Jcb 527 58 [engine jcb ter 3 (sd,sf), jcb tier 4i (sh)] telescopic handler service repair manual (from 1473000 to 1473999)
- 1. Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support 9813/0200-6 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Service Manual 527-58 Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Data Systems
- 2. Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support 9813/0200-6 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Section 1 General Information Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Data Systems
- 3. Page No.Contents Section 1 - 1 1-i 1-i Applications Introduction ................................................................................................ 1-1 Tier 4 Final Machines ............................................................................1-2 Section 1 - Applications ............................................................................. 1-4 Use Introduction ................................................................................................ 1-6 Scope ........................................................................................................ 1-7 Personnel ..............................................................................................1-7 Applications ...........................................................................................1-7 Newest Data ..........................................................................................1-7 Format ....................................................................................................... 1-8 Left and Right Sides .................................................................................. 1-9 Hydraulic Schematic Codes .................................................................... 1-10 Colour Codes ......................................................................................1-10 Machine Identification Introduction .............................................................................................. 1-12 Related Topics ......................................................................................... 1-13 Machine Identification Plate ..................................................................... 1-14 Typical Product Identification Number (PIN) .......................................1-15 Component Identification Plates .............................................................. 1-17 Typical Engine Identification Number ..................................................1-17 Transmission Identification Numbers ..................................................1-18 ROPS/FOPS and OECD Certification Plates ......................................1-20 Torque Settings Introduction .............................................................................................. 1-22 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 `Positional Type' Hydraulic Adaptors ....................................................... 1-31 Fitting Procedure .................................................................................1-31 Service Tools Introduction .............................................................................................. 1-32 Numerical List .......................................................................................... 1-33 Tool Detail Reference .............................................................................. 1-36 Rivet Nuts ................................................................................................ 1-60 Fitting Procedure .................................................................................1-61 Slide Hammer Kit ..................................................................................... 1-62 Fitting Procedure .................................................................................1-62 Service Consumables Introduction .............................................................................................. 1-64 Sealing and Retaining Compounds ......................................................... 1-65 Fuel Introduction .............................................................................................. 1-66 Related Topics ......................................................................................... 1-67
- 4. Section 1 - 1 Contents 1-ii 1-ii Page No.Contents Acceptable and Unacceptable Fuels ....................................................... 1-68 Additives ..............................................................................................1-69 Service Requirements for use of B20 Biodiesel ..................................1-69 Warranty ..............................................................................................1-69 Fuel Types ...........................................................................................1-70 Usage and Effects of Fuels .................................................................1-71 Sulphur Content ..................................................................................1-72 Effects of Fuel Contaminates ..............................................................1-73 Fuel Introduction .............................................................................................. 1-74 Related Topics ......................................................................................... 1-75 Acceptable and Unacceptable Fuels ....................................................... 1-76 Fuel Introduction .............................................................................................. 1-78 Related Topics ......................................................................................... 1-79 Acceptable and Unacceptable Fuels ....................................................... 1-80
- 5. Section 1 - 1 Applications Section 1 - Applications 1-4 1-49813/0200-5 (1-14-03) Section 1 - Applications Important: The machine model names are NOT referred to in the topics. You must refer to the applications table for the applicable machine models. Table entries shaded grey indicate a topic not included in this issue of the manual. Note: For full details of machine identification refer to Section 1 - Machine Identification. Machine models Topic Ref Title Variant 527-58 1-1 Use ALL 1-2 Applications ALL 1-3 Machine Identification ALL 1-4 Fuel (1-08-01) Machines with SD/SF Engines 1-5 Fuel (1-08-02) Machines with SL/SH Engines 1-6 Torque Settings ALL 1-7 Service Tools ALL 1-8 Service Consumables ALL
- 6. Section 1 - 1 1-6 1-61-01-03 Issue 01 Use Introduction This topic contains information about the structure of the manual and how to use the manual. K Scope ( T 1-7) K Personnel ( T 1-7) K Applications ( T 1-7) K Newest Data ( T 1-7) K Format ( T 1-8) K Left and Right Sides ( T 1-9) K Hydraulic Schematic Codes ( T 1-10) K Colour Codes ( T 1-10)
- 7. Section 1 - 2 Machine Identification Component Identification Plates 1-17 1-171-02-07 Issue 02 Component Identification Plates Typical Engine Identification Number Engine data labels A are located on the cylinder block at position C and rocker cover D (if fitted). The data label contains important engine information and includes the engine identification number E. A typical engine identification number is explained as follows: 1 Engine Type SD = turbocharged SE = electronic common rail fuel injection, turbocharged and intercooled. SF = turbocharged and intercooled. SH = 4.4 litre electronic common rail fuel injection with Variable Geometry Turbocharger (81kW, 93kW) SL = 4.4 litre electronic common rail fuel injection with Fixed Geometry Turbocharger (55kW) DH = 4.8 litre electronic common rail fuel injection with Variable Geometry Turbocharger (108kW) 2 Engine part number 3 Country of manufacture U = United Kingdom 4 Engine Serial Number 5 Year of Manufacture The last three parts of the engine identification number are stamped on the cylinder block at position B. C007280-C5.jpg Fig 2. Engine SD 320/40001 U 00001 04 1 2 3 4 5 U 00001 04
- 8. Section 1 - 2 Machine Identification Component Identification Plates 1-18 1-181-02-07 Issue 02 Transmission Identification Numbers Axles (Excluding 550-80 Machines) The transmission components have a serial number stamped on a data plate A as shown. A710840-C1 Fig 3. Front Axle A710830-C1 Fig 4. Rear Axle Axles (550-80 Machines) The axles have a serial number stamped on a data plate label A as shown. To view to the front axle data plate remove the cover B and the plate will be visible through hole C. C107510 Fig 5. Front Axle C107520 Fig 6. Rear Axle C B A A
- 9. Section 1 - 2 Machine Identification Component Identification Plates 1-19 1-191-02-07 Issue 02 HydroStatic Transmission Components Transmission Pump C094930 Fig 7. 1 Ordering Code 2 Pump Serial Number (8 Digits) Each motor has a unique serial number. 3 Direction of rotation - looking at the shaft. 4 Date of manufacture. 5 Speed. 6 Power. Transmission Motor 1 Motor Serial Number (6 Digits) Each motor has a unique serial number. 2 Type 3 Date of manufacture. C094920 Fig 8. Code Machine AA4VG56 20 and 34 kph AA10VG63 25 kph AA4VG71 40 kph
- 10. Section 1 - 2 Machine Identification Component Identification Plates 1-20 1-201-02-07 Issue 02 ROPS/FOPS and OECD Certification Plates Machines built to ROPS/FOPS standards have an identification label A fitted to the inside of the cab. Machines built to ROPS/FOPS and OECD standards have identification label B fitted to the inside of the cab. T016800-3-C1 Fig 9. 526-56 and 527-58 machines Definition of terms: ROPS Roll Over Protection Structure FOPS Falling Objects Protection Structure OECD Organisation for Economic Co-operation and Development.
- 11. Section 1 - 2 Machine Identification Component Identification Plates 1-21 1-211-02-07 Issue 02 445911-5 Fig 10. Other Machines
- 12. Section 1 - 3 1-22 1-221-05-01 Issue 01 Torque Settings Introduction This topic contains information about torques. Torque values are given for types and sizes of bolts and hydraulic connectors and adaptors. Where a torque is given as a single figure it may be varied by plus or minus 3%. Torque figures are given for fasteners with different surface treatments. Make sure you use the correct torque figures. Where torques are given in topics within the other sections always use these values. K Zinc Plated Fasteners and Dacromet Fasteners ( T 1-23) K Hydraulic Connections ( T 1-27) K `Positional Type' Hydraulic Adaptors ( T 1-31) K Fitting Procedure ( T 1-31)
- 13. Section 1 - 3 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners 1-23 1-231-05-01 Issue 01 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)
- 14. Section 1 - 3 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners 1-24 1-241-05-01 Issue 01 Table 2. Torque Settings - UNF Grade 'S' Fasteners Table 3. Torque Settings - Metric Grade 8.8 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 in. mm in. Nm kgf m lbf ft Nm kgf m lbf ft 1/4 6.3 7/16 11.2 1.1 8.3 10.0 1.0 7.4 5/16 7.9 1/2 22.3 2.3 16.4 20.0 2.0 14.7 3/8 9.5 9/16 40.0 4.1 29.5 36.0 3.7 26.5 7/16 11.1 5/8 64.0 6.5 47.2 57.0 5.8 42.0 1/2 12.7 3/4 98.00 10.0 72.3 88.0 9.0 64.9 9/16 14.3 13/16 140.0 14.3 103.2 126.0 12.8 92.9 5/8 15.9 15/16 196.0 20.0 144.6 177.0 18.0 130.5 3/4 19.0 1 1/8 343.0 35.0 253.0 309.0 31.5 227.9 7/8 22.2 1 15/16 547.0 55.8 403.4 492.0 50.2 362.9 1 25.4 1 1/2 814.0 83.0 600.4 732.0 74.6 539.9 1 1/8 31.7 1 7/8 1181.0 120.4 871.1 1063.0 108.4 784.0 1 1/4 38.1 2 1/4 1646.0 167.8 1214.0 1481.0 151.0 1092.3 Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft M5 5 8 5.8 0.6 4.3 5.2 0.5 3.8 M6 6 10 9.9 1.0 7.3 9.0 0.9 6.6 M8 8 13 24.0 2.4 17.7 22.0 2.2 16.2 M10 10 17 47.0 4.8 34.7 43.0 4.4 31.7 M12 12 19 83.0 8.5 61.2 74.0 7.5 54.6 M16 16 24 205.0 20.9 151.2 184.0 18.8 135.7 M20 20 30 400.0 40.8 295.0 360.0 36.7 265.5 M24 24 36 690.0 70.4 508.9 621.0 63.3 458.0 M30 30 46 1372.0 139.9 1011.9 1235.0 125.9 910.9 M36 36 55 2399.0 244.6 1769.4 2159.0 220.0 1592.4
- 15. Section 1 - 3 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners 1-25 1-251-05-01 Issue 01 Table 4. Metric Grade 10.9 Fasteners Table 5. Metric Grade 12.9 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft M5 5 8 8.1 0.8 6.0 7.3 0.7 5.4 M6 6 10 13.9 1.4 10.2 12.5 1.3 9.2 M8 8 13 34.0 3.5 25.0 30.0 3.0 22.1 M10 10 17 67.0 6.8 49.4 60.0 6.1 44.2 M12 12 19 116.0 11.8 85.5 104.0 10.6 76.7 M16 16 24 288.0 29.4 212.4 259.0 26.4 191.0 M20 20 30 562.0 57.3 414.5 506.0 51.6 373.2 M24 24 36 971.0 99.0 716.9 874.0 89.1 644.6 M30 30 46 1930.0 196.8 1423.5 1737.0 177.1 1281.1 M36 36 55 3374.0 344.0 2488.5 3036.0 309.6 2239.2 Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric Thread mm mm Nm kgf m lbf ft Nm kgf m lbf ft M5 5 8 9.8 1.0 7.2 8.8 0.9 6.5 M6 6 10 16.6 1.7 12.2 15.0 1.5 11.1 M8 8 13 40.0 4.1 29.5 36.0 3.7 26.5 M10 10 17 80.0 8.1 59.0 72.0 7.3 53.1 M12 12 19 139.0 14.2 102.5 125.0 12.7 92.2 M16 16 24 345.0 35.2 254.4 311.0 31.7 229.4 M20 20 30 674.0 68.7 497.1 607.0 61.9 447.7 M24 24 36 1165.0 118.8 859.2 1048.0 106.9 773.0 M30 30 46 2316.0 236.2 1708.2 2084.0 212.5 1537.1 M36 36 55 4049.0 412.9 2986.4 3644.0 371.6 2687.7
- 16. Section 1 - 3 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners 1-26 1-261-05-01 Issue 01 Table 6. Torque Settings - Rivet Nut Bolts/Screws Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size Nm kgf m lbf ft ISO Metric Thread mm M3 3 1.2 0.1 0.9 M4 4 3.0 0.3 2.0 M5 5 6.0 0.6 4.5 M6 6 10.0 1.0 7.5 M8 8 24.0 2.5 18.0 M10 10 48.0 4.9 35.5 M12 12 82.0 8.4 60.5 Bolt Size Nm kgf m lbf ft ISO Metric Thread M3 2.0 0.2 1.5 M4 6.0 0.6 4.5 M5 11.0 1.1 8.0 M6 19.0 1.9 14.0 M8 46.0 4.7 34.0 M10 91.0 9.3 67.0 M12 159.0 16.2 117.0 M16 395.0 40.0 292.0 M18 550.0 56.0 406.0 M20 770.0 79.0 568.0 M24 1332.0 136.0 983.0
- 17. Section 1 - 3 Torque Settings Hydraulic Connections 1-27 1-271-05-01 Issue 01 Hydraulic Connections T11-003 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port. Table 8. Torque Settings - BSP Adaptors Table 9. Torque Settings - SAE Connections BSP Adaptor Size Hexagon (A/F) Nm kgf m lbf ftin. mm 1/4 19.0 18.0 1.8 13.0 3/8 22.0 31.0 3.2 23.0 1/2 27.0 49.0 5.0 36.0 5/8 30.0 60.0 6.1 44.0 3/4 32.0 81.0 8.2 60.0 1 38.0 129.0 13.1 95.0 1 1/4 50.0 206.0 21.0 152.0 SAE Tube Size SAE Port Thread Size Hexagon (A/F) Nm kgf m lbf ftmm 4 7/16 - 20 15.9 20.0 - 28.0 2.0 - 2.8 16.5 - 18.5 6 9/16 - 18 19.1 46.0 - 54.0 4.7 - 5.5 34.0 - 40.0 8 3/4 - 16 22.2 95.0 - 105.0 9.7 - 10.7 69.0 - 77.0 10 7/8 - 14 27.0 130.0 - 140.0 13.2 - 14.3 96.0 - 104.0 12 1 1/16 - 12 31.8 190.0 - 210.0 19.4 - 21.4 141.0 - 155.0 16 1 5/16 - 12 38.1 290.0 - 310.0 29.6 - 31.6 216.0 - 230.0 20 1 5/8 47.6 280.0 - 380.0 28.5 - 38.7 210.0 - 280.0
- 18. Section 1 - 3 Torque Settings Hydraulic Connections 1-28 1-281-05-01 Issue 01 Hoses Screwed into Adaptors Fig 2. Hoses 2-B screwed into adaptors 2-A seal onto an `O' ring 2-C which is compressed into a 45° seat machined into the face of the adaptor port. Note: Dimension 2-D will vary depending upon the torque applied. Table 10. BSP Hose - Torque Settings BSP Hose Size Hexagon (A/F) Nm kgf m lbf ftin. mm 1/8 14.0 14.0 - 16.00 1.4 - 1.6 10.3 - 11.8 1/4 19.0 24.0 - 27.0 2.4 - 2.7 17.7 - 19.9 3/8 22.0 33.0 - 40.0 3.4 - 4.1 24.3 - 29.5 1/2 27.0 44.0 - 50.0 4.5 - 5.1 32.4 - 36.9 5/8 30.0 58.0 - 65.0 5.9 - 6.6 42.8 - 47.9 3/4 32.0 84.0 - 92.0 8.6 - 9.4 61.9 - 67.8 1 38.0 115.0 - 126.0 11.7 - 12.8 84.8 - 92.9 1 1/4 50.0 189.0 - 200.0 19.3 - 20.4 139.4 - 147.5 1 1/2 55.0 244.0 - 260.0 24.9 - 26.5 180.0 - 191.8
- 19. Section 1 - 3 Torque Settings Hydraulic Connections 1-29 1-291-05-01 Issue 01 Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size Nm kgf m lbf ftin. 1/8 20.0 2.1 15.0 1/4 34.0 3.4 25.0 3/8 75.0 7.6 55.0 1/2 102.0 10.3 75.0 5/8 122.0 12.4 90.0 3/4 183.0 18.7 135.0 1 203.0 20.7 150.0 1 1/4 305.0 31.0 225.0 1 1/2 305.0 31.0 225.0
- 20. Section 1 - 3 Torque Settings Hydraulic Connections 1-30 1-301-05-01 Issue 01 'Torque Stop' Hose System Fig 3. `Torque Stop' Hoses 3-B screwed into adaptors 3-A seal onto an 'O' ring 3-C which is compressed into a 45° seat machined in the face of the adaptor port. To prevent the 'O' ring being damages as a result of over tightening, 'Torque Stop' Hoses have an additional shoulder 3-D, which acts as a physical stop. Note: Minimum dimension 3-E fixed by shoulder 3-D. Table 12. BSP `Torque Stop' Hose - Torque Settings BSP Hose Size Hexagon (A/F) Nm kgf m lbf ftin. mm 1/8 14.0 14.0 1.4 10.0 1/4 19.0 27.0 2.7 20.0 3/8 22.0 40.0 4.1 30.0 1/2 27.0 55.0 5.6 40.0 5/8 30.0 65.0 6.6 48.0 3/4 32.0 95.0 9.7 70.0 1 38.0 120.0 12.2 89.0 1 1/4 50.0 189.0 19.3 140.0 1 1/2 55.0 244.0 24.9 180.0
- 21. Section 1 - 3 Torque Settings `Positional Type' Hydraulic Adaptors 1-31 1-311-05-01 Issue 01 `Positional Type' Hydraulic Adaptors Fitting Procedure On a typical machine, some hydraulic components may utilise `Positional Type' SAE Hydraulic Adaptors. When fitting `Positional Type' Hydraulic Adaptors it is important to adopt the following procedure. If this procedure is not followed correctly, damage to the `O' ring seal 4-A can occur resulting in oil leaks. 1 Ensure the locknut 4-B is screwed back onto the body of the adaptor as far as possible as shown. 2 Check the `O' ring backing washer 4-C is a tight fit on the adaptor. Note that the washer should not move freely, if the washer is slack do not use the adaptor. 3 Check the `O' ring 4-A is fitted and that it is free from damage or nicks. Before fitting the adaptor, smear the `O' ring with clean hydraulic fluid. Note: The dimensions and shore hardness of the `O' ring is critical. Should it become necessary to replace the `O' ring, ensure that only JCB Genuine Parts are used. 4 Screw the adaptor into the port of the hydraulic component as far as possible, so that ALL the threads engage and the `O' ring is correctly seated against the sealing face. 5 Set the angular position of the adaptor as required, then secure by tightening the locknut 4-B. Note: When fitted correctly no more than one thread should be visible at 5-Z as shown. 6 Torque tighten the locknut to 81 Nm (60 lbf ft). Fig 4. Fig 5.
- 22. Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means, electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE. World Class Customer Support 9813/0200-5 Publication No. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400 Section 2 Care and Safety Section 1 - General Information Section 2 - Care and Safety Section 3 - Routine Maintenance Section B - Body and Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section G - Brakes Section H - Steering Section K - Engine Section M - Electronic Data Systems
- 23. Page No.Contents Section 2 - 1 2-i 2-i Safety Notices Introduction ................................................................................................ 2-1 Important Information ................................................................................ 2-2 The Operator Manual ............................................................................2-2 Safety Warnings ....................................................................................2-2 Safety Check List ....................................................................................... 2-3 Safety - Yours and Others .....................................................................2-3 Common Rail (SE/SH/DH/SL Engine) Specific .....................................2-3 General Safety ......................................................................................2-5 Operating Safety ...................................................................................2-7 Maintenance Safety .............................................................................2-11 Safety Decals .......................................................................................... 2-16 Introduction ..........................................................................................2-16 General Procedures Introduction .............................................................................................. 2-17 Related Topics ......................................................................................... 2-19 Parking the Machine and Making it Safe ................................................. 2-20 Introduction ..........................................................................................2-20 Boom Safety Strut (P1) ............................................................................ 2-22 Installing ..............................................................................................2-23 Removing ............................................................................................2-24 Boom Safety Strut (P2) ............................................................................ 2-25 Installing the Maintenance Strut ..........................................................2-26 Removing the Maintenance Strut ........................................................2-28 Venting the Hydraulic Pressure ............................................................... 2-29 Venting the Brake System Pressure ........................................................ 2-31 Connecting/Disconnecting Hydraulic Hoses ............................................ 2-32 Introduction ..........................................................................................2-32 Connecting the Hoses .........................................................................2-32 Disconnecting the Hoses .....................................................................2-32 Quick Release Couplings ........................................................................ 2-33 Connecting and Disconnecting ............................................................2-33 Hydraulic Contamination ......................................................................... 2-35 Hydraulic Fluid Quality ........................................................................2-35 Effects of Contamination .....................................................................2-35 Cleaning Operation .............................................................................2-35 Contaminant Standards .......................................................................2-36 Filters ...................................................................................................2-36 Battery Disconnection/Connection .......................................................... 2-37 Disconnection ......................................................................................2-37 Connection ..........................................................................................2-37 Battery Charging System Precautions ..................................................... 2-38 Removing and Replacing Components ................................................... 2-39 Introduction ..........................................................................................2-39 Original Components ...........................................................................2-39 New Components ................................................................................2-39 Torques and Fixings ............................................................................2-40 Hydraulic Rams ....................................................................................... 2-41 Installation ...........................................................................................2-41 Caution During Use .............................................................................2-41 Maintenance, Inspection Points ..........................................................2-41 Gas Hydraulic Bladder Accumulators ...................................................... 2-43 Replacement .......................................................................................2-43 Charging ..............................................................................................2-43
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- 25. Section 2 - 1 2-1 2-12-01-06 Issue 01 Safety Notices Introduction In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. !MDANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured. INT-1-2-1 !MWARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-2 !MCAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine. INT-1-2-3
- 26. Section 2 - 1 Safety Notices Important Information 2-2 2-22-01-06 Issue 01 Important Information T1-042 The Operator Manual !MWARNING You and others can be killed or seriously injured if you operate or maintain the machine without first studying the Operator Manual. You must understand and follow the instructions in the Operator Manual. If you do not understand anything, ask your employer or JCB dealer to explain it. INT-1-4-2 Do not operate the machine without an Operator Manual, or if there is anything on the machine you do not understand. Treat the Operator Manual as part of the machine. Keep it clean and in good condition. Replace the Operator Manual immediately if it is lost, damaged or becomes unreadable. Safety Warnings In this publication and on the machine, there are safety notices. Each notice starts with a signal word. The signal word meanings are given below. !MDANGER Denotes an extreme hazard exists. If proper precautions are not taken, it is highly probable that the operator (or others) could be killed or seriously injured. INT-1-2-1 !MWARNING Denotes a hazard exists. If proper precautions are not taken, the operator (or others) could be killed or seriously injured. INT-1-2-2 !MCAUTION Denotes a reminder of safety practices. Failure to follow these safety practices could result in injury to the operator (or others) and possible damage to the machine. INT-1-2-3 This safety alert system identifies important safety messages in this manual. When you see this symbol, be alert, your safety is involved, carefully read the message that follows, and inform other operators.
- 27. Section 2 - 1 Safety Notices Safety Check List 2-3 2-32-01-06 Issue 01 Safety Check List Safety - Yours and Others INT-1-3-1_3 All machinery can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others. In this manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards and how to avoid them. If you do not fully understand the warning messages, ask your employer or JCB distributor to explain them. But safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them. Do not work with the machine until you are sure that you can control it. Do not start any job until you are sure that you and those around you will be safe. If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything. Remember BE CAREFUL BE ALERT BE SAFE Common Rail (SE/SH/DH/SL Engine) Specific In addition to the general safety notices and general good workshop practices issued in this section and throughout the manual, there are specific points to note when completing maintenance on engine equipment: Diesel Fuel Quality Important: The potential for engine damage due to the use of incorrect or contaminated fuel is much greater with common rail injection technology than with mechanical injection systems. For more information about cleanliness requirements and fuel types refer to Section 1 - General Information. !MCAUTION Do not allow dirt to enter the fuel system. Before disconnecting any part of the fuel system, thoroughly clean around the connection. When a component has been disconnected, for example a fuel pipe, always fit protective caps and plugs to prevent dirt ingress. Failure to follow these instructions will lead to dirt entering the fuel system. Dirt in the fuel system will seriously damage the fuel injection equipment and could be expensive to repair. ENG-1-7