4. 01 - Machine
03 - Safety
03 - Safety - Yours and Others
01 - 3 9813/6050-2 01 - 3
03 - Safety - Yours and Others
Introduction
All machinery can be hazardous. When a machine
is correctly operated and maintained, it is a safe
machine to work with. When it is carelessly operated
or poorly maintained it can become a danger to you
(the operator) and others.
In this manual and on the machine you will find
warning messages, you must read and understand
them. They inform you of potential hazards and how
to avoid them. If you do not fully understand the
warning messages, ask your employer or JCB dealer
to explain them.
Safety is not just a matter of responding to the
warnings. All the time you are working on or with the
machine you must be thinking of what hazards there
might be and how to avoid them.
Do not work with the machine until you are sure that
you can control it.
Do not start any work until you are sure that you and
those around you will be safe.
If you are not sure of anything, about the machine or
the work, ask someone who knows. Do not assume
anything.
Remember:
• Be careful
• Be alert
• Be safe.
5. 01 - Machine
03 - Safety
06 - Safety Warnings
01 - 4 9813/6050-2 01 - 4
06 - Safety Warnings
Introduction
In this manual there are safety notices. Each notice
starts with a signal word. The signal word meanings
are given below.
The signal word 'DANGER' indicates a hazardous
situation which, if not avoided, will result in death or
serious injury.
The signal word 'WARNING' indicates a hazardous
situation which, if not avoided, could result in death
or serious injury.
The signal word 'CAUTION' indicates a hazardous
situation which, if not avoided, could result in minor
or moderate injury.
The signal word 'Notice' indicates a hazardous
situation which, if not avoided, could result in
machine damage.
The safety alert system symbol (shown) also helps
to identify important safety messages in this manual.
When you see this symbol your safety is involved,
carefully read the message that follows.
Figure 1. The safety alert system symbol
6. 01 - Machine
03 - Safety
09 - General Safety
01 - 5 9813/6050-2 01 - 5
09 - General Safety
Introduction
Training
To operate the machine safely you must know the
machine and have the skill to use it. You must abide
by all relevant laws, health and safety regulations
that apply to the country you are operating in. The
operator's manual instructs you on the machine, its
controls and its safe operation; it is not a training
manual. Ensure that you receive the correct training
before operating any machinery. Failing to do so will
result in incorrect operation of the machine and you
will be putting yourself and others at risk. In some
markets, and for work on certain jobsites, you may
be required to have been trained and assessed in
accordance with an operator competence scheme.
Make sure that you and your machine comply with
relevant local laws and jobsite requirements – it is
your responsibility.
Care and Alertness
All the time you are working with or on the machine,
take care and stay alert. Always be careful. Always
be alert for hazards.
Clothing
You can be injured if you do not wear the correct
clothing. Loose clothing can get caught in the
machinery. Keep cuffs fastened. Do not wear a
necktie or scarf. Keep long hair restrained. Remove
rings, watches and personal jewellery.
Alcohol and Drugs
It is extremely dangerous to operate machinery when
under the influence of alcohol or drugs. Do not
consume alcoholic drinks or take drugs before or
while operating the machine or attachments. Be
aware of medicines which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are
feeling unwell. By doing so you could be a danger to
yourself and those you work with.
Mobile Phones
Switch off your mobile phone before entering an
area with a potentially explosive atmosphere. Sparks
in such an area could cause an explosion or fire
resulting in death or serious injury.
Switch off and do not use your mobile phone when
refuelling the machine.
Lifting Equipment
You can be injured if you use incorrect or faulty lifting
equipment. You must identify the weight of the item to
be lifted then choose lifting equipment that is strong
enough and suitable for the job. Make sure that lifting
equipment is in good condition and complies with all
local regulations.
Raised Equipment
Never walk or work under raised equipment unless
it is supported by a mechanical device. Equipment
which is supported only by a hydraulic device can
drop and injure you if the hydraulic system fails
or if the control is operated (even with the engine
stopped).
Make sure that no-one goes near the machine while
you install or remove the mechanical device.
Raised Machine
Never position yourself or any part of your body
under a raised machine which is not correctly
supported. If the machine moves unexpectedly you
could become trapped and suffer serious injury or be
killed.
Lightning
Lightning can kill you. Do not use the machine if there
is lightning in your area.
Machine Modifications
This machine is manufactured in compliance with
prevailing legislative requirements. It must not be
altered in any way which could affect or invalidate its
compliance. For advice consult your JCB dealer.
7. 21 - Cooling System
12 - Thermostat
00 - General
21 - 23 9813/6050-2 21 - 23
00 - General
Introduction .................................................... 21-23
Component Identification ............................... 21-24
Check (Condition) .......................................... 21-24
Check (Operation) ......................................... 21-25
Remove and Install ....................................... 21-25
Introduction
The thermostat is installed on the cylinder head. It is
located between the engine and the radiator in the
cooling circuit.
The function of the thermostat is to block the flow of
coolant to the radiator until the engine has warmed
up to a sufficient temperature.
When the engine is cold, no coolant flows through
the engine. Once the engine reaches its operating
temperature, refer to Cooling System - Technical
Data, the thermostat opens. By letting the engine
warm up as quickly as possible, the thermostat
reduces engine wear, deposits and emissions. Refer
to: PIL 21-00-00.
8. 21 - Cooling System
12 - Thermostat
00 - General
21 - 24 9813/6050-2 21 - 24
Component Identification
Figure 301.
A
B
C
D
E
A Bolt
B Outlet connection
C Joint
D Thermostat
E Thermostat housing
Check (Condition)
1. If the thermostat is suspected of being faulty,
perform a thermostat test, to confirm its
serviceability.
2. Note that the thermostat is a non-serviceable
item. If the thermostat is faulty or damaged it
must be renewed.
3. Inspect the seal for damage or splits. If necessary
replace the seal. Make sure that the seal is
correctly installed.
9. 21 - Cooling System
12 - Thermostat
00 - General
21 - 25 9813/6050-2 21 - 25
Check (Operation)
WARNING: Personal injury can result from the
escaping fluid under pressure. If a pressure
indication is shown on the indicator, push the release
valve to relieve pressure before removing any hose
from the radiator.
1. Remove the thermostat from the engine.
Refer to: PIL 21-12-00.
2. Heat the water in a pan until the temperature of
the water is equal to the fully open temperature
of the thermostat.
2.1. Stir the water in the pan. This will distribute
the temperature throughout the pan.
Figure 302.
3. Hang the thermostat in the pan of water. The
thermostat must be below the surface of the
water. The thermostat must be away from the
sides and the bottom of the pan.
4. Keep the water at the correct temperature for the
specified time.
Duration: 10 min
5. Remove the thermostat.
6. Immediately measure the opening of the
thermostat.
7. Make sure that the opening distance is within the
specified limit. If not, replace the thermostat.
Remove and Install
Remove
1. Drain the cooling system.
Refer to: PIL 21-00-00.
2. Remove the bolts.
3. Remove the outlet connection.
4. Identify the orientation of the outlet connection to
help installation.
5. Remove the joint.
6. Remove the thermostat from the thermostat
housing.
Figure 303.
A
B
C
D
E
A Bolt
B Outlet connection
C Joint
D Thermostat
E Thermostat housing
Install
1. Inspect the thermostat for wear, damage and
correct operation.
10. 21 - Cooling System
12 - Thermostat
00 - General
21 - 26 9813/6050-2 21 - 26
Refer to: PIL 21-12-00.
2. Make sure that the mating surfaces of the outlet
connection and the thermostat housing are clean
and free from damage.
3. Instal the thermostat to the thermostat housing.
4. Install a new joint.
5. Install the outlet connection to the thermostat
housing.
6. Make sure the correct orientation of the outlet
connection.
7. Install the bolt and tighten to the correct torque
value.
8. Fill the cooling system to the correct level.
Refer to: PIL 21-00-00.
Table 98. Torque Values
Item Description Nm
A Bolt 14
11. 21 - Cooling System
12 - Thermostat
03 - Housing
21 - 27 9813/6050-2 21 - 27
03 - Housing
Remove and Install
Remove
1. Drain the cooling system.
Refer to: PIL 21-00-00.
2. Loosen the hose clamp and disconnect the hose
from the thermostat housing.
3. Remove the bolt and the nut.
4. Remove the thermostat housing from the
cylinder head.
5. Remove the joint from the cylinder head.
6. If necessary, remove the thermostat.
Refer to: PIL 21-12-00.
Figure 304.
A
B
C
D
FE
A Joint
B Thermostat housing
C Nut
D Bolt
E Clamp
F Hose
Install
1. Make sure that the mating surfaces of the
cylinder head and the thermostat housing are
clean and free from damage.
2. Install a new joint to the cylinder head.
3. Install thermostat housing to the cylinder head.
4. Install the bolt and the nut.
5. Tighten the nut to the correct torque value.
6. Connect the hose to thermostat housing.
7. Tighten the hose clamp.
8. If removed, install the thermostat.
Refer to: PIL 21-12-00.
9. Fill the cooling system.
Refer to: PIL 21-00-00.
Table 99. Torque Values
Item Description Nm
C Nut 10
13. 21 - Cooling System
93 - Hose
00 - General
21 - 29 9813/6050-2 21 - 29
00 - General
Introduction .................................................... 21-29
Health and Safety .......................................... 21-30
Component Identification ............................... 21-31
Check (Condition) .......................................... 21-33
Introduction
The engine cooling hoses are essential parts of
the cooling system. They carry the liquid coolant
between the engine and the radiator/cooling pack.
14. 21 - Cooling System
93 - Hose
00 - General
21 - 30 9813/6050-2 21 - 30
Health and Safety
CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the
cap, hot coolant can spray out and burn you.
Make sure that the engine is cool before you work
on the cooling system.
15. 21 - Cooling System
93 - Hose
00 - General
21 - 31 9813/6050-2 21 - 31
Component Identification
Figure 305. Typical Cooling System
A
B
A Coolant outlet hose B Coolant inlet hose
16. 21 - Cooling System
93 - Hose
00 - General
21 - 32 9813/6050-2 21 - 32
Figure 306.
C
D
C Oil cooler inlet hose D Oil cooler outlet hose
17. 21 - Cooling System
93 - Hose
00 - General
21 - 33 9813/6050-2 21 - 33
Check (Condition)
1. Visually inspect the engine and related cooling
components for:
1.1. Leaks.
1.2. Cracked, burnt or perished hoses.
1.3. Hose clips are in good condition and
tightened to the correct torque value.
18. 27 - Driveline
27 - Hub
00 - General
27 - 14 9813/6050-2 27 - 14
Remove and Install
Consumables
Description Part No. Size
Clear Silicone Sealant 4102/0901 0.31 L
4003/2020 0.5 kg
4003/2017 0.4 kg
4003/2006 12.5 kg
Special HP Grease
4003/2005 50 kg
Remove
1. Make the machine safe. Refer to (PIL 01-03).
2. Remove the wheels from the machine. Refer to
(PIL 27-29).
3. Remove the drain plug.
4. Drain the oil from the chain case.
5. Loosen the nut.
6. Remove the bolts 2 (x4).
7. Remove the hub adjustment bolt and nut.
8. Swing the hub assembly towards the centre of
the machine so that the drive chain is at its
slackest position.
9. Use a suitable bar to wedge the hub. Refer to
Figure 315.
9.1. If the front hub is to be removed, both hubs
on that side must be rotated to slacken both
chains.
Figure 315.
Q
Q Bar
10. Remove the spider. Refer to (PIL 27-27).
11. Lift the appropriate chain from the drive sprocket.
Make a note that the inner chain drives the front
hub, therefore lift the rear chain first.
12. Remove the nut.
13. Remove the hub assembly.
14. Remove the chain from the sprocket.
15. Remove the hub assembly from the chassis.
16. Remove and discard the O-ring.
19. 27 - Driveline
27 - Hub
00 - General
27 - 15 9813/6050-2 27 - 15
Figure 316.
A
B
F
K
J P G
H
D
M
N
E
C
L
N
M
A Bolts 1 B Sprockets
C Spacer D Rear stub axle
E Front stub axle F Bearing
G Bearing cap H Shaft seal
J Case K O-ring
L Drain plug M Nut
N Bolt 2 P Hub face
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21. 27 - Driveline
27 - Hub
00 - General
27 - 16 9813/6050-2 27 - 16
Install
1. The installation procedure is the opposite of the
removal procedure. Additionally do the following
step.
2. Apply a thin layer of silicon sealer to the groove
before you install the new O-ring.
Consumable: Clear Silicone Sealant
3. Apply a layer of the specified grease to the hub
mounting face and O-ring.
Consumable: Special HP Grease
4. Adjust the drive chains as follows:
4.1. Install the hub onto the machine.
4.2. Install the nut.
4.3. Position the adjustment bolt and nut into the
slot in the adjustment bracket as shown at
position 1. Refer to Figure 317.
Figure 317.
R
R Position 1
4.4. Use the bolt to push the hub away from the
centre of the machine. This will tighten the
chain.
4.5. Rotate the sprocket so that one side of the
chain is tight.
4.6. Position the hub to give the specified
slackness on the opposite side of the chain
at the midway point.
Dimension: 25 mm
4.7. When the correct tension is achieved, install
the bolts 2.
4.8. Tighten the bolts 2 and nut to the correct
torque value.
Table 103. Torque Values
Item Nm
M 244
N 244
22. 27 - Driveline
27 - Hub
00 - General
27 - 17 9813/6050-2 27 - 17
Disassemble and Assemble
Consumables
Description Part No. Size
Cleaner/Degreaser
- General purpose
solvent based parts
cleaner
4104/1557 0.4 L
JCB Retainer (High
Strength)
4101/0602 0.05 L
4003/2020 0.5 kg
4003/2017 0.4 kg
4003/2006 12.5 kg
Special HP Grease
4003/2005 50 kg
Disassemble
1. Use the alphabetical sequence shown on the
illustration as a guide to disassembly.
2. Make a note that the spacer is only installed to
the front hubs.
3. Remove the bolts 1 (x6) and drive sprocket.
4. Support the assembly on the hub face.
5. Press out the stub axle assembly.
6. The bearing 1 will remain in the case. If
necessary, remove it separately.
7. The cap of the bearing 2 will also be left in the
case. If necessary, remove the cap of the bearing
2.
8. Remove and discard the shaft seal.
9. Inspect the stub axle and case for wear or
damage.
23. 27 - Driveline
27 - Hub
00 - General
27 - 18 9813/6050-2 27 - 18
Figure 318.
A
B
F
K
J P G
H
D
M
N
E
C
L
N
M
A Bolts 1 B Sprockets
C Spacer D Rear stub axle
E Front stub axle F Bearing 1
G Bearing 2 H Shaft seal
J Case K O-ring
L Drain plug M Nut
N Bolt 2 P Hub face
24. 27 - Driveline
27 - Hub
00 - General
27 - 19 9813/6050-2 27 - 19
Assemble
1. The assembly procedure is the opposite of
the disassembly procedure. Additionally do the
following step.
2. Lubricate all the bearings and seals with the
specified grease.
Consumable: Special HP Grease
3. Clean the mating faces of the sprocket and hub
with the specified cleaner.
Consumable: Cleaner/Degreaser - General
purpose solvent based parts cleaner
4. Place the sprocket onto the stub axle.
5. Apply a single run of the specified retainer to
each bolt hole in the stub axle.
Consumable: JCB Retainer (High Strength)
6. Apply three runs of the specified retainer to each
bolt 1.
Consumable: JCB Retainer (High Strength)
7. Install the bolts.
8. Tighten the bolts evenly to the correct torque
value in a diagonal sequence while you rotate the
hub to seat the bearings.
9. Make sure that the torque value required to rotate
the hub after assembly must not be more than
the specified value.
Torque: 30 N·m
Table 104. Torque Values
Item Nm
A 405
