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Section 1 - General Information

Contents

Contents Page No. Introduction About This Manual ....................................................................................1 - 1 Machine Model and Serial Number .....................................................1 - 1 Using the Service Manual ...................................................................1 - 1 Section Numbering ..............................................................................1 - 1 Units of Measurement .........................................................................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 Standard 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 - 18 Section B - Frame and Bodywork ......................................................1 - 18 Section C - Electrics ..........................................................................1 - 22 Section E - Hydraulics .......................................................................1 - 23 Section F - Transmission ...................................................................1 - 28 Section H - Steering ..........................................................................1 - 31 Section K - Engine .............................................................................1 - 32 Service Consumables Sealing and Retaining Compounds ........................................................1 - 33 Terms and Definitions Schematic Codes ...................................................................................1 - 34 Hydraulic Schematic Colour Codes ...................................................1 - 34

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Section 1 - General Information

Introduction
About This Manual
Machine Model and Serial Number
This manual provides information for the following model(s) in the JCB machine range: 926 from Machine Serial No. 602000 930 from Machine Serial No. 607700 940 1 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: 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.

Using the Service Manual


T11-004

2 3

This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. 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 illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. 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. 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.

The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: A B Attachments Body and Framework, etc.

Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.

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).

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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.

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 Cross References ( T 1-2).

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Introduction
Identifying Your Machine

Identifying Your Machine


Machine Identification Plate
Your machine has an identification plate mounted as shown. K Fig 2. ( T 1-3). 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. 1

Typical Vehicle Identification Number (VIN)


SLP 1 930 2 04 3 6 4 E 5 0123456 6

World Manufacturer Identification (3 Digits) SLP = JCB

2 3

Machine Model (3 Digits) Drive Type 02 = 2 Wheel Drive 04 = 4 Wheel Drive

Year of Manufacture 5 = 2005 6 = 2006 7 = 2007 8 = 2008

Manufacturer Location (1 Digit) E = England

Machine Serial Number (7 Digits) Each machine has a unique serial number.

Fig 2.

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Introduction
Identifying Your Machine

Component Identification Plates


Typical Engine Identification Number
For information on the Engine Identification Number refer to Section K, Technical Information.

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Introduction
Identifying Your Machine Transmission Identification Numbers
The transmission serial number is stamped on label Y which is mounted on the front face. K Fig 3. ( T 1-5). The front axle serial number is also stamped on a plate mounted to the front of the left hand axle arm. K Fig 4. ( T 1-5). Four Wheel Drive Models: The rear axle serial number is also stamped on a plate mounted to the left hand front face of the axle. K Fig 5. ( T 1-5).

Fig 3. Transmission

Fig 4. Front Axle

Fig 5. Rear Axle (Four Wheel Drive Models)

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Introduction
Identifying Your Machine FOPS Certification Plate

Fig 6. Machines built to FOPS standards have an identification label fitted to the inside of the cab. Definition of terms: FOPS = Falling Objects Protection Structure

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Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners

Standard Torque Settings


Zinc Plated Fasteners and Dacromet Fasteners
T11-002

Introduction
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. The two types of fasteners can be readily identified by colour and part number suffix. K Table 1. Fastener Types ( T 1-7). Table 1. Fastener Types Colour Part No. Suffix Golden finish 'Z' (e.g. 1315/3712Z)

Bolts and Screws


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. Torque settings are given for the following conditions:

Condition 1
Un-lubricated fasteners Zinc fasteners Yellow plated fasteners

Fastener Type Zinc and Yellow Dacromet

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. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification. Note: Dacromet bolts, due to their high corrosion resistance are used 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.

Verbus Ripp Bolts

Fig 1. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.

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Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Bolt Size 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 Table 2. Torque Settings - UNF Grade 'S' Fasteners Hexagon (A/F) Condition 1 in. 7/16 1/2 9/16 5/8 3/4 13/16 15/16 1 1/8 1 15/16 1 1/2 1 7/8 2 1/4 Nm 11.2 22.3 40.0 64.0 98.00 140.0 196.0 343.0 547.0 814.0 1181.0 1646.0 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 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 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 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

Bolt Size ISO Metric Thread M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 mm 5 6 8 10 12 16 20 24 30 36

Table 3. Torque Settings - Metric Grade 8.8 Fasteners Hexagon (A/F) Condition 1 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

Condition 2 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

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Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Bolt Size ISO Metric Thread M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 mm 5 6 8 10 12 16 20 24 30 36 Table 4. Metric Grade 10.9 Fasteners Hexagon (A/F) Condition 1 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 Condition 2 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

Bolt Size ISO Metric Thread M5 M6 M8 M10 M12 M16 M20 M24 M30 M36 mm 5 6 8 10 12 16 20 24 30 36

Table 5. Metric Grade 12.9 Fasteners Hexagon (A/F) Condition 1 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

Condition 2 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

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Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread M3 M4 M5 M6 M8 M10 M12 mm 3 4 5 6 8 10 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 M4 M5 M6 M8 M10 M12 M16 M18 M20 M24 Nm 2.0 6.0 11.0 19.0 46.0 91.0 159.0 395.0 550.0 770.0 1332.0 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

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Standard 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 Hexagon (A/F) Size in. 1/4 3/8 1/2 5/8 3/4 1 1 1/4 mm 19.0 22.0 27.0 30.0 32.0 38.0 50.0 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

SAE Tube Size 4 6 8 10 12 16 20

Table 9. Torque Settings - SAE Connections SAE Port Hexagon (A/F) Thread Size 7/16 - 20 9/16 - 18 3/4 - 16 7/8 - 14 1 1/16 - 12 1 5/16 - 12 1 5/8 mm 15.9 19.1 22.2 27.0 31.8 38.1 47.6 Nm 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 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

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Standard Torque Settings
Hydraulic Connections Hoses Screwed into Adaptors

Fig 2. Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring 2-C which is compressed into a 45 seat machined into the face of the adaptor port. Note: Dimension 2-D will vary depending upon the torque applied.

BSP Hose Size in. 1/8 1/4 3/8 1/2 5/8 3/4 1 1 1/4 1 1/2

Table 10. BSP Hose - Torque Settings Hexagon (A/F) mm 14.0 19.0 22.0 27.0 30.0 32.0 38.0 50.0 55.0 Nm 14.0 - 16.00 24.0 - 27.0 33.0 - 40.0 44.0 - 50.0 58.0 - 65.0 84.0 - 92.0 115.0 - 126.0 189.0 - 200.0 244.0 - 260.0 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

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Standard Torque Settings
Hydraulic Connections Adaptors into Component Connections with Bonded Washers
Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size in. 1/8 1/4 3/8 1/2 5/8 3/4 1 1 1/4 1 1/2 Nm 20.0 34.0 75.0 102.0 122.0 183.0 203.0 305.0 305.0 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

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Standard Torque Settings
Hydraulic Connections

'Torque Stop' Hose System

Fig 3. `Torque Stop' Hoses 3-B screwed into adaptors 3-A seal onto an 'O' ring 3-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 3-D, which acts as a physical stop. Note: Minimum dimension 3-E fixed by shoulder 3-D.

Table 12. BSP `Torque Stop' Hose - Torque Settings BSP Hose Size Hexagon (A/F) in. 1/8 1/4 3/8 1/2 5/8 3/4 1 1 1/4 1 1/2 mm 14.0 19.0 22.0 27.0 30.0 32.0 38.0 50.0 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

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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.

Part Number 4104/1310 892/00039 892/00041 892/00137 892/00167 892/00179 892/00180 892/00181 892/00223 892/00237 892/00253

Description Bearing Adapters - see Tool Detail Reference (Section 1) for content Bonded Washers - see Tool Detail Reference (Section 1) for content Female Cone Blanking Caps - see Tool Detail Reference (Section 1) for content Female Connectors - see Tool Detail Reference (Section 1) for content Gearbox Removal Fixture - see Tool Detail Reference (Section 1) for content Hydraulic Flow Test Equipment - see Tool Detail Reference (Section 1) for content Hydraulic Hand Pump Equipment - see Tool Detail Reference (Section 1) for content Male Adapters - BSP x BSP - see Tool Detail Reference (Section 1) for content Male Adapters - BSP x NPT (USA only) - see Tool Detail Reference (Section 1) for content Male Cone Blanking Caps - see Tool Detail Reference (Section 1) for content Pressure Test Points - Adaptors - see Tool Detail Reference (Section 1) for content Pressure Test Points - 'T' Adaptors - see Tool Detail Reference (Section 1) for content 'T' Adaptors - see Tool Detail Reference (Section 1) for content Rivet Nut Tool - see Tool Detail Reference (Section 1) for content Hand Cleaner Spool Clamp De-glazing Tool Micro-Bore Hose Ram Protection Sleeve for 90mm Rod Diameter Bearing Press Seal Fitting Tool Plastic Boss Hand Pump Flow Test Adapter complete - see Tool Detail Reference (Section 1) for content Hydraulic Circuit Pressure Test Kit - see Tool Detail Reference (Section 1) for content

See Section F E E E F E E E E E E E E B B E K E E F E H E F E

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Service Tools
Numerical List
Part Number 892/00254 892/00262 892/00271 892/00272 892/00273 892/00274 892/00275 892/00276 892/00277 892/00278 892/00279 892/00280 892/00284 892/00285 892/00295 892/00298 892/00301 892/00302 892/00304 892/00333 892/00334 892/00346 892/00347 892/00706 892/00817 892/00818 892/00819 892/00842 892/00843 892/00845 892/00846 892/00847 892/00848 892/00849 892/00916 892/00918 892/00921 Description Hose Test Point 1/4 in BSP Adapter Adapter Adapter Adapter Adapter Adapter Adapter Gauge 0-40 Bar Gauge 0-400 Bar Gauge 0-600 Bar Digital Tachometer Hyd. Oil Temperature Probe End Float Setting Tool Fluke Meter Flow Test Adapter Flow Test Adapter Flow Test Adapter Heavy Duty Socket Ram Seal Fitting Tool Gauge 0-70 Bar Connector Test Probe Heavy Duty Socket Heavy Duty Socket Heavy Duty Socket Glass Lifter Folding Stand for Holding Glass Cartridge Gun Glass Extractor (Handles) Nylon Spatula Wire Starter Braided Cutting Wire Clutch Pack Spring Compressor Spacer Setting Tool Kit - see Tool Detail Reference (Section 1) for content Torque Converter Alignment Bar See Section E E E E E E E E E E E E C C F C F F F F E E E E F F F B B B B B B B F F F

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Service Tools
Numerical List
Part Number 892/00923 892/01016 892/01017 892/01018 892/01019 892/01020 892/01021 892/01022 892/01023 892/01024 892/01025 892/01026 892/01027 921/52600 926/15500 992/02800 992/04000 992/04800 992/7603 992/09300 992/09400 992/09500 992/09600 992/09700 992/09900 992/10000 992/10100 992/12300 992/12400 992/12800 992/12801 993/68100 993/70111 Description Test Block for A.R.V. 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 (slew ram) Ram Protection Sleeve for 60 mm Rod Diameter Ram Protection Sleeve for 60 mm Rod Diameter (slew ram) 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 Spacer Kit - see Tool Detail Reference (Section 1) for content Rubber Spacer Blocks ARV Extractor Torque Multiplier Flange Spanner Replacer Bearing Cap Hexagon Spanner 55mm A/F Hexagon Spanner 65mm A/F Hexagon Spanner 75mm A/F Hexagon Spanner 85mm A/F Hexagon Spanner 95mm A/F Hexagon Spanner 115mm A/F Hexagon Spanner 125mm A/F Spool Clamp 12V Mobile Oven 24V Static Oven (2 Cartridge) Cut-Out Knife 'L' Blades Slide Hammer Kit - see Tool Detail Reference (Section 1) for content Breakback Torque Wrench See Section E E E E E E E E E E E E E F B E F F F E, H E, H E, H E, H E, H E, H E, H E B B B B B F

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Service Tools
Tool Detail Reference

Tool Detail Reference


Section B - Frame and Bodywork

Fig 1. 993/68100 Slide Hammer Kit 1 2 3 4 5 6 993/68101 993/68102 993/68103 993/68104 993/68105 993/68106 Slide Hammer End Stops Adaptor - M20 x 5/8" UNF Adaptor - M20 x 1" UNF Adaptor - M20 x M20 Adaptor - M20 x M24 1 826/01099 826/01101 826/01102 826/01103 826/01104 2 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 Installation Tool available from: Bollhoff Fastenings Ltd (www.bollhof.com) 7 8 9 10 11 993/68107 993/68108 993/68109 993/68110 993/68111 Bar - M20 x M20 X 800 mm Adaptor - M20 x 7/8" UNF Adaptor - M20 x M12 Adaptor - M20 x 5/8" UNF (Shoulder) Adaptor - M20 x 1/2" UNF

826/01105A M10 x 26 mm Rivet Nut

Fig 2. Rivet Nut Tool

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Service Tools
Tool Detail Reference

Fig 3. 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 6. 892/00846 Glass Extractor (Handles) Used with braided cutting wire to cut out broken glass. K Fig 9. ( T 1-20).

Fig 4. 892/00843 Folding Stand Essential for preparing new glass prior to installation.

Fig 7. 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 8. 892/00848 Wire Starter Used to access braided cutting wire through original polyurethane seal. K Fig 9. ( T 1-20).

Fig 5. 892/00845 Cartridge Gun Hand operated. Essential for the application of sealants, polyurethane materials etc.

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Service Tools
Tool Detail Reference

Fig 9. 892/00849 Braided Cutting Wire Consumable heavy duty cut-out wire used with the glass extraction tool. K Fig 6. ( T 1-19). Approx 25 m length.

Fig 12. 992/12400 Static Oven 240V Required to pre-heat adhesive prior to use. No plug supplied. Note: 110V models available upon request - contact JCB Technical Service.

Fig 10. 926/15500 Rubber Spacer Blocks Used to provide the correct set clearance between glass edge and cab frame. Unit quantity = 500 off.

Fig 13. 992/12800 Cut-Out Knife Used to remove broken glass.

Fig 11. 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 14. 992/12801 'L' Blades 25 mm (1 in.) cut. Replacement blades for cut-out knife. K Fig 13. ( T 1-20). Unit quantity = 5 off.

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Service Tools
Tool Detail Reference

Fig 15. 4104/1310 Hand Cleaner Special blend for the removal of polyurethane adhesives (454g; 1 lb tub).

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Service Tools
Tool Detail Reference

Section C - Electrics

Fig 16. 892/00298 Fluke Meter

Fig 17. 892/00285 Hydraulic Temperature Probe

Fig 18. 892/00284 Venture Microtach Digital Tachometer

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Service Tools
Tool Detail Reference

Section E - Hydraulics
Male Adapters - BSP x BSP 1606/2052 892/00071 1606/0004 3/8 in. x 1/4 in. 3/8 in. x 3/8 in. taper 1/2 in. x 1/4 in. 1604/0003A 3/8 in. x 3/8 in.

1606/0007A 1/2 in. x 3/8 in. Fig 19. Male Adaptors 1604/0004A 1/2 in. x 1/2 in. 1606/0017 1606/0008 Male Adapters - BSP x NPT (USA only) 816/00439 816/00440 816/15008 3/8 in. x 1/4 in. 1/2 in. x 1/4 in. 1/2 in. x 3/8 in. 1606/0009 1604/2055 1606/0012 1606/0014 1606/0015 892/00255 892/00256 892/00257 892/00258 816/15118 892/00259 892/00260 Fig 20. Pressure Test Adapters 892/00261 816/55045 816/55038 816/55040 892/00263 892/00264 892/00265 892/00266 892/00267 Fig 21. Pressure Test 'T' Adapters 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. 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 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

816/15007A 3/8 in. x 3/8 in.

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Service Tools
Tool Detail Reference
892/00047 892/00048 892/00049 816/50043 892/00051 816/50005 816/60096 Fig 22. 'T' Adapters 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)

892/00055A 1/4 in. BSP 892/00056A 3/8 in. BSP 892/00057 1/2 in. BSP 892/00058A 5/8 in. BSP 892/00059A 3/4 in. BSP Fig 23. Female Blanking Caps 892/00060 816/90045 1 in. BSP 1/4 in. BSP

816/00189A 3/8 in. BSP 816/00190A 1/2 in. BSP 816/90022 816/90274 Fig 24. Male Cone Blanking Caps 816/90205 892/00074 892/00075 892/00076 892/00077 5/8 in. BSP 3/4 in. BSP 1 in. BSP 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 25. Female Connectors 1406/0011 1406/0018 1406/0014 1406/0021 Fig 26. Bonded Washers 1406/0029 1/4 in. BSP 1/2 in. BSP 5/8 in. BSP 3/4 in. BSP 1.1/4 in. BSP

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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 Fig 27. Ram Protection Sleeves 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

7mm 11o 20mm 10mm

Fig 28. 892/00334 Ram Seal Fitting Tool


5mm

m 3m

110mm 175mm 3o

Fig 29. Hexagon Spanners for Ram Pistons and End Caps 992/09300 992/09400 992/09500 992/09600 992/09700 992/09900 992/10000 55mm A/F 65mm A/F 75mm A/F 85mm A/F 95mm A/F 115mm A/F 125mm A/F

1.4

mm

Fig 30. 892/01027 Piston Seal Assembly Tool

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Section 1 - General Information


Service Tools
Tool Detail Reference
892/00268 892/00269 892/00273 892/00293 892/00270 1406/0021 1612/2054 892/00271 892/00272 816/20008 892/00275 892/00276 892/00277 1606/0015 892/00078 1604/0008 Fig 31. Flow Test Equipment 1604/0008 816/20013 892/00201
1

Flow Monitoring Unit Sensor Head 0 - 100 l/min (0 - 22 UK gal/min) Sensor Head 0 - 380 l/min (0 - 85.5 UK gal/min) Connector Pipe Load Valve Bonded Washer Adapter 3/4 in F x 3/4 in M BSP Adapter 3/4 in F x 5/8 in M BSP Adapter 5/8 in F x 3/4 in M BSP Adapter 3/4 in F x 1/2 in M BSP Adapter 1/2 in F x 3/4 in M BSP Adapter 3/4 in F x 3/8 in M BSP Adapter 3/8 in F x 3/4 in M BSP Adapter 1.1/4 in M BSP x 1 in M BSP Connector 1 in F x 1 in F BSP Adapter 1 in M x 1 in M BSP Adapter 1 in M x 3/4 in M BSP Adapter 3/4 in F x 1 in M BSP Replacement Gauge 0-20 bar (0-300 lbf/in2) Replacement Gauge 0-40 bar (0-600 lbf/in2) Replacement Gauge 0-400 bar (0-6000 lbf/in2) Replacement Hose Seal Kit for 892/00254 (can also be used with probe 892/00706) Test Probe Connector - Hose to gauge

1604/0006A Adapter 3/4 in M x 3/4 in M BSP

892/00202 892/00203 892/00254 993/69800 892/00706 892/00347

Fig 32. 892/ 00253 Hydraulic Circuit Pressure Test Kit

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Service Tools
Tool Detail Reference
892/00280 892/00279 892/00346 892/00347 892/00254 Pressure Gauge 0-600 bar (0-9000 lbf/in2) Pressure Gauge 0-400 bar (0-6000 lbf/in2) Pressure Gauge 0-70 bar (0-1000 lbf/in2) Connector Hose

Fig 33. Hydraulic Circuit Test Gauges and Connections 892/00223 892/00137 892/00274 892/00262 892/00706 892/00278 892/00279 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 Gauge 0 - 40 bar (0 - 600 lbf/in2) Gauge 0 - 400 bar (0 - 6000 lbf/in2)

Fig 34. Hand Pump Equipment

Fig 35. Spool Clamps 892/00039 992/10100 992/02800 Spool Clamp Spool Clamp - Diameter 19mm (3/4 in) ARV Extractor Fig 36. 892/00923 - Test Block for A.R.V.

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Service Tools
Tool Detail Reference

Section F - Transmission

Fig 40. Bearing Adapters 992/07608 992/07609 992/07610 Fig 37. 892/00237 - Flow Test Adapter Complete A B C 892/00304 892/00301 892/00302 Flow Test Adapter Flow Test Adapter Flow Test Adapter 992/07611 992/07612 992/07613 Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter Bearing Adapter

Fig 38. Heavy Duty Sockets for Durlock Bolts 892/00817 892/00818 892/00819 892/00333 17mm A/F x 3/4in square drive 22mm A/F x 3/4in square drive 15mm A/F x 1/2in square drive 19mm A/F x 3/4in square drive Fig 41. 992/07603 - Replacer Bearing Cap

Fig 42. 892/00295 - End Float Setting Tool

Fig 39. 992/04000 - Torque Multiplier Use in conjunction with a torque wrench to give a 5:1 multiplication when tightening pinion nuts etc.

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Service Tools
Tool Detail Reference

Fig 43. 892/00179 - Bearing Press Fig 46. Gearbox Removal Fixture Fixture for Synchro Shuttle and Powershift Gearbox removal and replacement (For details see MI 373/H, 358/ E).

Fig 44. 992/04800 - Flange Spanner

Fig 47. 892/00916 - Clutch Pack Spring Compressor

Fig 45. 892/00921 - Torque Converter Alignment Bar

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Service Tools
Tool Detail Reference
921/52608 Spacer - 13.10mm thick 921/52609 Spacer - 13.15mm thick 921/52610 Spacer - 13.20mm thick 921/52611 Spacer - 13.25mm thick 921/52612 Spacer - 13.30mm thick 921/52613 Spacer - 13.35mm thick 921/52614 Spacer - 13.40mm thick 921/52615 Spacer - 13.45mm thick Fig 48. 892/00918 - Spacer Setting Tool Kit 921/52616 Spacer - 13.50mm thick 921/52617 Spacer - 13.55mm thick 921/52618 Spacer - 13.60mm thick 921/52619 Spacer - 13.65mm thick 921/52620 Spacer - 13.70mm thick 921/52621 Spacer - 13.75mm thick 921/52622 Spacer - 13.80mm thick 921/52623 Spacer - 13.85mm thick 921/52624 Spacer - 13.90mm thick
A396950-C1

921/52625 Spacer - 13.95mm thick 921/52626 Spacer - 14.00mm thick 921/52627 Spacer - 14.20mm thick Note: After using a spacer, obtain a replacement to keep the set complete.

Fig 49. 993/70111 - Breakback Torque Wrench

747030-C1

Fig 50. 921/52600 - Spacer Kit Consists of: 921/52628 Spacer - 12.60mm thick 921/52629 Spacer - 12.65mm thick 921/52630 Spacer - 12.70mm thick 921/52601 Spacer - 12.75mm thick 921/52602 Spacer - 12.80mm thick 921/52603 Spacer - 12.85mm thick 921/52604 Spacer - 12.90mm thick 921/52605 Spacer - 12.95mm thick 921/52606 Spacer - 13.00mm thick 921/52607 Spacer - 13.05mm thick

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Service Tools
Tool Detail Reference

Section H - Steering

Fig 51. 892/00180 - Seal Fitting Tool Seal Fitting Tool for fitting 'O' ring and back-up ring to Danfoss Orbitrol Unit. 892/00181 - Replacement Plastic Boss

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Service Tools
Tool Detail Reference

Section K - Engine

Fig 52. 892/00041 - De-glazing Tool for Cylinder Bores To assist bedding-in of new piston rings. For details of other engine service tools refer to: Publication No. 9806/0100 (AA engine builds) Publication No. 9806/2140 (AR engine builds) Publication No. 9806/2250 (RE engine builds) Publication No. 9806/3000 (SA engine builds)

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Section 1 - General Information


Service Consumables
Sealing and Retaining Compounds

Service Consumables
Sealing and Retaining Compounds
T11-001_3

Table 1. Type JCB Multi-Gasket Description Part No. Quantity 50 ml A medium strength sealant suitable for all sizes of 4102/1212 gasket flanges, and for hydraulic fittings of 25-65 mm diameter. A high strength locking fluid for use with threaded 4102/0551 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. A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter. 4101/0651 4101/0250 4101/0251

JCB High Strength Threadlocker

50 ml

JCB Retainer (High Strength) JCB Threadlocker and Sealer

50 ml 10 ml 50 ml

JCB Threadlocker and Sealer (High Strength) JCB Threadseal JCB Activator JCB Cleaner/Degreaser Direct Glazing Kit

A high strength locking fluid for sealing and retaining 4101/0550 nuts, bolts, and screws up to 50 mm diameter, and 4101/0552 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. For degreasing components prior to use of anaerobic adhesives and sealants. For one pane of glass; comprises of: 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. 4102/1951 4104/0251 4104/0253 4104/1557 993/55700

10 ml 200 ml 50 ml 200 ml (Aerosol) 1 ltr (Bottle) 400 ml (Aerosol)

Ultra Fast Adhesive Active Wipe 205 Black Primer 206J Clear Silicone Sealant Plastic to Metal Bonder Black Polyurethane Sealant

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.

4103/2109 4104/1203 4201/4906 4102/0901 4103/0956 4102/2309

310 ml 250 ml 30 ml 50 g 310 ml

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Section 1 - General Information

Terms and Definitions


Schematic Codes
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.

Red

Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and MRV operating pressure. Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red.

Pink

Orange

Servo: Oil pressure used in controlling a device (servo).

Blue

Neural: Neutral circuit pressure.

Green

Exhaust

Light Green

Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).

Yellow

Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).

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