 mm A/F 992/09500 75 mm A/F 992/09600 85 mm A/F 992/09700 95 mm A/F 992/09800 105 mm A/F 992/09900 115 mm A/F 992/10000 125 mm A/F Fig 52. Ram Protection Sleeves For 25 mm Rod Diameter For 30 mm Rod Diameter For 40 mm Rod Diameter For 50 mm Rod Diameter For 50 mm Rod Diameter (slew ram) For 60 mm Rod Diameter For 60 mm Rod Diameter (slew ram) For 65 mm Rod Diameter For 70 mm Rod Diameter For 75 mm Rod Diameter For 80 mm Rod Diameter For 90 mm Rod Diameter 892/01016 892/01017 892/01018 892/01019 892/01020 892/01021 892/01022 892/01023 892/01024 892/01025 892/01026 892/00167 7mm 11o 10mm 20mm 5mm R 3mm 110mm 175mm 3o R 1.4mm Fig 50. 892/01027 Piston Seal Assembly Tool 1-29 1-29 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference Fig 53. Spool Clamps Spool Clamp Spool Clamp 992/09100 892/00011 Fig 55. 892/00180 Seal Fitting Tool for fitting 'O' ring and kin ring to Hydraulic Steer Unit Replacement plastic boss 892/00181 Fig 54. 892/00881 Valve Spool Seal Fitting Tool 1-30 1-30 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference Fig 56. 992/04000 Torque Multiplier Fig 57. 892/00822 Splined Bolt Socket Fig 58. 892/00812 Drive Coupling Spanner 1-31 1-31 9803/9520-03

Section 1 - General Information Service Tools Tool Detail Reference 370.0 185.0 65.0 A A 171.0 0.3 X 2 DOWELS 8 x 32 LONG PRESS FIT 342.0 TYP TYP 57.0 x 45 5 3 x 35(25) 43.4 43.3 10.0 10.0 1.0 0.3 X 30.2 30.1 X 12.0 8.0 REF TYP 2 DOWELS 10.0 SECTION A-A A436700 Fig 59. 892/01110 Torque Converter Alignment Tool For use with 12" and W300 torque converters 1-32 1-32 9803/9520-03

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Section 1 - General Information Service Tools Tool Detail Reference Fig 60. 320/20050 Engine Lifting Bracket Kit Note: Brackets are designed to lift only the engine. They MUST NOT be used to lift the engine and transmission assembly. 1-33 1-33 9803/9520-03

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