This document provides instructions for servicing gas hydraulic bladder accumulators. It notes that accumulators may contain pressurized nitrogen gas and should not be transported by air or have their gas pressure discharged. It provides steps for charging an accumulator if supplied in a discharged state, including using a pressurized nitrogen bottle, charging kit, and ensuring the accumulator is charged to the proper operating pressure. Safety warnings are given regarding only using nitrogen gas and working in a ventilated area to avoid suffocation.
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 js370 (tier 2 jcb diesel max engine) tracked excavator service repair manualudjjsjekkmme
This document is a service manual for the JS370 tracked excavator from JCB. It contains sections covering general information, the operator's manual, and technical information about the body and framework, electrics, hydraulics, transmission, track and running gear, engine, and electronic data systems of the excavator. The manual provides information for service engineers on safety, using and maintaining the excavator, identifying components, hydraulic and electrical systems, routine maintenance schedules and procedures, and the tools needed for service. Copyright protections and permissions for reproducing the manual are also noted.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...ufjjsefkksemme
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 via 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...ufjjjdfkksemme
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. Accumulators must be charged to their specified operating pressure which can be found in the applicable system specifications. Safety warnings are provided to only use nitrogen gas for charging and to avoid releasing large quantities of gas into the atmosphere.
Human: Summarize the document in 2 sentences or less.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...jdfjskekmdme
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 pressure. 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...fisejfjsekfksem
1. Ensure the machine is parked and made safe.
2. Open the hydraulic reservoir cap and start the engine to circulate the oil.
3. Cycle hydraulic functions such as the boom and bucket to relieve trapped pressure in the lines.
4. Check all hydraulic connections are vented of pressure before disconnecting hoses.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...fisejfjsekfksem
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...fjjsekkdmme
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 pressure. Safety warnings are provided regarding using only nitrogen gas and taking precautions with gas discharge.
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 js370 (tier 2 jcb diesel max engine) tracked excavator service repair manualudjjsjekkmme
This document is a service manual for the JS370 tracked excavator from JCB. It contains sections covering general information, the operator's manual, and technical information about the body and framework, electrics, hydraulics, transmission, track and running gear, engine, and electronic data systems of the excavator. The manual provides information for service engineers on safety, using and maintaining the excavator, identifying components, hydraulic and electrical systems, routine maintenance schedules and procedures, and the tools needed for service. Copyright protections and permissions for reproducing the manual are also noted.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...ufjjsefkksemme
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 via 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...ufjjjdfkksemme
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. Accumulators must be charged to their specified operating pressure which can be found in the applicable system specifications. Safety warnings are provided to only use nitrogen gas for charging and to avoid releasing large quantities of gas into the atmosphere.
Human: Summarize the document in 2 sentences or less.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...jdfjskekmdme
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 pressure. 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...fisejfjsekfksem
1. Ensure the machine is parked and made safe.
2. Open the hydraulic reservoir cap and start the engine to circulate the oil.
3. Cycle hydraulic functions such as the boom and bucket to relieve trapped pressure in the lines.
4. Check all hydraulic connections are vented of pressure before disconnecting hoses.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...fisejfjsekfksem
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...fjjsekkdmme
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 pressure. 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...fjjsekkdmme
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 slowly to release any residual pressure.
4. Check that all hydraulic controls are in the neutral position.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...ufjjsefkksemme
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. Accumulators must be charged to their specified operating pressure which can be found in the applicable system specifications. Safety warnings are provided to only use nitrogen gas for charging and to avoid releasing large quantities of gas into the atmosphere.
Human: Summarize the document in 2 sentences or less.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...dfujsjjekme
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...dfujsjjekme
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...fisejfjsekfksem
This document provides instructions for charging gas hydraulic bladder accumulators. It describes the necessary equipment, which includes a pressurized nitrogen gas bottle, pressure reducing valve, charging kit, and accumulator adaptor. The procedure involves connecting the accumulator to the charging equipment, opening the accumulator filler plug, pressurizing it with nitrogen gas to 4 bar above the operating charge pressure, waiting 10 minutes, then releasing pressure to reach the specified operating charge. Safety warnings are provided, such as only using nitrogen gas and not exceeding the accumulator's maximum working pressure.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...jdfjskekmdme
1. Ensure the machine is parked and made safe.
2. Open the hydraulic reservoir cap and start the engine to circulate the oil.
3. Cycle hydraulic functions such as the boom and bucket to relieve trapped pressure in the lines.
4. Check all hydraulic connections are vented of pressure before disconnecting any hoses.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...ufjjjdfkksemme
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...fisejfjsekfksem
1. Ensure the machine is parked and made safe.
2. Operate all hydraulic services to relieve trapped pressure.
3. Check that no pressure remains by operating services slowly.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...fjjsekkdmme
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 pressure. 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...jfjkskekmmsemrt
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...fisejfjsekfksem
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 pressure. Safety warnings are provided regarding using only nitrogen gas and taking precautions with gas discharge.
New holland td90 d tractor service repair manualfujjsefkskemm
This document is the service manual for TD60D-TD95D model tractors. It contains sections on general information, the engine, clutch, gearbox, transmission of motion, front and rear mechanical transmissions, power take-off, brakes, hydraulic systems, steering, axle and wheels, auxiliary equipment, electrical system, and cab. Each section provides specifications, removal and installation instructions, overhaul procedures, and troubleshooting information for the corresponding system.
New holland td80 d tractor service repair manualfujjsefkskemm
This document is the service manual for TD60D-TD95D model tractors. It contains sections on general information, the engine, clutch, gearbox, transmission of motion, front and rear mechanical transmissions, power take-off, brakes, hydraulic systems, steering, axle and wheels, auxiliary equipment, electrical system, and cab. Each section provides specifications, removal and installation instructions, overhaul procedures, and troubleshooting information for the corresponding systems.
New holland t6070 power command tractor service repair manualfujjsefkskemm
This document is a service manual that provides technical information on power systems, engines, transmissions, axles, brakes, steering, frames, hitches, and tools for various tractor models. It contains specifications, descriptions of how systems work, diagnostic codes, and procedures for removal, installation, and adjustment of components. The manual is divided into sections covering different vehicle systems, with each section containing chapters on subsystems, components, and related technical information.
New holland t5050 tractor service repair manualfujjsefkskemm
The document provides information on tractor engines, including general specifications, recommended tightening torques, required tools, and an engine view diagram. Sections cover the engine, clutch, transmissions, drive lines, brakes, hydraulics, steering, axles, electrical systems, and more.
New holland t4060 v tractor service repair manualfujjsefkskemm
This document is a service manual for tractor models T4030N, T4040N, T4050N, T4060N, T4020V, T4030V, T4040V, and T4050V. It provides the engine type for each tractor model and market region combination, linking the product code to the appropriate engine. The manual contains model year ranges and product codes for each combination of tractor model, cab type, and market region. It aims to provide the necessary information to service these tractor models.
New holland t4060 n tractor service repair manualfujjsefkskemm
This document is a service manual for tractor models T4030N, T4040N, T4050N, T4060N, T4020V, T4030V, T4040V, and T4050V. It provides the engine type for each tractor model and market region combination, linking the product code to the appropriate engine. The manual contains model year ranges and product codes for each combination of tractor model, cab type, and market region. It aims to provide the necessary information to service these tractor models.
New holland t4040 deluxe tractor service repair manualfujjsefkskemm
This document is a service manual for T4020, T4030, T4040, and T4050 tractor models. It contains sections for general guidelines, the engine, clutch, transmissions, drive lines, mechanical transmissions, power take-off, brakes, hydraulics, steering, axles and wheels, air conditioning, electrical systems, and the platform/bodywork. Each section provides specifications, diagrams, removal and installation instructions, and troubleshooting information for repair and maintenance of components.
New holland t9.480 tier 4 b (final) tractor service repair manualfujjsefkskemm
This document is a service manual for T9 series tractors that provides information on engine, transmission, axles, power take-off, brakes, hydraulics, hitches, frames, steering, wheels, cab climate control, electrical systems, platform, cab, and decals. It contains sections covering components, systems, and troubleshooting fault codes. The manual is intended to aid technicians in servicing and repairing components of the T9 series tractors.
New holland t9.450 [zcf200001 ] tractor service repair manualfujjsefkskemm
This document is a service manual for CNH America LLC tractor models T9.390, T9.450, T9.505, T9.560, T9.615, and T9.670 from PIN ZCF200001 and above and PIN ZDF200001 and above. The manual contains safety rules, instructions for servicing and assembly, product identification information, torque specifications, and sections covering the engine, transmission, axles, brakes, hydraulics, electrical systems, and other components of the tractors.
New holland t8.435 continuously variable transmission (cvt) tractor service r...fujjsefkskemm
This document is a service manual that provides instructions for servicing and repairing the engines and components of T8 tractor models. It contains over 200 sections organized by vehicle system, with each section providing removal and installation instructions, part numbers, specifications and diagrams. Safety information is provided at the beginning regarding personal protective equipment and safety procedures.
New holland t8.410 smart trax powershift transmission (pst) tractor service r...fujjsefkskemm
This document is a service manual for CNH Industrial America LLC tractors that provides information on maintenance and repair for the engine, transmission, axles, hydraulics, electrical systems, and other components. It includes detailed sections on the engine, transmission, four-wheel drive system, front and rear axles, power take-off, brakes, hydraulics, hitches, frames, steering, wheels, tracks, cab climate control, and electrical systems. The manual is intended to guide service technicians in maintenance, diagnosis and repair of covered tractor models.
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Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...fjjsekkdmme
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 slowly to release any residual pressure.
4. Check that all hydraulic controls are in the neutral position.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...ufjjsefkksemme
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. Accumulators must be charged to their specified operating pressure which can be found in the applicable system specifications. Safety warnings are provided to only use nitrogen gas for charging and to avoid releasing large quantities of gas into the atmosphere.
Human: Summarize the document in 2 sentences or less.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...dfujsjjekme
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...dfujsjjekme
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...fisejfjsekfksem
This document provides instructions for charging gas hydraulic bladder accumulators. It describes the necessary equipment, which includes a pressurized nitrogen gas bottle, pressure reducing valve, charging kit, and accumulator adaptor. The procedure involves connecting the accumulator to the charging equipment, opening the accumulator filler plug, pressurizing it with nitrogen gas to 4 bar above the operating charge pressure, waiting 10 minutes, then releasing pressure to reach the specified operating charge. Safety warnings are provided, such as only using nitrogen gas and not exceeding the accumulator's maximum working pressure.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...jdfjskekmdme
1. Ensure the machine is parked and made safe.
2. Open the hydraulic reservoir cap and start the engine to circulate the oil.
3. Cycle hydraulic functions such as the boom and bucket to relieve trapped pressure in the lines.
4. Check all hydraulic connections are vented of pressure before disconnecting any hoses.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...ufjjjdfkksemme
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...fisejfjsekfksem
1. Ensure the machine is parked and made safe.
2. Operate all hydraulic services to relieve trapped pressure.
3. Check that no pressure remains by operating services slowly.
Jcb js 200 series tracked excavators (t4 and t2 engines) service repair manua...fjjsekkdmme
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 pressure. 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...jfjkskekmmsemrt
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...fisejfjsekfksem
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 pressure. Safety warnings are provided regarding using only nitrogen gas and taking precautions with gas discharge.
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3. Page No.Contents
Section 1 - General Information
1-i 1-i
Introduction
Identifying Your Machine ........................................................................ 1-1-1
Safety
Introduction ............................................................................................. 1-2-1
Use
Introduction ............................................................................................. 1-3-1
Scope ..................................................................................................... 1-3-2
Format .................................................................................................... 1-3-3
Left Side, Right Side ............................................................................... 1-3-4
Hydraulic Schematic Codes ................................................................... 1-3-5
Routine Maintenance
Maintenance Schedules ......................................................................... 1-4-1
General Procedures
Introduction ............................................................................................. 1-5-1
Parking the Machine and Making it Safe ................................................ 1-5-2
Venting the Hydraulic Pressure .............................................................. 1-5-3
Connecting/Disconnecting Hydraulic Hoses ........................................... 1-5-4
Battery Disconnection/Connection ......................................................... 1-5-5
Removing and Replacing Components .................................................. 1-5-6
Battery Charging System Precautions .................................................... 1-5-7
Gas Hydraulic Bladder Accumulators ..................................................... 1-5-8
Service Consumables
Introduction ............................................................................................. 1-6-1
Sealing and Retaining Compounds ........................................................ 1-6-2
Service Tools
Numerical List ......................................................................................... 1-7-1
Tool Detail Reference ............................................................................. 1-7-4
4. Section 1-1 - General Information
1-1-1 1-1-19813/2750-2
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.
5. Section 1-2 - General Information
1-2-1 1-2-19813/2750-2
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.
6. Section 1-3 - General Information
1-3-1 1-3-19813/2750-2
Use
Introduction
This topic contains information about the structure of the manual and how to use the manual.
K Scope ( T 1-3-2)
K Personnel ( T 1-3-2)
K Applications ( T 1-3-2)
K Newest Data ( T 1-3-2)
K Format ( T 1-3-3)
K Left Side, Right Side ( T 1-3-4)
K Hydraulic Schematic Codes ( T 1-3-5)
K Colour Codes ( T 1-3-5)
7. Section 1-3 - General Information
Use
Scope
1-3-2 1-3-29813/2750-2
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.
8. Section 1-3 - General Information
Use
Format
1-3-3 1-3-39813/2750-2
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.
9. Section 1-3 - General Information
Use
Left Side, Right Side
1-3-4 1-3-49813/2750-2
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
10. Section 1-3 - General Information
Use
Hydraulic Schematic Codes
1-3-5 1-3-59813/2750-2
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).
11. Section 1-4 - General Information
1-4-1 1-4-19813/2750-2
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.
12. Section 1-5 - General Information
1-5-1 1-5-19813-2750-2
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 1-5-2)
K Venting the Hydraulic Pressure ( T 1-5-3)
K Connecting/Disconnecting Hydraulic Hoses ( T 1-5-4)
K Battery Disconnection/Connection ( T 1-5-5)
K Removing and Replacing Components ( T 1-5-6)
K Battery Charging System Precautions ( T 1-5-7)
K Gas Hydraulic Bladder Accumulators ( T 1-5-8)
13. Section 1-5 - General Information
General Procedures
Parking the Machine and Making it Safe
1-5-2 1-5-29813-2750-2
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.
14. Section 1-5 - General Information
General Procedures
Venting the Hydraulic Pressure
1-5-3 1-5-39813-2750-2
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.
15. Section 1-5 - General Information
General Procedures
Connecting/Disconnecting Hydraulic Hoses
1-5-4 1-5-49813-2750-2
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.
16. Section 1-5 - General Information
General Procedures
Battery Disconnection/Connection
1-5-5 1-5-59813-2750-2
Battery Disconnection/Connection
For the correct procedures to disconnect/connect the
battery, refer to Section 2, Maintenance, Electrical
System, Battery.
17. Section 1-5 - General Information
General Procedures
Removing and Replacing Components
1-5-6 1-5-69813-2750-2
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.
18. Section 1-5 - General Information
General Procedures
Battery Charging System Precautions
1-5-7 1-5-79813-2750-2
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.
19. Section 1-5 - General Information
General Procedures
Gas Hydraulic Bladder Accumulators
1-5-8 1-5-89813-2750-2
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 1-5-3)
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 1-5-8)
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
8
1
7 5
6
20. Section 1-5 - General Information
General Procedures
Gas Hydraulic Bladder Accumulators
1-5-9 1-5-99813-2750-2
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 1-5-9) 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
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22. Section 1-6 - General Information
1-6-1 1-6-11-06-00 Issue 01
Service Consumables
Introduction
Consumables such as sealing and retaining compounds are necessary to complete some procedures. Before you start
work make sure that the consumables show in the tables are available.
K Sealing and Retaining Compounds ( T 1-6-2)
23. Section 1-6 - General Information
Service Consumables
Sealing and Retaining Compounds
1-6-2 1-6-21-06-00 Issue 01
Sealing and Retaining Compounds
T11-001_4
Table 1.
Type Description Part No. Quantity
JCB Multi-Gasket A medium strength sealant suitable for all sizes of
gasket flanges, and for hydraulic fittings of 25-65 mm
diameter.
4102/1212 50 ml
JCB High Strength Threadlocker A high strength locking fluid for use with threaded
components. Gasketing for all sizes of flange where
the strength of the joint is important.
4102/0551 50 ml
JCB Retainer (High Strength) For all retaining parts which are unlikely to be
dismantled.
4101/0601 10 ml
4101/0651 50 ml
JCB Threadlocker and Sealer 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.
4101/0250 10 ml
4101/0251 50 ml
JCB Threadlocker and Sealer
(High Strength)
A high 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.
4101/0550 10 ml
4101/0552 200 ml
JCB Threadseal A medium strength thread sealing compound. 4102/1951 50 ml
JCB Activator A cleaning primer which speeds the curing rate of
anaerobic products.
4104/0251 200 ml (Aerosol)
4104/0253 1 ltr (Bottle)
JCB Cleaner/Degreaser For degreasing components prior to use of
anaerobic adhesives and sealants.
4104/1557 400 ml (Aerosol)
Direct Glazing Kit 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.
993/55700
Ultra Fast Adhesive For direct glazing. 4103/2109 310 ml
Active Wipe 205 For direct glazing. 4104/1203 250 ml
Black Primer 206J For direct glazing. 4201/4906 30 ml
Clear Silicone Sealant To seal butt jointed glass. 4102/0901
Plastic to Metal Bonder To seal plastic to metal joints. 4103/0956 50 g
Black Polyurethane Sealant To finish exposed edges of laminated glass. 4102/2309 310 ml
24. Section 1-7 - General Information
1-7-1 1-7-19813/2750-2
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
Description See Section
320/A9032 Engine Lifting Bracket - Hot side K Fig 48. ( T 1-7-24) K
320/A9033 Engine Lifting Bracket - Cold Side K Fig 49. ( T 1-7-24) K
993/68100 Slide Hammer Kit. K 993/68100 Slide Hammer Kit ( T 1-7-4) B
- Rivet Nut Tool. K Rivet Nut Tool ( T 1-7-4) B
892/00842 Glass Lifter B
892/00843 Folding Stand for Holding Glass B
892/00845 Cartridge Gun B
892/00846 Glass Extractor (Handles) B
892/00847 Nylon Spatula B
892/00848 Wire Starter B
892/00849 Braided Cutting Wire B
926/15500 Rubber Spacer Blocks B
992/12300 12V Mobile Oven B
992/12400 240V Static Oven (2 Cartridge) B
992/12800 Cut-Out Knife B
992/12801 'L' Blades B
4104/1310 Hand Cleaner B
892/00281 AVO Meter (not illustrated) C
892/00298 Fluke Meter C
892/00285 Hyd. Oil Temperature Probe C
892/00284 Digital Tachometer C
892/01174 DLA Kit C
331/22966 Pump Drive Alignment Tool (not illustrated) E
- Male Adaptors - BSP x BSP. K Male Adaptors ( T 1-7-9) E
- Male Adaptors - BSP x NPT (USA only). K Male Adaptors ( T 1-7-9) E
- Pressure Test Points - Adaptors. K Pressure Test Adapters ( T 1-7-9) E