JCB MINI Excavator 8085 Service Repair Manual

Service Manual JCB 8085 Section 1 - General Information Section 2 - Care & Safety Section 3 - Routine Maintenance Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Tracks Section K - Engine Publication No. 9803/9990-1 World Class Customer Support 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. 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 Service Manual - JCB 8085 Section 1 - General Information Section 2 - Care & Safety Section 3 - Routine Maintenance Section A - Attachments Section B - Body & Framework Section C - Electrics Section E - Hydraulics Section F - Transmission Section J - Tracks Section K - Engine Publication No. 9803/9990-2 World Class Customer Support 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. Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Section 1 - Service Manual Notes: 1-0 9803/9990-2 1-0

Section 1 - 1 Contents Page No. Introduction About this Manual ...................................................................................... 1-1 Machine Identification Identifying Your Machine ........................................................................... 1-3 Service Tools Numerical List Section B - Body and Framework ...................................... 1-5 Tool Detail Reference Section B - Body and Framework .......................... 1-6 Numerical List Section C - Electrics ........................................................ 1-10 Tool Detail Reference Section C - Electrics ............................................. 1-11 Numerical List Section E- Hydraulics ...................................................... 1-12 Tool Detail Reference Section E- Hydraulics ........................................... 1-15 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners ..................................... 1-19 Hydraulic Connections ............................................................................. 1-23 Service Consumables Sealing and Retaining Compounds ......................................................... 1-27 Terms and Definitions Colour Coding .......................................................................................... 1-29 1-i 1-i

Section 1 - 1 Contents Page No. 1-ii 1-ii

Section 1 - General Information Introduction About this Manual Machine Model and Serial Number Finally, please remember above all else safety must come first! This manual provides information for the following model(s) in the JCB machine range: Section Numbering JCB 8085 from serial number 1071500. T11-005 Using the Service Manual The manual is compiled in sections, the first three are numbered and contain information as follows: T11-004 1 General Information - includes torque settings and This publication is designed for the benefit of JCB service tools. Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. 2 Care and Safety - includes warnings and cautions pertinent to aspects of workshop procedures etc. These personnel should have a sound knowledge of workshop practice, safety procedures, and general 3 Maintenance - includes service schedules and techniques associated with the maintenance and repair of recommended lubricants for all the machine. hydraulic earthmoving equipment. The remaining sections are alphabetically coded and deal The illustrations in this publication are for guidance only. with Dismantling, Overhaul etc. of specific components, for Where the machines differ, the text and/or the illustration example: will specify. A Attachments General warnings in Section 2 are repeated throughout the B Body and Framework, etc. manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them. Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of Renewal of oil seals, gaskets, etc., and any component each alphabetically coded section. showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be Cross References cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to T1-004_2 prevent excessive loss of hydraulic fluid and ingress of dirt. In this publication, page cross references are made by Where a torque setting is given as a single figure it may be presenting the subject title printed in bold, italic and varied by plus or minus 3%. Torque figures indicated are underlined. It is preceeded by the 'go to' symbol. The for dry threads, hence for lubricated threads may be number of the page upon which the subject begins, is reduced by one third. indicated within the brackets. For example: K Cross References ( T 1-1). The manufacturer's policy is one of continuous improvement. The right to change the specification of the machine without notice is reserved. No responsibility will be accepted for discrepancies which may occur between specifications of the machine and the descriptions contained in this publication. 1-1 9803/9990-1 1-1

Section 1 - General Information Introduction About this Manual Left Side, Right Side In this manual, 'left' A and 'right' B mean your left and right when you are seated correctly in the machine. 731911-3 Fig 1. Cab/Canopy T1-003_2 This manual frequently makes references to the cab. For instance, 'do not operate the machine without a manual in the cab'. It should be noted that these statements also apply to canopy build machines. Cross References T1-004_2 In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It is preceeded by the 'go to' symbol. The number of the page upon which the subject begins, is indicated within the brackets. For example: K Cross References ( T 1-1). 1-2 9803/9990-1 1-2

Section 1 - General Information Machine Identification Identifying Your Machine Machine Identification Identifying Your Machine Machine Identification Plate Typical Product Identification Number (PIN) Your machine has an identification plate A attached to the 12 3 4 right hand side of the kingpost. JCB 08085 L 01071500 A 1 World Manufacturer Identification (3 Digits). JCB = UK Build. 2 Machine Type and Model (5 Digits). 08085 = 8085. 3 Check Letter (1 Digit). The Check Letter is used to verify the authenticity of the machine’s PIN. 4 Machine Serial Number (8 Digits). Each machine has a unique serial number. JCB COMPACT PRODUCTS LIMITED HAREWOOD ESTATE, LEEK ROAD, CHEADLE, STOKE ON TRENT, UNITED KINGDOM, ST10 2JU 817/17768 Fig 1. 1-3 9803/9990-2 1-3

Component Identification Plates Section 1 - General Information Typical Engine Identification Number Machine Identification If the engine is replaced by a new one, the data plate serial Identifying Your Machine number B will be wrong. Either stamp the new number on the plate or stamp out the old one. This will prevent the ROPS, TOPS and FOGS wrong number being quoted when you order replacement parts. !MWARNING ab c d e Modified and wrongly repaired ROPS, TOPS & FOGS LE 50316 J 000001 Y Structures are dangerous. Do not modify the TOPS Structure. Do not attempt to repair the ROPS, TOPS & a Engine Type FOGS Structure. If the ROPS, TOPS & FOGS Structure b Engine Part number has been in an accident, do not use the machine until c Country of Manufacture the structure has been inspected and repaired. This d Engine Serial Number must be done by a qualified person. For assistance, e Year of Manufacture contact your JCB dealer. Failure to take precautions could result in death or injury to the operator. 5-3-1-7_2 A bolt on Falling Object Guard Structure (FOGS) is available which also carries a certified label. This label certifies the cab to a FOGS standard. K Fig 3. ( T 1-4). When a machine is used in an application with the risk of falling objects, the machine must be equipped with an optional FOGS. There are two guard options available depending on the application: – Level 1 (ISO10262). Is intended for protection from small objects for example small rocks, small debris and other small objects found in operations such as highway maintenance, landscaping and other construction site services. – Level 2. Is intended for protection from large objects for example large rocks, large debris and other large objects encountered in operations such as construction and demolition. B Fig 3. Fig 2. T049100 1-4 9803/9990-2 1-4

Section 1 - General Information Service Tools Numerical List Section B - Body and Framework The tools listed in the table are special tools required for Note: Tools other than those listed will be required. It is removal and replacement of Body and Framework parts. expected that such general tools will be available in any These tools are available from JCB Service. well equipped workshop or be available locally from any good tool supplier. Part Description Number Tool Detail Reference 4104/1310 Hand Cleaner K Fig 1. ( T 1-6) K Fig 15. ( T 1-9) 826/01099 Rivet Nut K Fig 15. ( T 1-9) K Fig 15. ( T 1-9) 826/01101 Rivet Nut K Fig 15. ( T 1-9) K Fig 15. ( T 1-9) 826/01102 Rivet Nut K Fig 15. ( T 1-9) K Fig 6. ( T 1-6) 826/01103 Rivet Nut K Fig 4. ( T 1-6) K Fig 12. ( T 1-8) 826/01104 Rivet Nut K Fig 2. ( T 1-6) K Fig 9. ( T 1-7) 826/01105 Rivet Nut K Fig 13. ( T 1-8) K Fig 7. ( T 1-7) 892/00842 Glass Lifter K Fig 11. ( T 1-8) K Fig 14. ( T 1-8) 892/00843 Folding Stand K Fig 3. ( T 1-6) K Fig 5. ( T 1-6) 892/00844 Long Knife K Fig 5. ( T 1-6) K Fig 8. ( T 1-7) 892/00845 Cartridge Gun K Fig 10. ( T 1-7) 892/00846 Glass Extractor (Handles) 892/00847 Nylon Spatula 892/00848 Wire Starter 892/00849 Braided Cutting Wire 926/15500 Rubber Spacer Blocks 992/12300 12V Mobile Oven 992/12400 Static Oven - 2 Cartridge 992/12600 Static Oven - 6 Cartridge 992/12800 Cut-Out Knife 992/12801 \"L\" Blades 1-5 9803-9990-1 1-5

Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework Tool Detail Reference Section B - Body and Framework Fig 1. Fig 2. Cartridge Gun - hand operated - essential for the application Hand Cleaner - special blend for the removal of polyurethane adhesives. of sealants, polyurethane materials etc. JCB part number - 4104/1310 (454g; 1 lb tub) JCB part number - 892/00845 Fig 3. Fig 4. 12V Mobile Oven - 1 cartridge capacity - required to pre-heat Folding Stand for holding glass - essential for preparing adhesive prior to use. It is fitted with a male plug (703/23201) new glass prior to installation. which fits into a female socket (715/04300). JCB part number - 892/00843 JCB part number - 992/12300 Fig 5. Fig 6. 1-6 9803-9990-1 1-6

Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework 240V Static Oven - available with 2 or 6 cartridge capacity - Glass Lifter - minimum 2 off - essential for glass installation, required to pre-heat adhesive prior to use. No plug supplied. 2 required to handle large panes of glass. Ensure suction Note: 110V models available upon request - contact JCB cups are protected from damage during storage. Technical Service. JCB part number - 892/00842 JCB part number: 992/12400 - 2 Cartridge x 240V9 992/12600 - 6 Cartridge x 240V Fig 8. Fig 7. Cut-Out Knife - used to remove broken glass. Wire Starter - used to access braided cutting wire (below) JCB part number - 992/12800 through original polyurethane seal. JCB part number - 892/00848 Fig 10. Fig 9. Glass Extractor (Handles) - used with braided cutting wire 'L' Blades - 25 mm (1 in) cut - replacement blades for cut-out (below) to cut out broken glass. knife (above). JCB part number - 892/00846 JCB part number - 992/12801 (unit quantity = 5 off) 1-7 9803-9990-1 1-7

Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework Fig 11. Fig 12. Braided Cutting Wire - consumable heavy duty cut-out wire Long Knife - used to give extended reach for normally used with the glass extraction tool (above). inaccessible areas. JCB part number - 892/00849 (approx 25 m length) JCB part number - 892/00844 Fig 13. Fig 14. Nylon Spatula - general tool used for smoothing sealants - Rubber Spacer Blocks - used to provide the correct set also used to re-install glass in rubber glazing because metal clearance between glass edge and cab frame. tools will chip the glass edge. JCB part number - 926/15500 (unit quantity = 500 off) JCB part number - 892/00847 1-8 9803-9990-1 1-8

Section 1 - General Information Service Tools Tool Detail Reference Section B - Body and Framework Fig 15. Rivet Nuts 826/01099 M6 x 16mm Rivet Nut 826/01101 M6 x 19mm Rivet Nut 826/01103 M8 x 18mm Rivet Nut 826/01102 M8 x 21mm Rivet Nut 826/01104 M10 x 23mm Rivet Nut 826/01105 M10 x 26mm Rivet Nut Installation Tool Available from: Bollhoff Fastenings Ltd. Midacre The Willenhall Estate Rose Hill Willenhall West Midlands, WV13 2JW 1-9 9803-9990-1 1-9

Section 1 - General Information Service Tools Numerical List Section C - Electrics Numerical List Section C - Electrics The tools listed in the table are special tools required for Note: Tools other than those listed will be required. It is testing electrics. These tools are available from JCB expected that such general tools will be available in any Service. well equipped workshop or be available locally from any good tool supplier. Part Description Number Tool Detail Reference 721/10885 Interconnecting Cable (part of 892/01033) K Fig 17. ( T 1-11) K Fig 16. ( T 1-11) 892/01033 Electronic Service Tool Kit 1-10 9803-9990-1 1-10

Section 1 - General Information Service Tools Tool Detail Reference Section C - Electrics Tool Detail Reference Section C - Electrics 3 CD BE CD BE A JF A HG JF HG 4 A408030 Fig 17. Interconnecting Cable 721/10885 Interconnecting cable, DLA to machine ECU diagnostics socket (part of 892/ 01033 Kit). 1 2 A406130-1 Fig 16. Electronic Service Tool Kit 892/01033 Tool Kit comprises: 1 Data Link Adaptor (DLA), enables data exchange between the machine ECU (Electronic Control Unit) and a laptop PC loaded with the applicable diagnostics software. 2 Interconnecting cable, DLA to laptop PC. Several cables are included to enable compatibility with different PC port types. 3 Interconnecting cable, DLA to machine ECU diagnostics socket. 4 Kit carrying case. 1-11 9803-9990-1 1-11

Section 1 - General Information Service Tools Numerical List Section E- Hydraulics Numerical List Section E- Hydraulics The tools listed in the table are special tools required for Note: Tools other than those listed will be required. It is testing, removing and replacing hydraulics. These tools expected that such general tools will be available in any are available from JCB Service. well equipped workshop or be available locally from any good tool supplier. Part Description Number Tool Detail Reference 1406/0011 Bonded Washer K Fig 23. ( T 1-16) K Fig 23. ( T 1-16) 1406/0018 Bonded Washer K Fig 23. ( T 1-16) K Fig 23. ( T 1-16) 1406/0021 Bonded Washer K Fig 24. ( T 1-16) K Fig 24. ( T 1-16) 1406/0029 Bonded Washer K Fig 24. ( T 1-16) K Fig 24. ( T 1-16) 1604/0003 Adapter K Fig 24. ( T 1-16) K Fig 24. ( T 1-16) 1604/0004 Adapter K Fig 24. ( T 1-16) K Fig 24. ( T 1-16) 1604/0006 Adapter K Fig 21. ( T 1-15) K Fig 26. ( T 1-16) 1606/0003 Adapter K Fig 26. ( T 1-16) K Fig 26. ( T 1-16) 1606/0004 Adapter K Fig 26. ( T 1-16) K Fig 26. ( T 1-16) 1606/0007 Adapter K Fig 26. ( T 1-16) K Fig 20. ( T 1-15) 1606/0008 Adapter K Fig 27. ( T 1-17) K Fig 19. ( T 1-15) 1606/0009 Adapter K Fig 19. ( T 1-15) K Fig 27. ( T 1-17) 1612/0006 Adapter K Fig 27. ( T 1-17) K Fig 27. ( T 1-17) 816/00189 Blanking Cap K Fig 25. ( T 1-16) K Fig 25. ( T 1-16) 816/00190 Blanking Cap K Fig 25. ( T 1-16) K Fig 25. ( T 1-16) 816/00193 Blanking Cap K Fig 25. ( T 1-16) 816/00196 Blanking Cap 816/00197 Blanking Cap 816/00294 Blanking Cap 816/15118 Pressure Test Adapter 816/50043 'T' Adapter 816/55038 Pressure Test 'T' Adapter 816/55040 Pressure Test 'T' Adapter 816/60096 'T' Adapter 892/00047 'T' Adapter 892/00048 'T' Adapter 892/00055 Blanking Plug 892/00056 Blanking Plug 892/00057 Blanking Plug 892/00059 Blanking Plug 892/00060 Blanking Plug 1-12 9803-9990-1 1-12

Part Description Section 1 - General Information Number Service Tools 892/00074 Female Connector Numerical List Section E- Hydraulics 892/00075 Female Connector Tool Detail Reference 892/00077 Female Connector K Fig 28. ( T 1-17) 892/00137 Hose K Fig 28. ( T 1-17) K Fig 28. ( T 1-17) 892/00167 Ram Seal Protection Sleeve K Fig 22. ( T 1-16) K Fig 32. ( T 1-18) 892/00223 Hand Pump K Fig 22. ( T 1-16) K Fig 18. ( T 1-15) 892/00253 Pressure Test Kit K Fig 20. ( T 1-15) K Fig 20. ( T 1-15) 892/00255 Pressure Test Adapter K Fig 20. ( T 1-15) K Fig 20. ( T 1-15) 892/00256 Pressure Test Adapter K Fig 20. ( T 1-15) K Fig 20. ( T 1-15) 892/00257 Pressure Test Adapter K Fig 20. ( T 1-15) K Fig 19. ( T 1-15) 892/00258 Pressure Test Adapter K Fig 19. ( T 1-15) K Fig 19. ( T 1-15) 892/00259 Pressure Test Adapter K Fig 19. ( T 1-15) K Fig 21. ( T 1-15) 892/00260 Pressure Test Adapter K Fig 21. ( T 1-15) K Fig 21. ( T 1-15) 892/00261 Pressure Test Adapter K Fig 21. ( T 1-15) K Fig 21. ( T 1-15) 892/00262 Pressure Test 'T' Adapter K Fig 22. ( T 1-16) K Fig 21. ( T 1-15) 892/00263 Pressure Test 'T' Adapter K Fig 21. ( T 1-15) K Fig 21. ( T 1-15) 892/00264 Pressure Test 'T' Adapter K Fig 22. ( T 1-16) K Fig 22. ( T 1-16) 892/00265 Pressure Test 'T' Adapter K Fig 31. ( T 1-18) K Fig 22. ( T 1-16) 892/00268 Flow Monitoring Unit K Fig 32. ( T 1-18) K Fig 32. ( T 1-18) 892/00269 Sensor Head K Fig 32. ( T 1-18) K Fig 32. ( T 1-18) 892/00270 Load Valve K Fig 32. ( T 1-18) K Fig 32. ( T 1-18) 892/00271 Adapter 892/00272 Adapter 892/00274 Adapter 892/00275 Adapter 892/00276 Adapter 892/00277 Adapter 892/00278 Gauge 892/00279 Gauge 892/00334 Ram Seal Fitting Tool 892/00706 Test Probe 892/01016 Ram Seal Protection Sleeve 892/01017 Ram Seal Protection Sleeve 892/01018 Ram Seal Protection Sleeve 892/01019 Ram Seal Protection Sleeve 892/01020 Ram Seal Protection Sleeve 892/01021 Ram Seal Protection Sleeve 1-13 9803-9990-1 1-13

Part Description Section 1 - General Information Number Service Tools 892/01022 Ram Seal Protection Sleeve Numerical List Section E- Hydraulics 892/01023 Ram Seal Protection Sleeve Tool Detail Reference 892/01024 Ram Seal Protection Sleeve K Fig 32. ( T 1-18) 892/01025 Ram Seal Protection Sleeve K Fig 32. ( T 1-18) K Fig 32. ( T 1-18) 892/01026 Ram Seal Protection Sleeve K Fig 32. ( T 1-18) K Fig 32. ( T 1-18) 992/09300 Spanner K Fig 29. ( T 1-17) K Fig 29. ( T 1-17) 992/09400 Spanner K Fig 29. ( T 1-17) K Fig 29. ( T 1-17) 992/09500 Spanner K Fig 29. ( T 1-17) K Fig 29. ( T 1-17) 992/09600 Spanner K Fig 29. ( T 1-17) 992/09700 Spanner 992/09900 Spanner 992/10000 Spanner The following parts are replacement items for kits and would normally be included in the kit numbers quoted above. Table 1. Replacement items for kit no. 892/00253 Part Description Tool Detail Reference Number K Fig 18. ( T 1-15) 892/00201 Replacement Gauge K Fig 18. ( T 1-15) K Fig 18. ( T 1-15) 892/00202 Replacement Gauge K Fig 18. ( T 1-15) 892/00203 Replacement Gauge 892/00254 Replacement Hose 1-14 9803-9990-1 1-14

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics Tool Detail Reference Section E- Hydraulics 892/00263 5/8 in BSP x 5/8 in F BSP x Test Point 892/00264 3/4 in BSP x 3/4 in F BSP x Test Point 892/00265 1 in M BSP x 1 in F BSP x Test Point Fig 18. Hydraulic Circuit Pressure test Kit Fig 20. Pressure Test Adapters 892/00253 Pressure Test Kit 892/00255 1/4 in BSP x Test Point 892/00201 Replacement gauge 0-20 bar (0-300 lbf/in2) 892/00256 3/8 in BSP x Test Point 892/00202 Replacement gauge 0-40 bar (0-600 lbf/in2) 892/00257 1/2 in BSP x Test Point 892/00203 Replacement gauge 0-400 bar (0-6000 lbf/ 892/00258 5/8 in BSP x Test Point in2) 816/15118 3/4 in BSP x Test Point 892/00254 Replacement Hose 892/00259 1 in BSP x Test Point 892/00260 1,1/4 in BSP x Test Point 892/00261 5/8 in UNF x Test Point Fig 19. Pressure Test `T' Adapters Fig 21. Flow Test Equipment 892/00262 1/4 in BSP x 1/4 in F BSP x Test Point 892/00268 Flow Monitoring Unit 816/55038 3/8 in M BSP x 3/8 in F BSP x Test Point 892/00269 Sensor Head 0 - 100 l/min (0 - 22 UK gal/ 816/55040 1/2 in M BSP x 1/2 in F BSP x Test Point min) 892/00270 Load Valve 1406/0021 Bonded Washer 1-15 9803-9990-1 1-15

1604/0006 Adapter 3/4 in M x 3/4 in M BSP Section 1 - General Information 1612/0006 Adapter 3/4 in F x 3/4 in M BSP 892/00271 Adapter 3/4 in F x 5/8 in M BSP Service Tools 892/00272 Adapter 5/8 in F x 3/4 in M BSP 816/20008 Adapter 3/4 in F x 1/2 in M BSP Tool Detail Reference Section E- Hydraulics 892/00275 Adapter 1/2 in F x 3/4 in M BSP 892/00276 Adapter 3/4 in F x 3/8 in M BSP Fig 24. Male Adapters - BSP x BSP 892/00277 Adapter 3/8 in F x 3/4 in M BSP 1606/0003 3/8 in x 1/4 in 1604/0003 3/8 in x 3/8 in 1606/0004 1/2 in x 1/4 in 1606/0007 1/2 in x 3/8 in 1604/0004 1/2 in x 1/2 in 1606/0008 3/4 in x 3/8 in 1606/0009 3/4 in x 1/2 in 1604/0006 3/4 in x 3/4 in Fig 22. Hand Pump Equipment Fig 25. Female Cone Blanking Plug 892/00223 Hand Pump 892/00055 1/4 in BSP 892/00137 Micro-bore Hose 1/4 in BSP x 5 metres 892/00056 3/8 in BSP 892/00274 Adapter 1/4 in M BSP x 3/8 in M BSP Taper 892/00057 1/2 in BSP 892/00262 1/4 in M BSP x 1/4 in F BSP x Test Point 892/00059 3/4 in BSP 892/00706 Test Probe 892/00060 1 in BSP'T' 892/00278 Gauge 0 - 40 bar (0 - 600 lbf/in2) 892/00279 Gauge 0 - 400 bar (0 - 6000 lbf/in2) Fig 23. Bonded Washers 1406/0011 1/4 in BSP 1406/0018 1/2 in BSP 1406/0021 3/4 in BSP 1406/0029 1.1/4 in BSP Fig 26. Male Cone Blanking Plug 1-16 9803-9990-1 1-16

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics 816/00294 1/4 in BSP Fig 29. Hexagon Spanners for Ram Pistons and End 816/00189 3/8 in BSP Caps 816/00190 1/2 in BSP 816/00197 5/8 in BSP 992/09300 55 mm A/F 816/00196 3/4 in BSP 992/09400 65 mm A/F 816/00193 1 in BSP 992/09500 75 mm A/F 992/09600 85 mm A/F Fig 27. `T' Adapters 992/09700 95 mm A/F 892/00047 3/8 in BSP (A) x 1/4 in BSP (B) 992/09900 115 mm A/F 892/00048 1/2 in BSP (A) x 1/4 in BSP (B) 992/10000 125 mm A/F 816/50043 3/4 in BSP (A) x 1/4 in BSP (B) 816/60096 3/4 in BSP (A) x 3/4 in BSP (B) 7mm 11o Fig 28. Female Connectors 892/00074 3/8 in BSP x 3/8 in BSP 20mm 10mm 892/00075 1/2 in BSP x 1/2 in BSP 892/00077 3/4 in BSP x 3/4 in BSP 5mm R 3mm 110mm 175mm 3o R 1.4mm Fig 30. Piston Seal Assembly Tool 892/01027 1-17 9803-9990-1 1-17

Section 1 - General Information Service Tools Tool Detail Reference Section E- Hydraulics Fig 31. Ram Seal Fitting Tool 892/00334 Fig 32. Ram Seal Protection Sleeves 892/01016 For 25 mm Rod Diameter 892/01017 For 30 mm Rod Diameter 892/01018 For 40 mm Rod Diameter 892/01019 For 50 mm Rod Diameter 892/01020 For 50 mm Rod Diameter (slew ram) 892/01021 For 60 mm Rod Diameter 892/01022 For 60 mm Rod Diameter (slew ram) 892/01023 For 65 mm Rod Diameter 892/01024 For 70 mm Rod Diameter 892/01025 For 75 mm Rod Diameter 892/01026 For 80 mm Rod Diameter 892/00167 For 90 mm Rod Diameter 1-18 9803-9990-1 1-18

Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Torque Settings Introduction Zinc Plated Fasteners and Dacromet Fasteners T11-002 Bolts and Screws Some external fasteners on JCB machines are Use the following torque setting tables only where no manufactured using an improved type of corrosion torque setting is specified in the text. resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on Note: Dacromet fasteners are lubricated as part of the earlier machines. plating process, do not lubricate. The two types of fasteners can be readily identified by Torque settings are given for the following conditions: colour and part number suffix. K Table 1. Fastener Types Condition 1 ( T 1-19). Table 1. Fastener Types – Un-lubricated fasteners – Zinc fasteners Fastener Colour Part No. Suffix – Yellow plated fasteners Type Golden finish 'Z' (e.g. 1315/3712Z) Condition 2 Zinc and Yellow Mottled silver finish 'D' (e.g. 1315/3712D) – Zinc flake (Dacromet) fasteners – Lubricated zinc and yellow plated fasteners Dacromet – Where there is a natural lubrication. For example, Note: As the Dacromet fasteners have a lower torque cast iron components setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener. Verbus Ripp Bolts 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 Fig 1. must not be replaced by bolts of a lesser tensile specification. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the Note: Dacromet bolts, due to their high corrosion required settings. 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. 1-19 9803/9990-1 1-19

Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' 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 Table 3. Torque Settings - Metric Grade 8.8 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric mm mm Nm kgf m lbf ft Nm kgf m lbf ft Thread 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 1-20 9803/9990-1 1-20