JCB Manual - Service and Repair Guide (EN)

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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 JS360 from serial number 1807000 to 1807299. T11-005 The manual is compiled in sections, the first three are numbered and contain information as follows: Using the Service Manual T11-004 This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department. 1 General Information - includes torque settings and service tools.

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 techniques associated with the maintenance and repair of hydraulic earthmoving equipment. 3 Maintenance - includes service schedules and recommended lubricants for all the machine. The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example: The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify. A Attachments B Body and Framework, etc.

General warnings in Section 2 are repeated throughout the 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 each alphabetically coded section. Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course. It is expected that components will be cleaned and lubricated where appropriate, and that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic fluid and ingress of dirt.

Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. 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 1-1 9803-9880-3

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Section 1 - General Information Introduction Identifying Your Machine Identifying Your Machine Machine Identification Plate Typical Product Identification Number (PIN) Your machine has a data plate, located on the outside the cab as shown at A . The machine serial number is inscribed at B which is the baseplate of the rear frame. JCB JS102 C 01474000 1 2 3 4 1 World Manufacturer Code (JCB) 2 Machine Type and Model (JS102 = JS330 Tracked) 3 Randomly Generated Check Letter 4 Machine Serial Number (01474000) Fig 2. Fig 3. 1-3 1-3 9803-9880-3

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Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Torque Settings Zinc Plated Fasteners and Dacromet Fasteners T11-002 Introduction Bolts and Screws 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. 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. The two types of fasteners can be readily identified by colour and part number suffix. K Table 1.

Fastener Types ( T 1-7) . Torque settings are given for the following conditions: Condition 1 Table 1. Fastener Types Un-lubricated fasteners Zinc fasteners Yellow plated fasteners Condition 2 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. Zinc flake (Dacromet) fasteners Lubricated zinc and yellow plated fasteners Where there is a natural lubrication. For example, cast iron components 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. Verbus Ripp Bolts 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. Fig 1. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings. 1-7 1-7 9803-9880-3 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)

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Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Torque Settings Zinc Plated Fasteners and Dacromet Fasteners T11-002 Introduction Bolts and Screws 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. 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. The two types of fasteners can be readily identified by colour and part number suffix. K Table 1.

Fastener Types ( T 1-7) . Torque settings are given for the following conditions: Condition 1 Table 1. Fastener Types Un-lubricated fasteners Zinc fasteners Yellow plated fasteners Condition 2 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. Zinc flake (Dacromet) fasteners Lubricated zinc and yellow plated fasteners Where there is a natural lubrication. For example, cast iron components 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. Verbus Ripp Bolts 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. Fig 1. Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings. 1-7 1-7 9803-9880-3 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)

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