JCB TM310, TM310S, TM310WM TELESCOPIC WHEELED LOADER Service Repair Manual Instant Download

Service Manual TM310 Service Manual - Service Manual 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. 9803/9520-7 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 - 1 Notes: 1-0 1-0 9803/9520-07

Section 1 - General Information Contents Introduction About this Manual ...................................................................................... 1-1 Machine Model and Serial Number .......................................................1-1 Using the Service Manual .....................................................................1-1 Section Numbering ................................................................................1-1 Left Side, Right Side ..............................................................................1-2 Cross References ..................................................................................1-2 Identifying your Machine ............................................................................ 1-3 Machine Identification Plate ..................................................................1-3 Component Identification Plates ............................................................1-4 Page No. Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ....................................... 1-7 Introduction ............................................................................................1-7 Bolts and Screws ...................................................................................1-7 Hydraulic Connections ............................................................................. 1-11 'O' Ring Face Seal System ..................................................................1-11 'Torque Stop' Hose System .................................................................1-14 Service Tools Numerical List .......................................................................................... 1-15 Tool Detail Reference .............................................................................. 1-16 Section B - Body and Framework ........................................................1-16 Section C - Electrics ............................................................................1-20 Section E - Hydraulics .........................................................................1-23 Section H - Steering ............................................................................1-31 Section K - Engine ...............................................................................1-32 Service Consumables Sealing and Retaining Compounds ......................................................... 1-35 Terms and Definitions Colour Coding .......................................................................................... 1-37 Hydraulic Schematic Colour Codes .....................................................1-37 1-i 1-i

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

Section 1 - General Information Introduction About this Manual Machine Model and Serial Number Finally, please remember above all else safety must come first! This manual provides information for the following model(s) in the JCB machine range: Section Numbering T11-005 TM310, TM310S and TM310WM from machine serial number 1314700. The manual is compiled in sections, the first three are numbered and contain information as follows: 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. 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. 1-1 1-1 9803/9520-07

Section 1 - General Information Introduction About this Manual Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. C087420 Fig 1. 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 9803/9520-07

Section 1 - General Information Introduction Identifying your Machine Identifying your Machine Machine Identification Plate Typical Product Identification Number (PIN) Your machine has an identification plate mounted as shown. The serial numbers of the machine and its major units are stamped on the plate. Note: The machine model and build specification is indicated by the VIN (earlier machines) or PIN (later machines). Refer to Typical Vehicle Identification Number (VIN) or Typical Product Identification Number (PIN). T033160-1. Fig 3. World Manufacturer Identification (3 Digits) 1 Model Number (3 Digits) 2 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. Loader End Type (1 Digit) 3 O = HT Loader End Z = ZX Loader End Designation (1 Digit) 4 The machine and engine serial numbers can help identify exactly the type of equipment you have. S = Farmmaster O = None Farmmaster I = India Check Letter (1 Digit) 5 The Check Letter is used to verify the authenticity of the machine's PIN. Year of Manufacture (1 Digit) 6 7 = 2007 8 = 2008 9 = 2009 A = 2010 B = 2011 C = 2012 Machine Serial Number (7 Digits) 7 Each machine has a unique serial number. C051170-C1 Fig 2. 1-3 1-3 9803/9520-07

Section 1 - General Information Introduction Identifying your Machine Typical Vehicle Identification Number Country of manufacture 3 U = United Kingdom 1 2 3 3 4 E 5 SLP TM310 1314700 Engine Serial Number 4 Year of Manufacture 5 World Manufacturer Identification (SLP = JCB) 1 The last three parts of the engine identification number are stamped on the cylinder block at position B. Machine Type (TM310, TM-W) 2 Year of Manufacture (1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004, 5 = 2005, 6 = 2006, 7 = 2007) 3 U 00001 04 Manufacturers Location (E = England) 4 E Machine Serial Number (1314700) 5 Component Identification Plates Typical Engine Identification Number T1-005_3 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. D K Fig 4. ( T T 1-4). B A typical engine identification number is explained as follows: SA 1 320/40001 2 U 3 00001 4 04 5 C B Engine Type 1 C007820-C2 Fig 4. Engine S = 4.4 litre series. JCB Dieselmax (Tier 2) A = Naturally aspirated B = Turbocharged C = Turbocharged and intercooled JCB Dieselmax (Tier 3) D = Turbocharged E = Electronic common rail fuel injection F = Turbocharged and after-cooled Engine part number 2 1-4 1-4 9803/9520-07

Section 1 - General Information Introduction Identifying your Machine 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 6. Fig 5. C Fig 7. 1-5 1-5 9803/9520-07

Section 1 - General Information Introduction Identifying your Machine FOPS Data Plate ROPS Data Plate !MWARNING !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. You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protection Structure (ROPS)/Falling Objects Protection Structure (FOPS) has been in an accident, do not use the machine until the structure has been renewed. Modifications and repairs that are not approved by the manufacturer may be dangerous and will invalidate the ROPS/FOPS certification. 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 INT-2-1-9_6 !MWARNING The falling objects protection structure (FOPS) is fitted with a dataplate. The dataplate indicates what level protection the structure provides. Seat Belts The ROPS/FOPS is designed to give you protection in an accident. If you do not wear your seat belt, you could be thrown out of the machine and crushed. You must wear a seat belt when using the machine. Fasten the seat belt before starting the engine. There are two levels of FOPS: 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. 0153 highway maintenance, Machines built to FOPS/ROPS standards have a data plate attached to the inside of the cab. JCB TELESCOPIC HANDLERS FOPS: COMPLIES TO ISO 3449:1992 EN 13627: 2000 LEVEL 1 ROPS: COMPLIES TO ISO 3471:1994 EN 13510:2000 TM310 J.C.B. CAB SYSTEMS LAKESIDE WORKS ROCESTER UTTOXETER, STAFFS ST14 5JP ENGLAND MAXIMUM UNLADEN MASS 10,250Kg YEAR: CAB PART NO: 332/P6978 SERIAL NO: 332/A5590 C051290 Fig 8. 1-6 1-6 9803/9520-07

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 1-7). 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 9. 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. 1-7 1-7 9803/9520-07

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 1-8 1-8 9803/9520-07

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 1-9 1-9 9803/9520-07

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 1-10 1-10 9803/9520-07

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 1-11 1-11 9803/9520-07

Section 1 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 10. Hoses 10-B screwed into adaptors 10-A seal onto an `O' ring 10-C which is compressed into a 45 seat machined into the face of the adaptor port. Note: Dimension 10-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 1-12 1-12 9803/9520-07

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 1-13 1-13 9803/9520-07

Section 1 - General Information Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 11. `Torque Stop' Hoses 11-B screwed into adaptors 11-A seal onto an 'O' ring 11-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 11-D, which acts as a physical stop. Note: Minimum dimension 11-E fixed by shoulder 11-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 1-14 1-14 9803/9520-07

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. Some tools are available as kits or sets, the part numbers for parts within such kits or sets are not listed here. For full details of all tools, including the content of kits and sets, refer to Tool Detail Reference, Section 1. 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. 1-15 1-15 9803/9520-07

Section 1 - General Information Service Tools Tool Detail Reference Tool Detail Reference Section B - Body and Framework Fig 12. 993/68100 Slide Hammer Kit 993/68101 993/68102 993/68103 Slide Hammer End Stops Adaptor - M20 x 5/8" UNF 993/68107 993/68108 993/68109 Bar - M20 x M20 X 800 mm Adaptor - M20 x 7/8" UNF Adaptor - M20 x M12 1 2 3 4 5 6 7 8 9 10 11 993/68104 993/68105 993/68106 Adaptor - M20 x 1" UNF Adaptor - M20 x M20 Adaptor - M20 x M24 993/68110 993/68111 Adaptor - M20 x 5/8" UNF (Shoulder) Adaptor - M20 x 1/2" UNF 826/01099 826/01101 826/01102 826/01103 826/01104 826/01105A - 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 Installation Tool available from: Bollhoff Fastenings Ltd (www.bollhof.com) 1 2 Fig 13. Rivet Nut Tool 1-16 1-16 9803/9520-07

Section 1 - General Information Service Tools Tool Detail Reference Fig 14. 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 17. 892/00846 Glass Extractor (Handles) Used with braided cutting wire to cut out broken glass. K K Fig 20. ( T T 1-18). 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 15. 892/00843 Folding Stand Essential for preparing new glass prior to installation. Fig 19. 892/00848 Wire Starter Used to access braided cutting wire through original polyurethane seal. K K Fig 20. ( T T 1-18). Fig 16. 892/00845 Cartridge Gun Hand operated. Essential for the application of sealants, polyurethane materials etc. 1-17 1-17 9803/9520-07

Section 1 - General Information Service Tools Tool Detail Reference Fig 23. 992/12400 Static Oven 240V Required to pre-heat adhesive prior to use. No plug supplied. 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 1-17). Approx 25 m length. Note: 110V models available upon request - contact JCB Technical Service. 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 24. 992/12800 Cut-Out Knife Used to remove broken glass. 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 25. 992/12801 'L' Blades 25 mm (1 in.) cut. Replacement blades for cut-out knife. K K Fig 24. ( T T 1-18). Unit quantity = 5 off. 1-18 1-18 9803/9520-07

Section 1 - General Information Service Tools Tool Detail Reference Fig 26. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub). Fig 29. 892/00848 Wire Starter Used to access braided cutting wire through original polyurethane seal. Fig 27. 892/00913 Grease Gun Attachment Fig 30. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off. Fig 28. 892/00844 Long Knife Used to give extended reach for normally inaccessible areas. 1-19 1-19 9803/9520-07

Section 1 - General Information Service Tools Tool Detail Reference Section C - Electrics 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 31. AVO Test Kit Fig 32. 993/85700 Battery Tester Fig 34. 892/00905 LMI Test Box For testing load moment indicator system D C B E A J F G H A406130-C2 Fig 33. 721/10885 Interconnecting Cable Use with 892/01033 1-20 1-20 9803/9520-07

Section 1 - General Information Service Tools Tool Detail Reference A406130-C1 Fig 35. 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 711300-C1 Fig 36. 892/01096 Speed Sensor Test Harness 1-21 1-21 9803/9520-07

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 37. 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 9803/9520-07

Section 1 - General Information Service Tools Tool Detail Reference Section E - Hydraulics Male Adapters - BSP x BSP 3/8 in. x 1/4 in. 3/8 in. x 3/8 in. 3/8 in. x 3/8 in. taper 1/2 in. x 1/4 in. 1/2 in. x 3/8 in. 1/2 in. x 1/2 in. 5/8 in. x 1/2 in. 3/4 in. x 3/8 in. 3/4 in. x 1/2 in. 3/4 in. x 3/4 in. 3/4 in. x 1 in. 3/4 in. x 1.1/4 in. 1 in. x 1.1/4 in. 1606/2052 1604/0003A 892/00071 1606/0004 1606/0007A 1604/0004A 1606/0017 1606/0008 1606/0009 1604/2055 1606/0012 1606/0014 1606/0015 Fig 38. Male Adaptors Male Adapters - BSP x NPT (USA only) 3/8 in. x 1/4 in. 1/2 in. x 1/4 in. 3/8 in. x 3/8 in. 1/2 in. x 3/8 in. 816/00439 816/00440 816/15007A 816/15008 892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 892/00261 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 Fig 39. Pressure Test Adapters 816/55045 816/55038 816/55040 892/00263 892/00264 892/00265 892/00266 892/00267 1/4 in. M BSP x 1/4 in. F BSP x Test Point 3/8 in. M BSP x 3/8 in. F BSP x Test Point 1/2 in. M BSP x 1/2 in. F BSP x Test Point 5/8 in. M BSP x 5/8 in. F BSP x Test Point 3/4 in. M BSP x 3/4 in. F BSP x Test Point 1 in. M BSP x 1 in. F BSP x Test Point 1.1/4 in. M BSP x 1.1/4 in. F BSP x Test Point 1.1/4 in. M BSP x 1.1/2 in. F BSP x Test Point Fig 40. Pressure Test 'T' Adapters 1-23 1-23 9803/9520-07

Section 1 - General Information Service Tools Tool Detail Reference 892/00047 892/00048 892/00049 816/50043 892/00051 816/50005 816/60096 816/00017 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) Fig 41. 'T' Adapters 892/00055A 892/00056A 892/00057 892/00058A 892/00059A 892/00060 1/4 in. BSP 3/8 in. BSP 1/2 in. BSP 5/8 in. BSP 3/4 in. BSP 1 in. BSP Fig 42. Female Blanking Caps 816/90045 816/00189A 816/00190A 816/90022 816/90274 816/90205 1/4 in. BSP 3/8 in. BSP 1/2 in. BSP 5/8 in. BSP 3/4 in. BSP 1 in. BSP Fig 43. Male Cone Blanking Caps 892/00074 892/00075 892/00076 892/00077 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 Fig 44. Female Connectors 1406/0011 1406/0018 1406/0014 1406/0021 1406/0029 1/4 in. BSP 1/2 in. BSP 5/8 in. BSP 3/4 in. BSP 1.1/4 in. BSP Fig 45. Bonded Washers 1-24 1-24 9803/9520-07

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Section 1 - General Information Service Tools Tool Detail Reference 892/01016 892/01017 892/01018 892/01019 892/01020 892/01021 892/01022 892/01023 892/01024 892/01025 892/01026 892/00167 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 Fig 46. Ram Protection Sleeves 7mm 11o 10mm 20mm Fig 47. 892/00334 Ram Seal Fitting Tool 5mm R 3mm 110mm 175mm 3o R 1.4mm Fig 48. Hexagon Spanners for Ram Pistons and End Caps 992/09300 55mm A/F 992/09400 65mm A/F 992/09500 75mm A/F 992/09600 85mm A/F 992/09700 95mm A/F 992/09900 115mm A/F 992/10000 125mm A/F Fig 49. 892/01027 Piston Seal Assembly Tool 1-25 1-25 9803/9520-07

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