Oil pressure generated by an auxiliary pump or circuit to assist a main service.
Blue Return: Oil returning to the reservoir after completing its function in a circuit.
Green Drain: Oil draining from a component by gravity or venting.
Black Neutral: Oil at reservoir pressure in a neutral circuit.
Yellow Suction: Oil being drawn from the reservoir into a pump or circuit.
White Vent: Oil venting or breathing to or from atmosphere.
Purple Pilot: Oil pressure generated by a pilot operated valve or circuit.
Brown Pilot: Oil pressure generated by a pilot operated valve or circuit.
The above colour coding is used on hydraulic schematics and illustrations throughout this manual
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This document provides instructions and safety information for servicing JCB wheeled excavators. It contains sections covering general information, operator manuals, and maintenance of specific components. The general information section outlines the manual's contents and format. It provides definitions for terms used and codes for hydraulic schematics. It also includes safety procedures for tasks like venting hydraulic pressure and disconnecting batteries. The document specifies torque settings for fasteners and lists the tools required for maintenance.
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This document summarizes information about how to use the service manual for JCB wheeled excavators. It provides information on the scope and intended users of the manual, its format and section organization, definitions for left and right sides, and color codes used in hydraulic schematics. The summary includes sections on personnel the manual is intended for, the applications it covers, ensuring the most up-to-date information is used, how the manual is organized into numbered and lettered sections, and how left and right are defined from the operator's perspective.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...ufjjsefkksemme
This document provides instructions and safety information for servicing JCB wheeled excavators. It contains sections covering general information, the operator's manual, and specific components and systems including the body and framework, electrics, hydraulics, transmission, and engine. The general information section provides an overview of the manual's contents and formatting. It also includes information on safety, identifying machines, maintenance schedules, general procedures for tasks like venting hydraulic pressure, and technical references for items like torque settings and service tools.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...jdfjskekmdme
This document provides an overview of the structure and content of the service manual. It discusses that the manual is intended for use by trained JCB service technicians. It provides information on the scope and applications of the manual, as well as noting that the newest data should always be referenced. The document outlines the manual's section-based format and defines terminology for left and right sides. It also introduces hydraulic schematic codes and color codes used in illustrations.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...jdfjskekmdme
This document summarizes information about how to use the service manual for JCB wheeled excavators. It provides information on the scope and intended users of the manual, its format and section organization, definitions for left and right sides, and color codes for hydraulic schematics. The summary includes sections on personnel the manual is intended for, the applications it contains data for, ensuring the most up-to-date information is used, how the manual is organized into numbered and lettered sections, and how left and right are defined from the operator's perspective.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...jfskekfsmemm
This document provides instructions and safety information for servicing JCB wheeled excavators. It contains sections covering general information, the operator's manual, and specific components and systems including the body and framework, electrics, controls, hydraulics, transmission, and engine. The general information section provides an overview of the manual's contents and formatting. It also includes information on safety, identifying machines, maintenance schedules, general procedures for tasks like parking and venting hydraulic pressure, service consumables, torque settings, service tools, and more.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...dfujsjjekme
This document provides instructions and safety information for servicing JCB wheeled excavators. It contains sections covering general information, operator manuals, and maintenance of specific components. The general information section includes topics such as safety, machine identification, maintenance schedules, general procedures for tasks like venting hydraulic pressure, and service tools. It provides torque specifications for fasteners and instructions for tasks like charging hydraulic accumulators. The document emphasizes safety practices and contains warnings regarding hazards like high pressure hydraulics.
This document provides instructions for servicing JCB excavators with Tier 4i Isuzu engines. It contains sections on general information, the operator's manual, body and framework, electrics, hydraulics, transmission, track and running gear, and the engine. The general information section covers identifying machines, safety, scope of the manual, left/right terminology, hydraulic schematics, maintenance schedules, general procedures, service consumables, torque settings, and service tools.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...ufjjsefkksemme
This document provides instructions and safety information for servicing JCB wheeled excavators. It contains sections covering general information, operator manuals, and maintenance of specific components. The general information section outlines the manual's contents and format. It provides definitions for terms used and codes for hydraulic schematics. It also includes safety procedures for tasks like venting hydraulic pressure and disconnecting batteries. The document specifies torque settings for fasteners and lists the tools required for maintenance.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...jfskekfsmemm
This document summarizes information about how to use the service manual for JCB wheeled excavators. It provides information on the scope and intended users of the manual, its format and section organization, definitions for left and right sides, and color codes used in hydraulic schematics. The summary includes sections on personnel the manual is intended for, the applications it covers, ensuring the most up-to-date information is used, how the manual is organized into numbered and lettered sections, and how left and right are defined from the operator's perspective.
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This document provides instructions and safety information for servicing JCB wheeled excavators. It contains sections covering general information, the operator's manual, and specific components and systems including the body and framework, electrics, hydraulics, transmission, and engine. The general information section provides an overview of the manual's contents and formatting. It also includes information on safety, identifying machines, maintenance schedules, general procedures for tasks like venting hydraulic pressure, and technical references for items like torque settings and service tools.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...fjjsekkdmme
This document summarizes information about how to use the service manual for JCB wheeled excavators. It provides information on the scope and intended users of the manual, its format and section organization, definitions for left and right sides, and color codes for hydraulic schematics. The summary includes sections on personnel the manual is intended for, the applications it covers, ensuring the most up-to-date information is used, how the manual is organized into numbered and lettered sections, and how left and right are defined from the operator's perspective.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...fisejfjsekfksem
This document summarizes information about how to use the service manual for JCB wheeled excavators. It provides information on the scope and intended users of the manual, its format and section organization, definitions for left and right sides, and color codes used in hydraulic schematics. The summary includes sections on personnel the manual is intended for, the applications it covers, ensuring the most up-to-date information is used, how the manual is organized into numbered and lettered sections, and how left and right are defined from the operator's perspective.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...fjjsekkdmme
This document provides instructions and safety information for servicing JCB wheeled excavators. It contains sections covering general information, the operator's manual, and specific components and systems including the body and framework, electrics, hydraulics, transmission, and engine. The general information section provides an overview of the manual's contents and formatting. It also includes information on safety, identifying machines, maintenance schedules, general procedures for tasks like venting hydraulic pressure, and technical references for things like torque settings and service tools.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...dfujsjjekme
This document provides instructions and safety information for servicing JCB wheeled excavators. It contains sections covering general information, the operator's manual, and specific components and systems including the body and framework, electrics, hydraulics, transmission, and engine. The general information section provides an overview of the manual's contents and formatting. It also includes information on safety, identifying machines, maintenance schedules, general procedures for tasks like venting hydraulic pressure, and technical references for items like torque settings and service tools.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...jfjkskekmmsemrt
This document summarizes information about how to use the service manual for JCB wheeled excavators. It provides information on the scope and intended users of the manual, its format and section organization, definitions for left and right sides, and color codes used in hydraulic schematics. The summary includes sections on personnel the manual is intended for, the applications it covers, ensuring the most up-to-date information is used, how the manual is organized into numbered and lettered sections, and how left and right are defined from the operator's perspective.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...ufjjjdfkksemme
This document provides instructions and safety information for servicing JCB wheeled excavators. It contains sections covering general information, the operator's manual, and specific components and systems including the body and framework, electrics, hydraulics, transmission, and engine. The general information section provides an overview of the manual's contents and formatting. It also includes information on safety, identifying machines, maintenance schedules, general procedures for tasks like venting hydraulic pressure, and technical references for items like torque settings and service tools.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...ufjjjdfkksemme
This document provides instructions and safety information for servicing JCB wheeled excavators. It contains sections covering general information, operator manuals, and maintenance of specific components. The general information section outlines the manual's contents and format. It provides definitions for terms used and codes for hydraulic schematics. It also includes safety procedures for tasks like venting hydraulic pressure and disconnecting batteries. The document specifies torque settings for fasteners and lists the tools required for maintenance.
Jcb js200 w tier 2 and tier 4i wheeled excavator service repair manual (from ...jfjkskekmmsemrt
This document summarizes information about how to use the service manual for JCB wheeled excavators. It provides information on the scope and intended users of the manual, its format and section organization, definitions for left and right sides, and color codes for hydraulic schematics. The summary includes sections on personnel the manual is intended for, the applications it covers, ensuring the most up-to-date information is used, how the manual is organized into numbered and lettered sections, and how left and right are defined from the operator's perspective.
Jcb s2032 e mobile elevating work platform service repair manual sn 2532501 a...jfskekfsmemm
This document is a service manual for JCB mobile elevating work platforms models S1530E through S4550E. It contains instructions for maintenance and repair of the machines. Safety is emphasized throughout, with warnings about operating or maintaining the machines without understanding the manual, as serious injury or death could result from improper use. Training requirements and general safety practices like wearing appropriate clothing and footwear are also outlined.
Jcb s1930 e mobile elevating work platform service repair manual sn 2532501 a...jfskekfsmemm
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Jcb s1530 e mobile elevating work platform service repair manual sn 2532501 a...jfskekfsmemm
This document is a service manual for JCB mobile elevating work platforms between the years 1998-2017. It contains safety information and instructions for maintenance and operation. The manual advises reading it fully to understand how to safely operate and service the machines. It warns that improper use can result in death or serious injury.
Jcb jz141 [t4 f] excavator service repair manual sn 2479659 and upjfskekfsmemm
This document provides service information for valves on an excavator engine. It includes technical specifications for the valves and valve components. The document describes how the valve train operates and provides instructions for adjusting valve clearances when the engine is cold. Procedures are provided for removing and installing valves, including inspecting components and installing new valve stem seals. Special tools are listed that are required for tasks like adjusting clearances and compressing valve springs.
Jcb jz140 [t4i] excavator service repair manual sn 2375081 and upjfskekfsmemm
This document provides service information for valves on an excavator engine. It includes technical specifications for the valves and valve components. The document describes how the valve train operates and provides instructions for adjusting valve clearances when the engine is cold. Procedures are provided for removing and installing valves, including inspection criteria. Special tools are listed that are required for tasks like compressing valve springs and installing new valve stem seals.
Jcb js370 excavator service repair manual sn from 2491607 onwardsjfskekfsmemm
This service manual provides information on servicing and maintaining excavators models JS300, JS330, and JS370. It contains 22 sections covering various systems of the excavator like the engine, fuel system, cooling system, driveline, hydraulic system, and electrical system. The manual instructs technicians on procedures like valve clearance adjustment, rocker cover removal and installation, and push rod inspection. Safety warnings are provided throughout and technicians are advised to thoroughly study the manual before working on the excavator.
Jcb js330 excavator service repair manual sn from 2491581 onwardsjfskekfsmemm
This service manual provides instructions for servicing excavator models JS300, JS330, and JS370. It contains sections covering the entire machine including the engine, fuel and exhaust systems, cooling system, driveline, hydraulic system, electrical system, and various components. The manual provides introduction and operation details for components like the crankcase ventilation filter and sensors to aid technicians in maintenance and repair.
Jcb js300 excavator service repair manual sn from 2491541 onwardsjfskekfsmemm
This service manual provides information on servicing and maintaining excavators models JS300, JS330, and JS370. It contains 22 sections covering various systems of the excavator like the engine, fuel system, cooling system, driveline, hydraulic system, and electrical system. The manual instructs technicians on procedures like valve clearance adjustment, rocker cover removal and installation, and push rod inspection. Safety warnings are provided throughout and technicians are advised to thoroughly study the manual before working on the excavator.
Jcb js235 t4 f excavator service repair manual (from 2424851 to 2425350)jfskekfsmemm
This service manual provides instructions for servicing excavator models JS200, JS210, JS220, and JS235. It contains sections covering the entire machine including the engine, fuel system, cooling system, driveline, hydraulics, electrical system, and various components. The manual instructs technicians on inspection, removal and installation of parts, lists required consumables, and provides torque specifications. Safety warnings are provided throughout advising technicians to thoroughly read and understand the instructions before working on the machine.
Jcb js220 t4 f excavator service repair manual (from 2424851 to 2425350)jfskekfsmemm
This service manual provides instructions for servicing and repairing excavators models JS200, JS210, JS220, and JS235. It contains sections covering the entire machine including the engine, fuel system, cooling system, driveline, hydraulics, electrical system, and other components. The document provides detailed procedures, diagrams, specifications, and part numbers needed for maintenance and repairs. Safety warnings are included throughout advising technicians to read and understand instructions before working on the machine.
Jcb js210 lc tracked excavator service repair manual sn2163079 to 2168079jfskekfsmemm
This document provides information about torque settings for fasteners on JCB machines. It discusses zinc plated fasteners, which are the original type used, and Dacromet fasteners, which are an improved corrosion resistant type. Dacromet fasteners have a lower torque setting than zinc fasteners. The document provides tables with torque settings for UNF and metric fasteners under lubricated and unlubricated conditions. It stresses that the correct torque must be used depending on the type of fastener.
Jcb js210 t4 f excavator service repair manual (from 2424851 to 2425350)jfskekfsmemm
This service manual provides instructions for servicing excavator models JS200, JS210, JS220, and JS235. It contains sections covering the entire machine including the engine, fuel system, cooling system, driveline, hydraulics, electrical system, and various components. The manual instructs technicians on inspection, removal and installation of parts, lists required consumables, and provides torque specifications. Safety warnings are provided throughout advising technicians to thoroughly read and understand the instructions before working on the machine.
Jcb js200 t4 f excavator service repair manual (from 2424851 to 2425350)jfskekfsmemm
This service manual provides instructions for servicing and repairing excavators models JS200, JS210, JS220, and JS235. It contains sections covering the entire machine including the engine, fuel system, cooling system, driveline, hydraulics, electrical system, and other components. The document provides detailed procedures, diagrams, specifications, and part numbers needed for maintenance and repairs. Safety warnings are included throughout advising technicians to read and understand instructions before working on the machine.
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This document provides information about torque settings for different types of fasteners used on JCB machines. It defines zinc plated fasteners and Dacromet fasteners, which have a silver/mottled finish. Dacromet fasteners require lower torque settings than zinc plated fasteners due to differences in material properties. The document provides tables with torque settings for UNF and metric fasteners under conditioned 1 (unlubricated) and condition 2 (lubricated), specifying the appropriate settings based on fastener type, size, and condition. It advises not to mix Dacromet and zinc plated fasteners.
Jcb js81 tracked excavator service repair manual sn 1798936 to 1799936jfskekfsmemm
This document provides information about torque settings for different types of fasteners used on JCB machines. It defines zinc plated fasteners and Dacromet fasteners, which have a silver/mottled finish. Dacromet fasteners require lower torque settings than zinc plated fasteners due to differences in material properties. The document provides tables with torque settings for UNF and metric fasteners under conditioned 1 (unlubricated) and condition 2 (lubricated), specifying the appropriate settings based on fastener type, size, and condition. It advises not to mix Dacromet and zinc plated fasteners.
Jcb js81 tracked excavator service repair manual sn 1480500 to 1481999jfskekfsmemm
This document provides information about torque settings for different types of fasteners used on JCB machines. It discusses zinc plated fasteners, Dacromet fasteners which have a corrosion resistant finish, and how to identify each type by color and part number suffix. Torque tables are included specifying the settings for UNF Grade 'S' fasteners and Metric Grade 8.8 fasteners under different lubrication conditions. Dacromet fasteners have a lower torque setting than zinc or yellow plated fasteners due to their lubricated surface from the plating process.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...jfskekfsmemm
1. Position the machine on level ground and lower all attachments to the ground.
2. Stop the engine and remove the ignition key.
3. Open the hydraulic reservoir filler cap to allow air into the system.
4. Operate all hydraulic controls to release any trapped pressure.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...jfskekfsmemm
This document provides instructions for charging gas hydraulic bladder accumulators. It explains that accumulators may be supplied in a discharged state and outlines the necessary equipment and steps to safely charge them with nitrogen gas. Key steps include connecting the accumulator to a nitrogen gas bottle using an adapter, slowly increasing the pressure while monitoring the gauge until it reaches the operating charge pressure plus a safety margin of 4 bar, then releasing pressure to reach the exact operating charge. Safety warnings are provided regarding using only nitrogen gas and taking precautions with gas discharge.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...jfskekfsmemm
1. Position the machine on level ground and lower all attachments to the ground.
2. Stop the engine and remove the ignition key.
3. Open the hydraulic reservoir filler cap to allow air into the system.
4. Operate all hydraulic controls to release any trapped pressure.
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What Could Be Behind Your Mercedes Sprinter's Power Loss on Uphill RoadsSprinter Gurus
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Understanding Catalytic Converter Theft:
What is a Catalytic Converter?: Learn about the function of catalytic converters in vehicles and why they are targeted by thieves.
Why are They Stolen?: Discover the valuable metals inside catalytic converters (such as platinum, palladium, and rhodium) that make them attractive to criminals.
Steps to Prevent Catalytic Converter Theft:
Parking Strategies: Tips on where and how to park your vehicle to reduce the risk of theft, such as parking in well-lit areas or secure garages.
Protective Devices: Overview of various anti-theft devices available, including catalytic converter locks, shields, and alarms.
Etching and Marking: The benefits of etching your vehicle’s VIN on the catalytic converter or using a catalytic converter marking kit to make it traceable and less appealing to thieves.
Surveillance and Monitoring: Recommendations for using security cameras and motion-sensor lights to deter thieves.
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Recent Trends: Current trends and patterns in catalytic converter thefts to help you stay aware of emerging hotspots and tactics used by thieves.
Benefits of This Presentation:
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This presentation aims to equip you with the knowledge and tools needed to protect your vehicle from catalytic converter theft, ensuring you are prepared and proactive in safeguarding your property.
Ever been troubled by the blinking sign and didn’t know what to do?
Here’s a handy guide to dashboard symbols so that you’ll never be confused again!
Save them for later and save the trouble!
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EV Charging at MFH Properties by Whitaker JamiesonForth
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Implementing ELDs or Electronic Logging Devices is slowly but surely becoming the norm in fleet management. Why? Well, integrating ELDs and associated connected vehicle solutions like fleet tracking devices lets businesses and their in-house fleet managers reap several benefits. Check out the post below to learn more.
3. Page No.Contents
Section 1 - 1
1-1 1-1
Introduction
Identifying Your Machine ........................................................................... 1-1
Safety
Introduction ................................................................................................ 1-3
Use
Introduction ................................................................................................ 1-5
Scope ........................................................................................................ 1-6
Personnel ..............................................................................................1-6
Applications ...........................................................................................1-6
Newest Data ..........................................................................................1-6
Format ....................................................................................................... 1-7
Left Side, Right Side .................................................................................. 1-8
Hydraulic Schematic Codes ...................................................................... 1-9
Colour Codes ........................................................................................1-9
Routine Maintenance
Maintenance Schedules .......................................................................... 1-11
General Procedures
Introduction .............................................................................................. 1-13
Parking the Machine and Making it Safe ................................................. 1-14
Venting the Hydraulic Pressure ............................................................... 1-15
Connecting/Disconnecting Hydraulic Hoses ............................................ 1-16
Battery Disconnection/Connection .......................................................... 1-17
Removing and Replacing Components ................................................... 1-18
Preparation ..........................................................................................1-18
Original Components ...........................................................................1-18
New Components ................................................................................1-18
Torques and Fixings ............................................................................1-18
Battery Charging System Precautions ..................................................... 1-19
Gas Hydraulic Bladder Accumulators ...................................................... 1-20
Replacement .......................................................................................1-20
Charging ..............................................................................................1-20
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1-23
Introduction ..........................................................................................1-23
Bolts and Screws .................................................................................1-23
Hydraulic Connections ............................................................................. 1-27
'O' Ring Face Seal System ..................................................................1-27
'Torque Stop' Hose System .................................................................1-30
JCB Standard Torque Settings ................................................................ 1-31
B.S.P. Port Connection (Colour Coded) ..............................................1-31
Hose Ends and Flanged Fittings (Colour Coded) ................................1-32
Service Consumables
Introduction ........................................................................................... 1-6-33
Sealing and Retaining Compounds ...................................................... 1-6-34
Service Tools
Numerical List .......................................................................................... 1-35
4. Section 1 - 1
Contents
1-2 1-2
Page No.Contents
Tool Detail Reference .............................................................................. 1-38
Section B - Body and Framework ........................................................1-38
Section C - Electrics ............................................................................1-42
Section E - Hydraulics .........................................................................1-43
5. Section 1 - General Information
1-1 1-19813/4100-1
Introduction
Identifying Your Machine
For information about identifying your machine and its
main components, refer to Section 2, About the
Machine, Machine and Component Identification.
6. Section 1 - General Information
1-3 1-39813/4100-1
Safety
Introduction
In this manual and on the machine there are safety notices.
The safety notices have different signal words as follows:
– DANGER
– WARNING
– CAUTION
– Notice
For an explanation of the safety notice signal words, refer
to Section 2, Introduction, Safety.
For general safety notices, refer to Section 2,
Introduction, Safety.
For maintenance safety notices, refer to Section 2,
Maintenance, Maintenance Safety.
For safety notices specific to maintenance procedures,
refer to the relevant procedure.
If you do not fully understand a safety notice ask your
employer to explain it.
7. Section 1 - General Information
1-5 1-59813/4100-1
Use
Introduction
This topic contains information about the structure of the manual and how to use the manual.
K Scope ( T 1-6)
K Personnel ( T 1-6)
K Applications ( T 1-6)
K Newest Data ( T 1-6)
K Format ( T 1-7)
K Left Side, Right Side ( T 1-8)
K Hydraulic Schematic Codes ( T 1-9)
K Colour Codes ( T 1-9)
8. Section 1 - General Information
Use
Scope
1-6 1-69813/4100-1
Scope
Personnel
This manual 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. Finally, please
remember above all else SAFETY MUST COME FIRST!
Applications
This manual contains data relevant to a range of
machines. Make sure you reference the data for the
correct machine.
Newest Data
From time to time new machines, systems or devices
require the manual to be re-issued. Make sure you have
the newest issue.
Always check the on-line JCB data system for relevant
technical information.
9. Section 1 - General Information
Use
Format
1-7 1-79813/4100-1
Format
The manual is compiled in sections, the first two are
numbered and contain information as follows:
1 General Information - The section includes general
information such as torque settings and service tools.
2 Operator Manual - The section contains a copy of
the applicable machine Operator Manual. Refer to
this section when necessary for information about the
main machine components and controls. Refer also
to the safety and daily / weekly maintenance
information.
The remaining sections are alphabetically coded and deal
with dismantling, overhaul etc. of specific components, for
example:
Each section contains data such as technical data,
descriptions, fault finding and test procedures.
Some sections contain procedures and specifications
for different variants. This happens because of market
requirements, or when the machine specification changes
after a period of time. Where applicable, a table contains
information to help you identify the correct data and
procedures.
A Attachments
B Body and Framework...etc.
10. Section 1 - General Information
Use
Left Side, Right Side
1-8 1-89813/4100-1
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.
C017280
Fig 1.
A
B
11. Section 1 - General Information
Use
Hydraulic Schematic Codes
1-9 1-99813/4100-1
Hydraulic 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.
Red
Full Pressure: Pressure generated from operation of a service. Depending on application this
may be anything between neutral circuit pressure and LSRV operating pressure.
Pink Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red.
Orange Pilot: Oil pressure used in controlling a device (Pilot).
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).
12. Section 1 - General Information
1-11 1-119813/4100-1
Routine Maintenance
Maintenance Schedules
This publication contains procedures for carrying out the
routine maintenance tasks listed on the maintenance
schedules. Refer to Section 2, Maintenance Schedules.
The procedures for the daily and weekly (10 and 50 hour)
tasks are given in Section 2, Maintenance.
The procedures for the 100 hour and above tasks are
given in the related sections of this publication. For
example the procedures for engine related tasks are given
in Section K.
13. Section 1 - General Information
1-13 1-139813-4100-1
General Procedures
Introduction
When work is done on the machine it is important that the correct care is taken. This will help to prevent personal injury
and reduce the risk of component failure.
As part of the procedures in this manual you will need to do some general procedures. Two examples of these general
procedures are; parking the machine and making it safe, and venting hydraulic pressure.
These procedures are given here as an alternative to again and again in the manual. Where applicable you will see a
cross reference to this section so that you can refer to the detailed procedures.
K Parking the Machine and Making it Safe ( T 1-14)
K Venting the Hydraulic Pressure ( T 1-15)
K Connecting/Disconnecting Hydraulic Hoses ( T 1-16)
K Battery Disconnection/Connection ( T 1-17)
K Removing and Replacing Components ( T 1-18)
K Battery Charging System Precautions ( T 1-19)
K Gas Hydraulic Bladder Accumulators ( T 1-20)
14. Section 1 - General Information
General Procedures
Parking the Machine and Making it Safe
1-14 1-149813-4100-1
Parking the Machine and Making it Safe
For the correct procedures to park and make the machine
safe, refer to Section 2, Maintenance, Maintenance
Positions.
15. Section 1 - General Information
General Procedures
Venting the Hydraulic Pressure
1-15 1-159813-4100-1
Venting the Hydraulic Pressure
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses
or couplings, vent the pressure trapped in the hoses in
accordance with the instructions given in this
publication.
HYD-1-5
For the correct procedures to vent the hydraulic pressure,
refer to Section 2, Maintenance, Hydraulic System,
General, Discharge.
16. Section 1 - General Information
General Procedures
Connecting/Disconnecting Hydraulic Hoses
1-16 1-169813-4100-1
Connecting/Disconnecting Hydraulic Hoses
!MWARNING
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you.
Before disconnecting or connecting hydraulic hoses
or couplings, vent the pressure trapped in the hoses in
accordance with the instructions given in this
publication.
HYD-1-5
For the correct procedures to connect/disconnect
hydraulic hoses, refer to Section 2, Attachments,
Connecting/Disconnecting Hydraulic Hoses.
17. Section 1 - General Information
General Procedures
Battery Disconnection/Connection
1-17 1-179813-4100-1
Battery Disconnection/Connection
For the correct procedures to disconnect/connect the
battery, refer to Section 2, Maintenance, Electrical
System, Battery.
18. Section 1 - General Information
General Procedures
Removing and Replacing Components
1-18 1-189813-4100-1
Removing and Replacing Components
Preparation
Before removing and replacing components do the
following:
– To prevent contamination of the machine systems,
clean the machines in the area of the applicable
components. Refer to Section 2, Preservation and
Storage, Cleaning the Machine.
– Make sure that the correct maintenance procedures
are available.
– Make sure that the correct tools and equipment are
available.
– Make sure that the correct replacement parts,
consumables, fluids and lubricants are available.
Original Components
Always Install new oil seals, gaskets, etc.
Components showing obvious signs of wear or damage
should be replaced with new ones.
Before re-installing original components do the following:
– Clean components using the applicable cleaning
materials.
– Inspect components for signs of excessive wear or
defects.
– Check the component specifications such as wear
limits where applicable.
New Components
Make sure that the correct new components are installed.
Do not substitute components from another machine.
Components may look the same but may not be
interchangeable. Refer to the JCB parts systems.
Torques and Fixings
When replacing components always tighten the applicable
fixings to the correct torque. For the torque setting to be
effective do the following before installing the fixings:
– Make sure that all the applicable component
assemblies are correct.
– Make sure that the applicable fixings are to the
correct specification. If necessary discard the original
fixings and replace them with new ones. The relevant
procedures indicate when this is necessary.
– Make sure that the applicable fixings and threaded
holes are free from contamination. This includes; dirt,
debris, old sealants and compounds, fluids and
lubricants.
This manual provides reference to the correct torque
settings as follows:
– Where no torque setting is given in the applicable
procedure, use the standard torque setting. To obtain
the correct standard torque setting refer to Torque
Settings in this section.
– Where torque settings are given in the applicable
procedure use the settings given. These settings may
be different to the standard torque settings in the case
of special fixings for example.
19. Section 1 - General Information
General Procedures
Battery Charging System Precautions
1-19 1-199813-4100-1
Battery Charging System Precautions
Obey the procedures below to prevent damage to the
alternator and battery.
– Ensure that the battery negative terminal is
connected to the earthing cable.
– Never make or break connections to the battery or
alternator, or any part of the charging circuit whilst the
engine is running. Disregarding this instruction will
result in damage to the regulator or rectifying diodes.
– Main output cables are 'live' even when the engine is
not running. Take care not to earth connectors in the
moulded plug if it is removed from the alternator.
– When arc welding on the machine, protect the
alternator by removing the moulded plug (or if
separate output cables fitted, remove the cables).
– Follow the correct procedures when jump starting the
engine. Refer to Section 2, Operation, Moving a
Disabled Machine.
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21. Section 1 - General Information
General Procedures
Gas Hydraulic Bladder Accumulators
1-20 1-209813-4100-1
Gas Hydraulic Bladder Accumulators
Some hydraulic circuits and valve blocks are fitted with gas
hydraulic bladder type accumulators.
Before removing accumulators make sure hydraulic
pressure is vented. K Venting the Hydraulic
Pressure ( T 1-15)
Even when the hydraulic pressure is vented the
accumulator still contains pressurised nitrogen gas. DO
NOT attempt to discharge the gas pressure.
DO NOT transport accumulators charged with pressurised
gas by air freight.
Replacement
Replacement accumulators are generally supplied in a
discharged state with no nitrogen gas. A label attached to
the accumulator indicates the gas charge state.
Charging
K Fig 1. ( T 1-20)
Important: The following charging procedure is only
applicable to accumulators supplied in a discharged state.
To carry out the charging procedure the following is
required:
– Pressurised bottle of nitrogen gas with a suitable
pressure reducing valve (3).
– Correct gas bottle adaptor depending on territory.
– Charging kit 892/00239. Refer to Section 1.
Operating charge pressures; accumulators are charged
to different operating pressures depending on the
application. For the correct charge pressure refer to the
applicable system specifications.
Before fitting a replacement accumulator charge it with
nitrogen gas as follows:
!MWARNING
Use only nitrogen gas to charge accumulators. The
use of any other gas can cause the accumulators to
explode. Remember that although nitrogen is not
poisonous you can be killed by suffocation if it
displaces the air in your workplace. Do not allow
excessive quantities of nitrogen to be discharged into
the atmosphere.
B-3-1-6
C110540-C2
Fig 1.
1 Hold the accumulator upright and remove the plastic
cap from the top of the accumulator.
Note: Some accumulators are supplied with a measured
quantity of oil inside the gas chamber. Take care to prevent
oil loss.
2 Using a suitable allen key, slowly remove the filler
plug 2.
Lightly oil the sealing washer beneath. Replace the
washer and plug. Loosen the plug by 1/8 of a turn.
2
3
4
1
5
22. Section 1 - General Information
General Procedures
Gas Hydraulic Bladder Accumulators
1-21 1-219813-4100-1
3 Connect the accumulator adaptor 1 (from kit 892/
00239) to the accumulator. Connect the charging unit
6 to the accumulator adaptor.
Connect the charging hose to the pressure regulator
3 using the correct adaptor.
Set the pressure regulator 3 to the minimum
pressure.
4 Via the charging tool knob 7, open the filler plug 2 by
three turns.
5 Open the discharge valve 5 on the charging unit.
Carefully open the nitrogen gas bottle valve 4 and
confirm that the nitrogen gas flows freely.
Shut the gas bottle valve and the discharge valve 5.
6 Carefully open the gas bottle valve. Slowly increase
the pressure using the gas bottle pressure regulator
and watching the gauge 8 on the charging unit, allow
nitrogen to flow until the pressure reading reaches 4
bar (72.5 psi) ABOVE the operating charge pressure.
Important: DO NOT exceed the maximum working
pressure of the accumulator. The maximum working
pressure is marked on the accumulator body.
Close the gas bottle valve.
7 Wait 10 minutes to dissipate the heat generated
during charging.
8 Reduce the pressure in the accumulator to the
specified operating charge pressure by carefully
opening and closing the discharge valve 5. Turn the
knob 7 to shut the filler plug 2 and tighten to a torque
of 20 Nm (15 lb ft).
9 Release the pressure from the charging hose by
opening the discharge valve 5.
Disconnect the charging unit and adaptor from the
accumulator.
10 Check the gas-tightness of filler plug 2 by pouring
some oil around it.
11 Replace the plastic cap.
C110550
Fig 2.
12 K Fig 2. ( T 1-21) Remove the discharged state label
3 and attach the pressurised warning label 2 at
position 1 on the accumulator.
Install the accumulator and make sure the
pressurised warning label is clearly visible.
1
3
2
23. Section 1 - General Information
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
1-23 1-239813/4100-1
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 1-23).
Table 1. Fastener Types
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.
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
Condition 2
– Zinc flake (Dacromet) fasteners
– Lubricated zinc and yellow plated fasteners
– Where there is a natural lubrication. For example,
cast iron components
Verbus Ripp Bolts
Fig 1.
Torque settings for these bolts are determined by the
application. Refer to the relevant procedure for the
required settings.
Fastener
Type
Colour Part No. Suffix
Zinc and
Yellow
Golden finish 'Z' (e.g. 1315/3712Z)
Dacromet Mottled silver finish 'D' (e.g. 1315/3712D)