75 - Consumable Products

Contents Page No.

Acronyms Glossary .................................................................................................................................... 75-2

75-00 Consumable Products

75-00-00 General ............................................................................................................................. 75-3
75-00-03 Parts List ........................................................................................................................ 75-12
75-03 Oil
75-03-00 General ........................................................................................................................... 75-15
75-03-03 Engine ............................................................................................................................ 75-16
75-03-21 Refrigerant ...................................................................................................................... 75-18
75-06 Grease
75-06-00 General ........................................................................................................................... 75-21
75-09 Fluids
75-09-00 General ........................................................................................................................... 75-25
75-09-03 Antifreeze ....................................................................................................................... 75-26
75-10 Locking Fluids
75-10-00 General ........................................................................................................................... 75-29
75-14 Solvents and Primers
75-14-00 General ........................................................................................................................... 75-33
75-15 Adhesive
75-15-00 General ........................................................................................................................... 75-37
75-16 Sealant
75-16-00 General ........................................................................................................................... 75-43
75-18 Fuel
75-18-00 General ........................................................................................................................... 75-49

9813/7000-2
2018-01-17
Acronyms Glossary

2WD Two Wheel Drive

2WS Two Wheel Steer
4WD Four Wheel Drive
4WS Four Wheel Steer
DEF Diesel Exhaust Fluid
LSD Limited Slip Differential
PTFE Polytetrafluoroethylene
SAE Society of Automotive Engineers

9813/7000-2
2018-01-17
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Contents Page No.

75-00-00 General ............................................................................................................................. 75-3

75-00-03 Parts List ........................................................................................................................ 75-12

75 - 1 9813/7000-2 75 - 1
Notes:

75 - 2 9813/7000-2 75 - 2
 75 - Consumable Products
00 - Consumable Products
00 - General

00 - General Introduction
Introduction ...................................................... 75-3 JCB recommend that you use the JCB lubricants
Health and Safety ........................................... 75-4 shown as they have been verified by JCB for use
Technical Data ................................................. 75-6 on JCB machines. However, you could use other
lubricants that are equivalent to the JCB standards
and quality or offer the same machine component
protection.

Before you start work, make sure that:

• All safety precautions are observed in

accordance with the information contained
within the relevant support documentation.
• The consumables are used in accordance with
the manufacturer's recommendations.
• The consumables shown are available in the
correct quantity.

Consumables other than those listed may be

required. It is expected that general consumables will
be available in any well equipped workshop or be
available locally.

75 - 3 9813/7000-2 75 - 3
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00 - General

Health and Safety

Oil Waste Disposal

Oil is toxic. If you swallow any oil, do not induce CAUTION It is illegal to pollute drains, sewers
vomiting, seek medical advice. Used engine oil or the ground. Clean up all spilt fluids and/or
contains harmful contaminants which can cause skin lubricants.
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves Used fluids and/or lubricants, filters and
to prevent skin contact. Wash skin contaminated with contaminated materials must be disposed of in
oil thoroughly in warm soapy water. Do not use petrol, accordance with local regulations. Use authorised
diesel fuel or paraffin to clean your skin. waste disposal sites.
Fluid Under Pressure CAUTION Damaged or spent batteries and any
residue from fires or spillage must be put in a
Fine jets of fluid at high pressure can penetrate the suitable closed receptacle and must be disposed
skin. Keep face and hands well clear of fluid under of in accordance with local environmental waste
pressure and wear personal protective equipment. regulations.
Hold a piece of cardboard close to suspected
leaks and then examine the cardboard for signs of
fluid. If fluid penetrates your skin, get medical help All waste products must be disposed of in
immediately. accordance with all the relevant regulations.
Fuel The collection and disposal of used oil must be in
Fuel is flammable, keep naked flames away from the accordance with any local regulations. Never pour
fuel system. Stop the engine immediately if a fuel used engine oil into sewers, drains or on the ground.
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the Handling
engine running. Completely wipe off any spilt fuel
CAUTION The temperature of the hydraulic oil
which could cause a fire. There could be a fire and
will be high soon after stopping the machine. Wait
injury if you do not follow these precautions.
until it cools before beginning maintenance.
Hygiene
New Oil
JCB lubricants are not a health risk when used
correctly for their intended purposes. There are no special precautions needed for the
handling or use of new oil, beside the normal care
However, excessive or prolonged skin contact can and hygiene practices.
remove the natural fats from your skin, causing
dryness and irritation. Used Oil
Low viscosity oils are more likely to do this, so take Used engine crankcase lubricants contain harmful
special care when handling used oils, which might be contaminants.
diluted with fuel contamination.
Here are precautions to protect your health when
Whenever you are handling oil products you must handling used engine oil:
maintain good standards of care and personal and
plant hygiene. For details of these precautions we • Avoid prolonged, excessive or repeated skin
advise you to read the relevant publications issued contact with used oil
by your local health authority, plus the following. • Apply a barrier cream to the skin before
handling used oil. Note the following when
Storage removing engine oil from skin:
• Wash your skin thoroughly with soap and
Always keep lubricants out of the reach of children. water
• Using a nail brush will help
Never store lubricants in open or unlabelled • Use special hand cleansers to help clean
containers. dirty hands
• Never use petrol, diesel fuel, or paraffin for
washing
• Avoid skin contact with oil soaked clothing
• Don't keep oily rags in pockets
• Wash dirty clothing before re-use

75 - 4 9813/7000-2 75 - 4
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00 - General

• Throw away oil-soaked shoes Battery

Warning Symbols
The following warning symbols may be found on the
battery.

Figure 1903.
A B C D E F

A Keep away from children B Shield eyes

C No smoking, no naked flames, no sparks D Explosive gas
E Battery acid F Note operating instructions

First Aid - Oil Swallowing

Eyes Do not induce vomiting. Drink large quantities of

water or milk. Then drink milk of magnesia, beaten
In the case of eye contact, flush with water for 15min. egg or vegetable oil. Get medical help.
If irritation persists, get medical attention.
Skin
Swallowing
Flush with water, remove affected clothing. Cover
If oil is swallowed do not induce vomiting. Get burns with a sterile dressing then get medical help.
medical advice.
First Aid - DEF (if applicable)
Skin
Do not drink or inhale DEF (Diesel Exhaust Fluid).
In the case of excessive skin contact, wash with soap If large quantities of DEF have been swallowed
and water. a doctor should be called immediately. Do not
induce vomiting unless directed to do so by medical
Spillage personnel. Never give anything by mouth to an
unconscious person.
Absorb with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a Avoid prolonged or repeated skin contact. After
chemical disposal area. contact with skin wash thoroughly with plenty of soap
and water. If irritation develops seek medical advice.
Fires
Avoid contact with eyes, skin and clothing. Wear
WARNING Do not use water to put out an oil fire. chemical resistant gloves, overalls and safety
This will only spread it because oil floats on water. goggles complying with an approved standard. If
Extinguish oil and lubricant fires with carbon in contact with eyes, rinse immediately with plenty
dioxide, dry chemical or foam. of clean water. If irritation occurs seek medical
attention. Always wash hands and arms thoroughly
after handling before eating, drinking, smoking or
First Aid - Electrolyte using the lavatory.

Eyes
In the case of eye contact, flush with water for 15min.
always get medical attention.

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Technical Data

For: 3CX [T2/T3], 4CX [T2/T3], UK Tier 2/3 Do not weld near the affected area during the
..................................................... Page 75-6 drying period. Take the same precautions as for
For: 5CX [T2/T3] ......................... Page 75-8 oil to keep Waxoyl off your skin. Do not breathe
For: 3CX [T2/T3], Brazil Tier 2/3, India Tier the fumes. Apply in a well-ventilated area.
2/3 ............................................... Page 75-9
JCB recommend that you use the JCB lubricants
(For: 3CX [T2/T3], 4CX [T2/T3], UK Tier shown as they have been verified by JCB for use
on JCB machines. However, you could use other
2/3) lubricants that are equivalent to the JCB standards
CAUTION Waxoyl contains turpentine substitute and quality or offer the same machine component
which is flammable. Keep flames away when protection.
applying Waxoyl. Waxoyl can take a few weeks
to dry completely. Keep flames away during the No warranty liability will be accepted for engine
drying period. failures where unacceptable fuel grades (or their
equivalent) have been used at any stage.

Table 598.
Item Capacity Fluid/Lubricant JCB Part
Container Specification
Number
Size
(1)

Fuel tank 160L Diesel oil - -

Engine (oil)
(2)
Minimum JCB engine oil EP 15W/40 -10°C 4001/1805 20L API CH-4/SJ,
12L Maxi- (14.0°F) to 50°C (121.9°F) ACEA E5, E3,
mum 15L JCB cold climate engine oil EP 4001/2705 20L B3, A3
5W/40 -20°C (-4.0°F) to 50°C
(121.9°F)
JCB cold climate engine oil FE 4001/3305 20L
5W30 -30°C (-22.0°F) to -40°C
(-39.9°F) certain markets only -
consult your JCB dealer
Engine (coolant)
(3)
20.5L Wet JCB antifreeze HP coolant/ water 4006/1120 20L ASTM D3306,
21.5L Dry ASTM D4985,
ASTM D6210,
SAE (Soci-
ety of Auto-
motive Engi-
neers) J1034,
BS6580
(1992),
AFNOR NF
R15- 601
Syncro shut- 14.4L Dry JCB extreme performance EP
tle (2WD (Two
Wheel Drive))
(4)

10L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)
Syncro shut- 15.4L Dry JCB extreme performance EP
tle (4WD (Four
Wheel Drive))
(3)

11L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
11L Wet SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)

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00 - General

Item Capacity Fluid/Lubricant JCB Part Container Specification

Number Size
(1)

Powershift 6 16L Dry JCB extreme performance EP

speed
(3)

11.5L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)
Powershift 4 15.5L Dry JCB extreme performance EP
speed
(3)

11L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)
Front axle (4WD) JCB gear oil HP90 (without LSD 4000/0305 20L
(Limited Slip Differential))
Housing 2WS 13L JCB gear oil HP plus (with LSD) 4000/2205 20L
(Two Wheel
Steer)
Housing (4WS 18L JCB gear oil LS plus (with LSD) 4000/3905 20L
(Four Wheel
Steer))
(5)

Hubs (x2) 2L JCB gear oil HP90 4000/0305 20L

Rear axle (4WS) JCB gear oil HP plus 4000/2205 20L
Housing
(6)
16.5L JCB gear oil LS plus (with LSD) 4000/3905 20L
Hubs (x2) 1.9L JCB gear oil HP90 4000/0305 20L
Rear axle (2WS) 21L JCB gear oil HP90 (without LSD) 4000/0305 20L
JCB gear oil HP plus (with LSD) 4000/2205 20L
Brake system - Uses hydraulic system oil - -
Hydraulic system 130L JCB hydraulic fluid HP46 above 4002/0805 20L
(gear pump ma- 38°C (100.3°F)
chines)
(7)
JCB hydraulic fluid HP32 below 4002/1025 20L
38°C (100.3°F)
Hydraulic system 130L JCB Optimum Performance hy- 4002/2005 20L
(variable pump draulic fluid 46
machines)
Grease points - JCB special HP grease 4003/2017 0.4kg x24
- JCB special MPL-EP grease
(8)
4003/1501 0.4kg x24
Extending dipper - JCB waxoyl 4004/0502 5L

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00 - General

Item Capacity Fluid/Lubricant JCB Part Container Specification

Number Size
(1)

Electrical connec- - As a corrosion and moisture in- - -

tions hibitor all exposed connections
should be coated liberally with pe-
troleum jelly
Power sideshift - JCB chain lubricant 4004/0237A 0.3L
cable
(1) For information about the different container sizes that are available (and their part numbers), contact your
JCB dealer.
(2) Caution - Do not use ordinary engine oil.
(3) It is recommended that the cooling system be filled at a maximum rate of 10 litres per minute. If the fill rate
is any higher than this there is a possibility of air becoming trapped in the system.
(4) The figure quoted is total system capacity. Use the minimum and maximum marks on the dipstick when
filling the system.
(5) 4WS axles with limited slip differential must use JCB Special Gear Oil Plus.
(6) Must be used with oil immersed brakes and LSD (Limited Slip Differentials).
(7) The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch
level indicator on hydraulic tank.
(8) JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing
must be carried out more frequently.

(For: 5CX [T2/T3]) JCB recommend that you use the JCB lubricants
shown as they have been verified by JCB for use
CAUTION Waxoyl contains turpentine substitute on JCB machines. However, you could use other
which is flammable. Keep flames away when lubricants that are equivalent to the JCB standards
applying Waxoyl. Waxoyl can take a few weeks and quality or offer the same machine component
to dry completely. Keep flames away during the protection.
drying period.
No warranty liability will be accepted for engine
Do not weld near the affected area during the
failures where unacceptable fuel grades (or their
drying period. Take the same precautions as for
equivalent) have been used at any stage.
oil to keep Waxoyl off your skin. Do not breathe
the fumes. Apply in a well-ventilated area.

Table 599.
Item Capacity Fluid/Lubricant JCB Part Number Container Size
(1)

Fuel tank 160L Diesel oil - -

Engine (oil)
(2)
Minimum 12L, Maxi- JCB Engine Oil 4001/1805 20L
mum 15L EP 15W40 -10°C
(14.0°F) to 50°C
(121.9°F)
JCB Engine Oil EP 4001/2705 20L
5W40 -20°C (-4.0°F)
to 50°C (121.9°F)
JCB Engine Oil 4001/3305 20L
FE 5W30 -30°C
(-22.0°F) to -40°C
(-39.9°F) certain
markets only - con-
sult your JCB deal-
er.
Engine (coolant)
(3)
17.5L Wet JCB Antifreeze HP 4006/1120 20L
17.5L Dry Coolant/Water
Transmission 6 16L Dry JCB Extreme Per-
speed formance EP
11.5L Wet 10W -32°C (-25.6°F) 4000/2505 20L
to 40°C (103.9°F)

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00 - General

Item Capacity Fluid/Lubricant JCB Part Number Container Size

(1)

SAE30 -5°C 4000/2605 20L

(23.0°F) to 46°C
(114.7°F)
Front axle (4WD) 18L JCB Gear Oil HP90 4000/0305 20L
(without LSD)
Housing (4WS)
(4)
JCB Gear Oil LS 4000/3905 20L
Plus (with LSD)
Hubs (x2) 2L JCB Gear Oil HP90 4000/0305 20L
Rear axle (4WS) 16.5L JCB Gear Oil HP 4000/2205 20L
Plus
Housing
(5)
JCB Gear Oil LS 4000/3905 20L
Plus (with LSD)
Hubs (x2) 1.9L JCB Gear Oil HP90 4000/0305 20L
Brake system - Uses Hydraulic sys- -
tem Oil
Hydraulic system 130L JCB Hydraulic Flu- 4002/0805 20L
(manual and easy id HP46 Above 38°C
control)
(6)
(100.3°F)
JCB Hydraulic Flu- 4002/1025 20L
id HP46 Below 38°C
(100.3°F)
Hydraulic system 130L JCB Optimum Per- 4002/2005 20L
(advanced easy formance Hydraulic
control) Fluid
Grease points - JCB Special HP 4003/2017 0.4kg
Grease
- JCB Special MPL- 4003/1501 0.4kg
EP Grease
(7)

Extending dipper - JCB Waxoyl 4004/0502 5L

Electrical connec- - As a corrosion and - -
tions moisture inhibitor
all exposed con-
nections should be
coated liberally with
petroleum jelly.
(1) For information about the different container sizes that are available (and their part numbers), contact your
JCB dealer.
(2) Caution - Do not use ordinary Engine Oil.
(3) It is recommended that the cooling system be filled at a maximum rate of 10 litres per minute. If the fill rate
is any higher than this there is a possibility of air becoming trapped in the system.
(4) 4WS axles with limited slip differential must use JCB Special Gear Oil Plus.
(5) Must be used with oil immersed brakes and LSD (Limited Slip Differentials).
(6) The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch
level indicator on hydraulic tank.
(7) JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing
must be carried out more frequently.

Do not weld near the affected area during the

(For: 3CX [T2/T3], Brazil Tier 2/3, India Tier drying period. Take the same precautions as for
2/3) oil to keep Waxoyl off your skin. Do not breathe
the fumes. Apply in a well-ventilated area.
CAUTION Waxoyl contains turpentine substitute
which is flammable. Keep flames away when JCB recommend that you use the JCB lubricants
applying Waxoyl. Waxoyl can take a few weeks shown as they have been verified by JCB for use
to dry completely. Keep flames away during the on JCB machines. However, you could use other
drying period. lubricants that are equivalent to the JCB standards

75 - 9 9813/7000-2 75 - 9
 75 - Consumable Products
00 - Consumable Products
00 - General

and quality or offer the same machine component No warranty liability will be accepted for engine
protection. failures where unacceptable fuel grades (or their
equivalent) have been used at any stage.

Table 600.
Item Capacity Fluid/Lubricant JCB Part Container Specification
Number Size
(1)

Fuel tank 127L Diesel oil - -

Engine (oil)
(2)
Minimum JCB engine oil EP 5W/40 -30°C 4001/2705 20L API CH-4/
12L Maxi- (-22.0°F) to 46°C (114.7°F) CG-4,
mum 15L CF-4,CF,SJ.ACEA,
E2, B3, A3
JCB engine oil EP 15W/40 -15°C 4001/1805 API CH-4/SJ,
(5.0°F) to 46°C (114.7°F) ACEA E5, E3,
B3, A3
Engine (coolant)
(3)
20.5L Wet JCB antifreeze HP coolant/ water 4006/1120 20L ASTM D3306,
21.5L Dry ASTM D4985,
ASTM D6210,
SAE J1034,
BS6580
(1992),
AFNOR NF
R15- 601
Syncro shuttle 14.4L Dry JCB extreme performance EP
(2WD)
(4)

10L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)
Syncro shuttle 15.4L Dry JCB extreme performance EP
(4WD)
(3)

11L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
11L Wet SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)
Powershift 6 16L Dry JCB extreme performance EP
speed
(3)

11.5L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)
Powershift 4 15.5L Dry JCB extreme performance EP
speed
(3)

11L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)
Front axle (4WD) JCB gear oil HP90 (without LSD) 4000/0305 20L
Housing 2WS 13L JCB gear oil HP plus (with LSD) 4000/2205 20L
Hubs (x2) 2L JCB gear oil HP90 4000/0305 20L
Rear axle (2WS) 21L JCB gear oil HP90 (without LSD) 4000/0305 20L
JCB gear oil HP plus (with LSD) 4000/2205 20L
Housing
(6)
16.5L JCB gear oil LS plus (with LSD) 4000/3905 20L
Hubs (x2) 1.9L JCB gear oil HP90 4000/0305 20L
Brake system 1L JCB Hydraulic Fluid HP15 4002/0503 1L

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00 - General

Item Capacity Fluid/Lubricant JCB Part Container Specification

Number Size
(1)

Hydraulic system 130L JCB hydraulic fluid HP46 above 4002/0805 20L
(gear pump ma- 38°C (100.3°F)
chines)
(7)
JCB hydraulic fluid HP32 below 4002/1025 20L
38°C (100.3°F)
Hydraulic system 130L JCB optimum performance hy- 4002/2005 20L
(variable pump draulic fluid
machines)
Grease points - JCB special HP grease 4003/2017 0.4kg
- JCB special MPL-EP grease
(8)
4003/1501 0.4kg
Extending dipper - JCB waxoyl 4004/0502 5L
Electrical connec- - As a corrosion and moisture in- - -
tions hibitor all exposed connections
should be coated liberally with pe-
troleum jelly
(1) For information about the different container sizes that are available (and their part numbers), contact your
JCB dealer.
(2) Caution - Do not use ordinary engine oil.
(3) It is recommended that the cooling system be filled at a maximum rate of 10 litres per minute. If the fill rate
is any higher than this there is a possibility of air becoming trapped in the system.
(4) The figure quoted is total system capacity. Use the minimum and maximum marks on the dipstick when
filling the system.
(6) Must be used with oil immersed brakes and LSD (Limited Slip Differentials).
(7) The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch
level indicator on hydraulic tank.
(8) JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing
must be carried out more frequently.

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03 - Parts List

03 - Parts List Introduction

Consumables
Description Part No. Size
Antifreeze HP/Coolant ASTM D6210 Concentrate 4006/1101 5L
4006/1120 20L
4006/1103 200L
Black Polyurethane Sealant 4102/2310 0.31L
Black Primer/Activator 4104/2304 0.1L
Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4L
Clear Silicone Sealant 4102/0901 0.31L
EP Hammer Grease 4003/2107 0.4kg
4003/2106 12.5kg
Extreme Performance Moly Grease 4003/1327 0.4kg
4003/1326 12.5kg
Glass Replacement Kit 993/55701 -
Hand Cleaner 4104/1310 -
JCB Activator 4104/0251 0.2L
4104/0253 1L
JCB Autogrease 4003/2305 0.5kg
JCB Gear Oil HP 4000/0505 20L
4000/0503 200L
JCB Glass Cleaner 4006/3175 0.75L
JCB High Strength Threadlocker 4102/0551 0.05L
JCB Hydraulic Fluid HP 46 4002/0801 5L
4002/0805 20L
4002/0803 200L
JCB Liquid Maintenance 993/99166 0.4L
JCB Multi-Gasket 4102/1212 0.05L
JCB Threadlocker and Sealer (High Strength) 4101/0550 0.01L
4101/0552 0.2L
JCB Threadlocker and Sealer (Medium Strength) 4101/0250 0.01L
4101/0251 0.05L
JCB Threadseal 4102/1951 0.05L
JCB Transmission Fluid EP SAE 30 4000/2601 5L
4000/2605 20L
4000/2603 200L
Polyurethane Adhesive 4103/2110 0.31L
Special HP Grease 4003/2017 0.4kg
4003/2006 12.5kg
4003/2005 50kg
Special Hammer Grease 4003/1119 0.4kg
Special MPL-EP Grease 4003/1501 0.4kg
4003/1506 12.5kg
4003/1510 50kg
Special Slew Pinion Grease 4003/1619 0.4kg
Special Slide Grease 4003/1115 0.4kg
Surface Cleaning Fluid 4103/1204 1L
Threaded Insert (M10 x 23mm) 826/01104 -
Threaded Insert (M10 x 26mm) 826/01105A -

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03 - Parts List

Description Part No. Size

Threaded Insert (M6 x 16mm) 826/01099 -
Threaded Insert (M6 x 19mm) 826/01101 -
Threaded Insert (M8 x 18mm) 826/01102 -
Threaded Insert (M8 x 21mm) 826/01103 -
Waxoyl 4004/0501A 0.4L
4004/0502 5L
4004/0505 200L
Wiring Splice (0.5-1.5mm Red, contains 50 off) 892/00351 -
Wiring Splice (1.5-2.5mm Blue, contains 50 off) 892/00352 -
Wiring Splice (3-6mm Yellow, contains 50 off) 892/00353 -

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03 - Oil

03 - Oil

Contents Page No.

75-03-00 General ........................................................................................................................... 75-15

75-03-03 Engine ............................................................................................................................ 75-16
75-03-21 Refrigerant ...................................................................................................................... 75-18

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03 - Oil
00 - General

00 - General

Introduction

New Oil
There are no special precautions needed for the
handling or use of new oil, besides the normal
health and safety practices mentioned in the relevant
section of this service manual.

Used Oil
Used engine crankcase lubricants contain harmful
contaminants. Here are precautions to protect your
health when handling used engine oil:

1. Avoid prolonged, excessive or repeated skin

contact with used oil.
2. Apply a barrier cream to the skin before handling
used oil.
3. Note the following when removing engine oil from
skin:
3.1. Wash your skin thoroughly with soap and
water.
3.2. Using a nail brush will help.
3.3. Use special hand cleansers to help clean
dirty hands.
3.4. Never use petrol, diesel fuel, or paraffin for
washing.
4. Avoid skin contact with oil soaked clothing.
5. Don't keep oily rags in pockets.
6. Wash dirty clothing before re-use.
7. Throw away oil-soaked shoes.

First Aid
EYES - In the case of eye contact, flush with water for
15 minutes. If irritation persists, get medical attention.

SWALLOWING - If oil is swallowed do not induce

vomiting. Get medical advice.

SKIN - In the case of excessive skin contact, wash

with soap and water.

SPILLAGE - Absorb on sand or a locally approved

brand of absorbent granules. Scrape up and remove
to a chemical disposal area.

FIRES - Extinguish with carbon dioxide, dry chemical

or foam. Firefighters should use self-contained
breathing apparatus.

75 - 15 9813/7000-2 75 - 15
 75 - Consumable Products
03 - Oil
03 - Engine

03 - Engine Introduction
Introduction .................................................... 75-16 New engines DO NOT require a running-in period.
Technical Data ............................................... 75-17 The engine/machine should be used in a normal
work cycle immediately, glazing of the piston cylinder
bores, resulting in excessive oil consumption, could
occur if the engine is gently run-in. Under no
circumstances should the engine be allowed to idle
for extended periods; (e.g. warming up without load).

The choice of lubricant viscosity should be made

based on the lowest ambient temperature at which
the machine will be started and the maximum
ambient temperature at which it will operate.

The technical data section provides guidance as to

the temperature range that can be accommodated
by standard oil viscosities and can be used to select
an appropriate grade.

When selecting the oil viscosity grade, make

sure that the oil conforms with or exceeds the
recommended specification.

75 - 16 9813/7000-2 75 - 16
 75 - Consumable Products
03 - Oil
03 - Engine

Technical Data

Table 601.
Engine Code Oil API Specifica- Viscosity Minimum Maximum
tion Temperature°C (°F) Temperature°C (°F)
SA, SB, SC, SK, CF/ CH-4 SAE 5W30 -30°C (-22.0°F) 30°C (86.0°F)
SG, SD, SE, SF, CH-4 SAE 15W40 -5°C (23.0°F) 50°C (121.9°F)
DA, DB, DC, DE, CH-4 SAE 10W40 -15°C (5.0°F) 46°C (114.7°F)
DG, DD, DK, DF,
EC, EE, EF, EK CH-4 SAE 5W40 -30°C (-22.0°F) 46°C (114.7°F)

Table 602.
Engine Code Oil API Specifica- Viscosity Minimum Maximum
tion Temperature°C (°F) Temperature°C (°F)
SL, SH, DH, DM CH-4 SAE 5W40 -30°C (-22.0°F) 46°C (114.7°F)
CJ-4 SAE 5W40 -30°C (-22.0°F) 46°C (114.7°F)
CH-4 SAE 15W40 -5°C (23.0°F) 50°C (121.9°F)

Table 603.
Engine Code Oil API Specifica- Viscosity Minimum Maximum
tion Temperature°C (°F) Temperature°C (°F)
SJ, DJ, FL CJ-4 SAE 5W40 -30°C (-22.0°F) 46°C (114.7°F)
CJ-4 SAE 5W30 -30°C (-22.0°F) 30°C (86.0°F)
CJ-4 SAE 10W30 -15°C (5.0°F) 46°C (114.7°F)

Table 604. Capacity

Engine Code Minimum Maximum
SA, SB, SC, SK, SG, SD, SE, SF, 11.5L 14L
DA, DB, DC, DE, DG, DD, DK, DF,
SL, SH, DH, SJ, DJ, DM
EC, EE, EF, EK 20L 24L
FL 12.3L 14.5L

For information on how to identify the correct engine

code. Refer to Operator Station, Identification Label,
Engine (PIL 06-63-06).

75 - 17 9813/7000-2 75 - 17
 75 - Consumable Products
03 - Oil
21 - Refrigerant

21 - Refrigerant Introduction
Introduction .................................................... 75-18 Refrigerants are the basic ingredient of all air
Health and Safety .......................................... 75-19 conditioning systems and are used to transfer the
heat energy around the system. Refrigerant type
R134a is used in the air conditioning system. It's
full chemical name is: 1, 1, 1, 2 - Tetrafluoroethane
(CH²FCF²).

R134a is a HFC (Hydrofluorocarbon) and is non-

toxic, non-flammable and non-explosive at normal
atmospheric temperature and pressure. It can be
flammable under certain pressure and air mixtures.

Due to environmental concerns, the use of ozone

depleting chlorofluorocarbons (CFCs) in the air
conditioning systems is being gradually phased
out. The R-12 refrigerant used in some systems
contains CFCs. Air conditioning systems using
R-134a refrigerant are not compatible with systems
using R-12 refrigerant. No attempt should be made
to charge R-134a systems with R- 12 refrigerant.

Important: Refer to the safety procedures within the

Air conditioning section before handling refrigerants.

Good installation practice is required to avoid

the release of refrigerant into the atmosphere.
Refrigerant R134a contains no chlorine and has an
Ozone Depleting Potential (ODP) of zero, and a
Global Warming Potential (GWP) of 0.1.

PAG Type Refrigerant Oil

The system requires a PAG type refrigerant oil to
lubricate the compressor. The oil mixes with the
refrigerant and is carried around the system.

It is important that the recommended grade of

refrigerant oil is used. Mineral oil is not suitable for
R134a refrigerant systems. Do not mix oil types.

The compressor is supplied with an oil charge, but

additional oil will be required when the receiver drier
is replaced. The oil is added to the compressor
through the oil filling plug before the evacuation
procedure is started.

Only use fresh, unused oil. Oil that has been exposed
to the air will have absorbed water.

75 - 18 9813/7000-2 75 - 18
 75 - Consumable Products
03 - Oil
21 - Refrigerant

Health and Safety

CAUTION Polyalkylene Glycol (PAG) type oil is
an irritant. It can cause skin irritation. Breathing
PAG vapour can cause irritation of the eyes,
nose and lungs. Prolonged inhalation can cause
drowsiness.
WARNING Polyalkylene Glycol (PAG) type oil
vapour is extremely flammable. Do not smoke
or eat near PAG contaminated material. Exercise
caution when working around hot and moving
engine parts.

75 - 19 9813/7000-2 75 - 19
 75 - Consumable Products
06 - Grease

06 - Grease

Contents Page No.

75-06-00 General ........................................................................................................................... 75-21

75 - 20 9813/7000-2 75 - 20
 75 - Consumable Products
06 - Grease
00 - General

00 - General Consumable: JCB Autogrease

6. JCB EP Hammer Grease
Introduction Consumable: EP Hammer Grease
Special Tools 7. JCB Special Hammer Grease
Description Part No. Qty.
Consumable: Special Hammer Grease
Grease Gun 892/00913 1
Attachment 8. JCB Special Slew Pinion Grease
Grease Gun 992/11300 1
Consumable: Special Slew Pinion Grease
Consumables
Description Part No. Size Greasing Procedure
EP Hammer Grease 4003/2107 0.4kg 1. Make the machine safe.
4003/2106 12.5kg
Extreme Performance 4003/1327 0.4kg 2. If necessary, install any maintenance or
Moly Grease articulation struts.
4003/1326 12.5kg
JCB Autogrease 4003/2305 0.5kg 3. Make a note of the following:
Special HP Grease 4003/2017 0.4kg 3.1. The machine must always be greased after
4003/2006 12.5kg pressure washing or steam cleaning.
4003/2005 50kg
3.2. Greasing must be done with a grease gun.
Special Hammer 4003/1119 0.4kg Normally, two strokes of the gun should be
Grease sufficient.
Special MPL-EP 4003/1501 0.4kg
Special Tool: Grease Gun (Qty.: 1)
Grease 4003/1506 12.5kg Special Tool: Grease Gun Attachment (Qty.:
4003/1510 50kg 1)
Special Slew Pinion 4003/1619 0.4kg 3.3. Stop greasing when fresh grease appears
Grease at the joint.
Special Slide Grease 4003/1115 0.4kg
3.4. Use only the recommended type of grease.
There are various greasing points on the machine. 3.5. Do not mix different types of grease, keep
You must grease the machine regularly to keep them separate.
it working efficiently. Regular greasing will also
lengthen the machine's working life. You must grease 4. Count off the grease points as you grease each
the machine as stated in the maintenance schedule. one.
Refer to: PIL 78-24-06.
5. Install the dust caps after greasing (if installed).
JCB grease is manufactured to provide significant
load protection for your machine. It is recommended JCB Special HP Grease
to use only JCB grease on your machine because
they are specifically designed for the particular JCB Special HP grease is a premium quality,
application. The list of JCB greases comprises: extreme pressure grease. It is recommended
for use in arduous operating conditions, such
1. JCB Special HP Grease as high temperatures, excessive loading and
Consumable: Special HP Grease extensive exposure to water. The sophisticated
additive package combines with excellent adhesive
2. JCB Special MPL-EP Grease properties to give high performance protection to
your machine.
Consumable: Special MPL-EP Grease
Table 605. JCB Special HP Grease Properties
3. JCB Extreme Performance Moly Grease
Description Data
Consumable: Extreme Performance Moly
Grease Colour Blue
Soap type Lithium complex
4. JCB Special Slide Grease Drop point 245°C (472.7°F)
Consumable: Special Slide Grease Working temperature -20–150°C (-4.0–
range 301.8°F)
5. JCB Autogrease

75 - 21 9813/7000-2 75 - 21
 75 - Consumable Products
06 - Grease
00 - General

JCB Special MPL-EP Grease JCB Autogrease

JCB Special MPL-EP grease is a true multipurpose JCB Autogrease is for use with the automatic
grease. It is recommended for a wide range of greasing system. It is a mineral oil based paste.
lubricating applications, such as pivot pins and wheel It contains an aluminium complex soap and solid
bearings, where excellent anti wear and anti rust lubricants. It is suitable for use under water or in
performance is required. Its EP additive makes it high ambient temperatures. The specially designed
particularly suitable for the shock load and vibrating cartridges screw into the automatic greasing system
conditions found on machines. installed on the machine.

Table 606. JCB Special The clear cartridge allows the operator to easily
MPL-EP Grease Properties monitor the grease usage from inside of the operator
station.
Description Data
Colour Brown Table 609. JCB Autogrease
Soap type Lithium Description Data
Drop point 180°C (355.7°F) Colour Black
Working temperature -20–130°C (-4.0– Soap type Aluminium complex, sol-
range 265.8°F) id lubricants
Drop point 260°C (499.6°F)
JCB Extreme Performance Moly Grease
Working temperature -20–110°C (-4.0–
JCB Extreme Performance Moly grease is an range 229.8°F)
advanced performance, multipurpose grease. It is
recommended for heavily loaded bearing surfaces JCB EP Hammer Grease
and in particular where limited or oscillating
motion causes fretting. The addition of molybdenum JCB EP Hammer grease is a unique formulation
disulphide provides extra protection against scoring aluminium complex grease for use where extremes
and wear. This grease is ideal for automotive, of pressure and temperature are likely to be
industrial, agricultural and earthmoving equipment. encountered. It is suitable for the hammer
applications where resistance to water washing and
Table 607. JCB Extreme migration may be critical.
Performance Moly Grease Properties
Table 610. JCB EP Hammer Grease
Description Data
Colour Grey Black Description Data
Soap type Lithium Colour Black
Drop point 185°C (364.7°F) Soap type Aluminium complex
Working temperature -20–120°C (-4.0– Drop point 250°C (481.6°F)
range 247.8°F) Working temperature -20–160°C (-4.0–
range 319.8°F)
JCB Special Slide Grease
JCB Special Hammer Grease
JCB Special Slide grease is formulated to provide
excellent protection under heavy load and extreme JCB Special Hammer grease provides a highly
pressure, where water and dirt are prevalent. It effective lubricant on slow moving slides and an
maintains a film of lubrication on slow moving slides. excellent corrosion resistant property. It combines
It has an excellent resistance to squeeze out and the self healing action of oils and the resistance to
superb corrosion resistance. drip of viscous compounds.

Table 608. JCB Special Slide Grease Properties Table 611. JCB Special Hammer Grease
Description Data Description Data
Colour Dark grey Colour Dark grey
Soap type Lithium Soap type Lithium
Drop point 180°C (355.7°F) Drop point 185°C (364.7°F)
Working temperature -20–120°C (-4.0– Working temperature -15–120°C (5.0–
range 247.8°F) range 247.8°F)

75 - 22 9813/7000-2 75 - 22
 75 - Consumable Products
06 - Grease
00 - General

JCB Special Slew Pinion Grease

JCB Special Slew Pinion grease is a soft, black and
tenacious grease. It is designed specifically for the
lubrication of large and heavy duty open gears. It has
an excellent corrosion protection and load carrying
properties throughout a large temperature range.

Table 612. JCB Special Slew Pinion Grease

Description Data
Colour Black
Soap type Organically modified
clay
Working temperature -40–100°C (-39.9–
range 211.9°F)

75 - 23 9813/7000-2 75 - 23
 75 - Consumable Products
09 - Fluids

09 - Fluids

Contents Page No.

75-09-00 General ........................................................................................................................... 75-25

75-09-03 Antifreeze ....................................................................................................................... 75-26

75 - 24 9813/7000-2 75 - 24
 75 - Consumable Products
09 - Fluids
00 - General

00 - General

Introduction

It is most important that you read and understand this

information and the publications referred to. Make
sure all your colleagues who are concerned with
lubricants read it too.

Hygiene
JCB lubricants are not a health risk when used
properly for their intended purposes.

However, excessive or prolonged skin contact can

remove the natural fats from your skin, causing
dryness and irritation.

Low viscosity oils are more likely to do this, so take

special care when handling used oils, which might be
diluted with fuel contamination.

Whenever you are handling oil products you should

maintain good standards of care and personal and
plant hygiene. For details of these precautions we
advise you to read the relevant publications issued
by your local health authority, plus the following.

Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled
containers.

Waste Disposal
All waste products should be disposed of in
accordance with all the relevant regulations.

The collection and disposal of used oil should be in

accordance with any local regulations. Never pour
used engine oil into sewers, drains or on the ground.

75 - 25 9813/7000-2 75 - 25
 75 - Consumable Products
09 - Fluids
03 - Antifreeze

03 - Antifreeze Introduction
Introduction .................................................... 75-26
Health and Safety .......................................... 75-27
Coolant Mixtures
Technical Data ............................................... 75-27 Check the strength of the coolant mixture at least
once a year, preferably at the start of the cold period.
Do not use solutions of more than 60% or damage to
the engine may occur. Replace the coolant mixture
according to the intervals shown in the machine's
maintenance schedule.

You must dilute full strength antifreeze with clean

water before use. Use clean water of no more
than a moderate hardness (pH value 8.5). If this
cannot be obtained, use de-ionized water. For further
information advice on water hardness, contact your
local water authority.

The correct concentration of antifreeze protects the

engine against frost damage in winter and provides
year round protection against corrosion. Always
renew the antifreeze every two years.

The protection provided by High Performance

Antifreeze and Inhibitor is shown below. If any
other antifreeze is used, refer to the manufacturer's
instructions and make sure that a corrosion inhibitor
is included.

Table 613.
Solution Maintains cir- Protects
culation down against dam-
to: age down to:
50% Concen- -33°C (-27.4°F) -40°C (-39.9°F)
tration (Stan-
dard)
60% Concen- -42°C (-43.5°F) -56°C (-68.7°F)
tration (Stan-
dard)

Important: Do not exceed a 60% concentration, as

the freezing protection provided reduces beyond this
point.

If you use any other brand of antifreeze:

• Make sure that the antifreeze complies with

International Specification ASTM D6210.
• Always read and understand the
manufacturer's instructions.
• Make sure that a corrosion inhibitor is included.
Serious damage to the cooling system can
occur if corrosion inhibitors are not used.
• Make sure that the antifreeze is ethylene
glycol based and does not use Organic Acid
Technology (OAT).

75 - 26 9813/7000-2 75 - 26
 75 - Consumable Products
09 - Fluids
03 - Antifreeze

Health and Safety Technical Data

CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the Table 614.
cap, hot coolant can spray out and burn you. Item Fluid
Make sure that the engine is cool before you work
on the cooling system. Engine coolant Antifreeze HP/Coolant
ASTM D6210
CAUTION Antifreeze can be harmful. Obey the
manufacturer's instructions when handling full
strength or diluted antifreeze.

75 - 27 9813/7000-2 75 - 27
 75 - Consumable Products
10 - Locking Fluids

10 - Locking Fluids

Contents Page No.

75-10-00 General ........................................................................................................................... 75-29

75 - 28 9813/7000-2 75 - 28
 75 - Consumable Products
10 - Locking Fluids
00 - General

00 - General Introduction
Introduction .................................................... 75-29 All locking fluids should be used at all times in line
Technical Data ............................................... 75-30 with the manufacturer’s recommendations.

Locking fluids are used for the locking of threaded

fasteners and for the retention of ball & roller
bearings and similar cylindrical items on to shafts and
into housings. These fluids consist of an anaerobic
resin in a liquid form which hardens when confined
between closely fitting metal to metal and many
metal to non-metal surfaces.

The fluids available possess a wide span of

break-loose strengths, viscosities and gap filling
properties and are marketed for a variety of locking
and retaining purposes requiring different strength
grades. Some of the sealants in use in JCB are
also of anaerobic resin type and only differ from
the locking fluids in respect of viscosity and other
technical details.

Strength grades
Various strength grades of fluid are available,
the highest strength type for permanent locking
where disassembly is unlikely, medium strength
for permanent locking but allowing disassembly
with ordinary tools and low strength for locking
of components where frequent adjustment or easy
dismantling is required.

It is recommended that trials be carried out before

scheduling locking fluids for any new type of
application that has not been already proved as
satisfactory in production or when use at elevated
temperatures is intended.

Additional technical information is normally available

from the product manufacturers.

Approved locking fluids

The table shown in Technical Data shows the
approved locking fluids available to use on JCB
machines. The table also provides basic details to
help with selection of locking fluids. More up to
date information can be found on the manufacturer’s
website.

75 - 29 9813/7000-2 75 - 29
 75 - Consumable Products
10 - Locking Fluids
00 - General

Technical Data

Table 615. Locking Fluids Approved Product Information

Subsec- Commer- Product Colour Shelf Strength Comments
tion cial name Number life
High Loctite 4101/0100 Green 365d 80–120bar For the retention of threads up to M20 di-
strength 270
(1)
fluores- (1,159.4– ameter where disassembly is unlikely and
cent 1,739.1psi) for locking bearings etc. onto shafts and
R.A.S. Red breakaway into housing. Has a maximum gap fill of
threadlock strength 0.05mm.
for studs
(1)

High Loctite 4101/1400 Green, 365d More than Maximum gap fill of 0.25mm. Maximum
strength 638 UV fluo- 250bar strength at room temperature.
rescent (3,623.2psi)
compres-
sive shear
strength
High Per- 4101/0500 Red, flu- 365d 100–150bar Fast curing (10–15min) thread locking up
strength mabond ores- (1,449.3– to M20, especially for use on oily surfaces,
A115
(1)
cent 2,173.9psi) plated and clean parts.
Loctite prevailing
262 strength
High Loctite 4101/0600 Green, 365d More than Designed for holding gears and sprockets
strength 648(1) fluores- 250bar onto gearbox shafts and rotors on electric
Per- cent (3,623.2psi) motor shafts.
mabond compres-
A118 sive shear
strength
High Loctite 4101/1700 Green 365d 260–500bar Designed for permanent locking and seal-
strength 2701 (3,768.1– ing of threaded fasteners. Particularly suit-
7,246.3psi) ed for use on inactive substrates and/or
breakaway where maximum resistance to hot oil is re-
torque quired.
Medium Loctite 4101/1100 Blue 365d 140–340bar Suitable for all nuts, bolts, screws up to
to high 243 (2,029.0– M36.
4,927.5psi)
breakaway
torque
Medium Per- 4101/0900 Blue 365d 80–120bar Maximum gap fill of 0.25mm. Handling
strength mabond (1,159.4– strength in 10–15min.
A119
(1)
1,739.1psi)
static shear
strength
Medium Loctite 4101/1200 Green, 365d 150–330bar Product has a slow cure rate, used on parts
strength 640 fluores- (2,173.9– unlikely to be disassembled.
cent 4,782.6psi)
static shear
strength
Medium Loctite 4101/0200 Blue, 365d 80–120bar Suitable for all nuts, bolts and screws up to
strength 242(1) fluores- (1,159.4– M36 and hydraulic fittings up to 25mm in di-
Per- cent 1,739.1psi) ameter. Permabond A113 and A1042 are
mabond static shear the preferred choices. The difference be-
A1042 strength tween A113 and A1042 is timing for han-
dling and working strength. A113 handling
Per- time 10–25min, working strength 1h. A1042
mabond handling time 5–10min, working strength
A113 30min.

75 - 30 9813/7000-2 75 - 30
 75 - Consumable Products
10 - Locking Fluids
00 - General

Subsec- Commer- Product Colour Shelf Strength Comments

tion cial name Number life
Low Loctite 4101/0300 Purple, 365d 15–40bar For screwed fasteners up to M20 that re-
strength 222 fluores- (217.4– quire easy disassembly or frequent ad-
cent 579.7psi) justment. Maximum gap fill of 0.05mm.
Achieves handling strength in 10–30min.
Low Per- 4101/1500 Blue 365d 120bar Allows dismantling of parts for mainte-
strength mabond (1,739.1psi) nance. Suitable for sealing small hydraulic
A1098 shear and pneumatic fittings. Handling strength in
strength 5–10min.
Low Loctite 4101/1600 Off- 365d 17bar For the locking and sealing of metal ta-
strength 567 white (246.4psi) pered threads and fittings. High lubricat-
breakaway ing properties prevent galling on stainless
torque steel, aluminium and all other metal pipe
threads and fittings.
Very low Loctite 4101/0400 Brown/ 365d 7–18bar Can be disassembled with hand tools. 10–
strength 932(1) red (101.4– 30min cure time for handling strength. Used
Per- 260.9psi) on large diameter screw threads bigger
mabond average than 50mm.
A011 shear
strength
(1) This is a non preferred product.

75 - 31 9813/7000-2 75 - 31
 75 - Consumable Products
14 - Solvents and Primers

14 - Solvents and Primers

Contents Page No.

75-14-00 General ........................................................................................................................... 75-33

75 - 32 9813/7000-2 75 - 32
 75 - Consumable Products
14 - Solvents and Primers
00 - General

00 - General Introduction
Introduction .................................................... 75-33 This section contains information on primers,
Technical Data ............................................... 75-34 solvents, cleaning solutions etc. that are in use at
JCB.

All primers and solvents should be used at all times

in line with the manufacturer’s recommendations.

Approved primers and solvents

The table shown in Technical Data shows the
approved primers and solvents available to use on
JCB machines. The table also provides basic details
to help with the selection of primers and solvents.
More up to date information can be found on the
manufacturer’s website.

75 - 33 9813/7000-2 75 - 33
 75 - Consumable Products
14 - Solvents and Primers
00 - General

Technical Data

Table 616. Primers and Solvents Approved Product Information

Subsec- Commer- Product Colour Shelf Drying Comments
tion cial name Number life Time
Activa- Loctite 332/U7901 Colour- 365d Less than Used to make low energy surfaces suit-
tor/Primer 770 less 5s able for bonding with cyanocrylate adhe-
sives. It is recommended for polyethylene,
polypropylene, PTFE and thermoplastic
rubber materials. Can be used with Loctite
406 (332/U7899).
Activator Loctite 4104/1700 Clear 730d Apply and HIGHLY FLAMMABLE. Organic accelera-
7455 amber leave to dry tor, non CFC solvent based surface activa-
for 30s be- tor. Designed to promote the speed of cure
fore apply- of cyanoacrylic adhesives.
ing adhe-
sive
Activator Loctite 4104/0200 Colour- 365d 1–3min Used with anaerobic products it increases
7471 less cure speed. Recommended for inert sur-
Per- faces and large bond gaps.
mabond
A905
Water Loctite 4104/0500 - - - A water proofing solution for protecting
proofing water joints made using cyanoacrylate adhesive.
proofing Apply to Loctite 495 (4103/0900).
Solvent Loctite 4104/1500 Colour- 365d 1min at HIGHLY FLAMMABLE, cleaner and de-
7063 less 20°C greaser. Removes grease, oil and dirt from
(68.0°F) electrical parts, tools and precision equip-
ment.
Cleaning Loctite 4101/2200 Colour- 365d No wipe Cleaning treatment to remove most greas-
fluid 7070 less 5–10min, es, oils, lubrication fluids and metal cuttings
post wipe
1–2min
Cleaning Simple 332/E9240 Colour- 365d - An all purpose cleaner and degreaser used
fluid green ex- less diluted in water for direct, spray and dip
treme tank procedures.
Applica- A4GBCJCB4104/3300 Blue 730d - Vinyl labels application fluid for use with the
tion fluid insignia/livery labels.
Gasket Loctite 4104/3200 Colour- 730d Allow 10– This is a product to aid the removal of
cleaner 7200 less 15min for cured chemical gaskets. Apply for time
gasket, specified and remove gasket with soft
30min for scraper.
silicone
gasket.
Hand Loctite 4104/3100 Light 540d - Is a heavy duty hand cleaner, specially for-
cleaner 7855 grey mulated for the most difficult to remove
soils like polyurethane, paints, primers, ad-
hesives etc. The product is free from sil-
icone and harsh solvents. Can be used
without water.
Hand Sika hand 4104/1300 Off - - A non-abrasive hand cleaner for use when
cleaner cleaner white using direct glazing materials.

75 - 34 9813/7000-2 75 - 34
 75 - Consumable Products
14 - Solvents and Primers
00 - General

Subsec- Commer- Product Colour Shelf Drying Comments

tion cial name Number life Time
Direct Sika acti- 4104/2100 Clear 365d 10min mini- HIGHLY FLAMMABLE. A cleaning and acti-
glazing vator mum drying vating agent specifically formulated for the
time treatment of bonded faces in direct glaz-
ing applications prior to applying the direct
glazing adhesive.
Direct Sika re- 4104/1900 Trans- - - A cleaning agent for removing contami-
glazing mover parent nates on painted surfaces and glass.
208 (use
4104/3600)
Direct Sika 4104/1200 Clear - - A cleaning agent for removing contami-
glazing cleaner nates on painted surfaces and glass.
205 (use
4104/3600)
Direct Sika 4104/2300 Black 270d Application Used to prime painted surfaces and plas-
glazing primer tempera- tic substrates prior to bonding with Sikaflex
209 (use ture 10– products.
4104/3500) 35°C (50.0–
95.0°F)
Direct Sika akti- 4104/2400 Clear 365d 10min Used to clean and give improved adhe-
glazing vator at more sion on glass, ceramic-coated glass, the cut
than 15°C face of old polyurethane adhesive beads,
(59.0°F) polyurethane coated windows glass and
or 30min paints.
at less
than 15°C
(59.0°F)
Active Tero- 4104/3400 Colour- 270d Minimum Applied with a clean cloth to the surface,
wipe for stat 8560 less 30s and the adhesive may then be applied after the
surface AC-25 maximum drying time. Applied to glass or ceramic
1h coating but only in the bonding area.
Direct Terostat 4102/3500 Black 0.1L Approx. Used to promote adhesion in direct glazing
glazing 8519 P bot- 2min to glass and glass ceramics.
tle =
365d.
0.01L
and
0.035L
bot-
tle =
540d
Cleaner Teroson 4104/3600 Clear 730d Depend- Used for degreasing and cleaning of sub-
FL clean- ing on con- strates prior to application of adhesives and
er ditions be- sealants.
tween 2–
10min.

75 - 35 9813/7000-2 75 - 35
 75 - Consumable Products
15 - Adhesive

15 - Adhesive

Contents Page No.

75-15-00 General ........................................................................................................................... 75-37

75 - 36 9813/7000-2 75 - 36
 75 - Consumable Products
15 - Adhesive
00 - General

00 - General Introduction
Introduction .................................................... 75-37 All adhesives should be used at all times in line with
Technical Data ............................................... 75-38 the manufacturer’s recommendations.

Adhesives are used for the bonding of a number

of engineering materials used in production at JCB.
Many types are available on the market but in the
interests of variety reduction and economy only a
limited selection is purchased for regular use.

Types of adhesive
Various types of adhesive are covered by JCB
Standards:

1. General purpose adhesives for bonding

laminated plastics, wood, rubber etc. to
themselves and to each other.
2. The more expensive cyanoacrylate adhesives
for use where high strength, resistance to many
chemicals and fast cure times are required.
3. Adhesives specially developed for bonding of
foam rubber to painted metal surfaces.

Additional health and safety for

cyanoacrylates
These adhesives require very careful handling on
account of their exceptional properties. They bond
together strongly and rapidly to most surfaces
including body tissue, the curing process being
initiated by surface moisture. For further information
on cyanoacrylates refer to the Manufacturer’s
recommendations.

Approved adhesives
The tables shown in Technical Data are the approved
adhesives available to use on JCB machines. The
tables also provide basic details to help with the
selection of adhesives. More up to date information
can be found on the manufacturer’s website.

75 - 37 9813/7000-2 75 - 37
 75 - Consumable Products
15 - Adhesive
00 - General

Technical Data

Table 617. Adhesives Approved Product Information

Subsec- Commer- Product Colour Shelf Technical Comments
tion cial name Number life data
High Per- 4103/3100 Mixed 730d 3–5min for Two part adhesive mixed in equal parts. A
strength mabond grey handling toughened adhesive system which bonds
5002 strength metals, plastics, wood, glass, ceramics and
composites; even plated or coated surfaces
can be securely fastened.
High Loctite 4103/1000 Green 365d 16–30bar This product is a single component anaero-
strength 601 fluores- (231.9– bic adhesive. Used to bond cylindrical fitting
cent 434.8psi) parts, particularly where low viscosity is re-
static shear quired. Maximum gap fill is 0.15mm.
strength
Cyano- Loctite 4103/3500 Colour- - 18–26bar Suitable for most materials including plas-
acrylate 424 less to (260.9– tic and rubber. Takes 30s to cure to working
straw 376.8psi) strength.
shear
strength
Cyano- Loctite 4103/2300 Colour- 180d 18–26bar Designed for general purpose use. For use
acrylate 401 less (260.9– on acidic and porous surfaces, reaching
376.8psi) handling strength in seconds. Materials in-
tensile clude plated metals, composite materials,
strength wood, cork, foam, leather and paper.
Cyano- Loctite 332/U7899 Colour- 180d 18–26bar Designed for bonding of plastics and elas-
acrylate 406 less (260.9– tomeric materials where very fast fixturing
376.8psi) is required. Can be used with Loctite 770
lap shear as a primer (332/U7901)
strength
Cyano- Loctite 4103/2400 Black 120d 22bar 0.2mm, gap fill. A rubber toughened ethyl
acrylate 410 (318.8psi) cyanoacrylate adhesive with enhanced re-
lap shear sistance to peel and shock. Bonds rubber,
strength metals and plastics for use in difficult condi-
tions.
Cyano- Loctite 4103/3800 Black - 22–30bar A rubber toughened adhesive with in-
acrylate 480 (318.8– creased flexibility and peel strength along
434.8psi) with enhanced resistance to shock.
lap shear
strength
Cyano- Loctite 4103/0900 Colour- 270d 12h maxi- High speed bonding, suitable for rubber to
acrylate 495 less mum cure itself and other materials reaching handling
Per- time strength in a matter of seconds. Joint must
mabond be waterproofed with Loctite water proofing
C2 (4104/0500).
Low Dunlop 4103/1100 Clear 90d - Sprayable adhesive, non-structural appli-
strength 1727 to light cations. For the bonding of flexible foam
British vita straw to themselves, wood, painted metal, chip-
company board, fibreglass, hessian, felt etc.
VB 165
Acrylic 3M 4941P 4103/3900 Dark 730d Peel ad- High bond acrylic double sided foam tape.
foam grey hesion Its allows more complete bond contact area
strip ad- 350N/ when bonding rigid or irregular materials
hesive 100mm due to its conformability. Its core adhesive
composition makes the product well suited
to many paints and primers.

75 - 38 9813/7000-2 75 - 38
 75 - Consumable Products
15 - Adhesive
00 - General

Subsec- Commer- Product Colour Shelf Technical Comments

tion cial name Number life data
General Araldite 4103/1400 Clear / 730d 560bar Two part, equal parts by weight. Wear pad
purpose XD 580 cream (8,115.9psi)
fixing to castings and telescopic compo-
gap fill- flexural nents, alignments of fixings pads without
ing ma- strength expensive machining. This product is a
terial general purpose gap-filling material. Cure
time 2h at 25°C (77.0°F).
Methacry- Loctite 4103/3600 Cream - - This is a sag resistant, two component,
late Speed- to light equal parts, methacrylate adhesive system
bonder yellow formulated to bond automotive grade cold
H3151 rolled steel without the use of an external
primer. Suitable for bonding a wide variety
of plastic and metal substrates. Provides a
long open time (40–60min) for correct align-
ing of parts.
Methacry- Plexus 4103/3700 Off- 365d 186– Two part methacrylate adhesive for struc-
late MA420 white or 206bar tural bonding of thermoplastic, metal and
blue (2,695.6– composite assemblies. Combined at 10:1
2,985.5psi) ratio. It has a working time of 4–6min.
Structur- Scotch- 332/S7420 Black 180d - Two part acrylic based adhesive (10:1 ra-
al plastic weld tio by vol.) that can bond many low surface
structural energy plastics, including many grades of
plastic ad- polypropylene, polyethylene and TPO’s
hesive without special surface preparation.
Non-pre- Evo-Stick 4103/0800 None- 365d HIGHLY A thin even film of adhesive should be ap-
ferred 528 pre- FLAMMA- plied to both surfaces being bonded and al-
adhesive ferred BLE lowed to become touch dry. This is a con-
tact adhesive and coated surfaces can-
not therefore be slid into position since the
bond forms on contact. It is often conve-
nient to align the parts along an edge and
then bring the two areas into contact.
Direct Sika 4103/2100 Black - - A one component polyurethane pre-poly-
glazing 250PC mer based adhesive. A mastic adhesive
Sikat- which reacts with atmospheric moisture to
ack Ultra- form a rubber like solid.
fast (use
4103/4000
or
4102/4900)
Direct Sika 4103/2200 Black - - For bonding glass to cab frames. A mas-
glazing 255FC tic adhesive which reacts with atmospheric
(use moisture to form a rubber like solid. When
4102/5000) using this product ensure both surfaces
are clean and dry. Use Sika cleaner 205
(4104/1200).
Direct Sikaflex 4103/3200 Black - - A high performance, elastic, gap, filling one
glazing 552 (use part structural adhesive cures on exposure
4102/5000) to atmospheric moisture to form a durable
elastomer. Contains no isocyanate.

75 - 39 9813/7000-2 75 - 39
 75 - Consumable Products
15 - Adhesive
00 - General

Subsec- Commer- Product Colour Shelf Technical Comments

tion cial name Number life data
Industri- Loctite 333/Y7062 Light - 307bar Single component, heat activated formu-
al grade Hysol Grey (4,449.3psi) lation develops tough, strong, structur-
epoxy E-214 HP Paste tensile al bonds which provide excellent peel re-
adhesive strength sistance and impact strength. When ful-
ly cured, the product offers superior ther-
mal shock resistance, excellent mechan-
ical and electrical resistance properties
and withstands exposure to a wide vari-
ety of solvents and chemicals. Bonds to a
wide variety of materials, including metals,
glass, ceramics and plastics. Cure at 120°C
(247.8°F) or above until completely firm.
Heat up to 150°C (301.8°F) for 2h, to maxi-
mize properties.
Anaero- Scotch- 333/L9575 Green 365d - Single component anaerobic adhesives de-
bic ad- weld signed to secure cylindrical metal assem-
hesive RT-20 blies such as bearings on shafts, bush-
(Dimethacry- ings, sleeves, housings, and keyways.
late) Help prevent loosening, corrosion and leak-
age caused by shock and vibration. Full
cure time 24h. Temperature range = -54°C
(129.1°F) to 450°C (841.4°F). Not recom-
mended for use on most plastics due to po-
tential cracking of plastic parts.
Direct Terostat 4102/4900 Black 540d - Cure rate: approx. 3–4mm/24h. Glazing
glazing 8597 CT in time: maximum 20min (period of time be-
orig- tween beginning of material application until
inal inserting of the pane).
pack-
aging
Direct Teroson 4102/5000 Black, 365d - Skin formation time: approx. 10min. Cure
glazing 939CT / off- in rate: approx. 3mm/24h.
Terostat white, orig-
MS939 grey, inal
black pack-
aging
Direct Terostat 4103/4000 Black 180d 80bar One component, pumpable adhe-
glazing 8900 HV (1,159.4psi)sive/sealant based on polyurethane, which
tensile cures by reaction with moisture to an elas-
strength tic rubber. The skin formation and curing
time are dependent on humidity, tempera-
ture and depth of joint. High temperature
and high moisture reduces curing time.
Sag resistant, temperature range of -40°C
(103.9°F) to 90°C (193.9°F).
Direct Tero- 4103/4100 Black 270d 85bar Single component, moisture curing, ad-
glazing stat 8594 (1,231.9psi) hesive/sealant for repair. Product with
HMLC tensile high shear modulus and low conductivity.
strength Suitable for all applications that require very
high electrical insulation of the adhesive
used for the bonding of windows. Sag resis-
tant.

75 - 40 9813/7000-2 75 - 40
 75 - Consumable Products
15 - Adhesive
00 - General

Subsec- Commer- Product Colour Shelf Technical Comments

tion cial name Number life data
Direct Terostat 4103/4200 Black 365d 80bar One component, pumpable adhe-
glazing 8900 LV in (1,159.4psi) sive/sealant based on polyurethane, which
car- tensile cures by reaction with moisture to an elas-
tridges.strength tic rubber. The skin formation and curing
180d time are dependent on humidity, tempera-
in ture and depth of joint. High temperature
sausage and high moisture reduces curing time.
pack. Sag resistant, temperature range of -40°C
180d (103.9°F) to 90°C (193.9°F) short exposure
in (up to 1h) of 130°C (265.8°F).
hob-
bocks
and
drums
Direct Sika 295 4103/4300 Black, 365d - Direct glazing adhesive for plastic glaz-
glazing UV white ing panels. One component polyurethane
adhesive of paste like consistency. 60min
tack free time, 1d cure time (4mm at 23°C
(73.4°F)). Good UV, fresh water and sea-
water resistance. Do not apply below tem-
peratures of 10°C (50.0°F) or above 35°C
(95.0°F).

75 - 41 9813/7000-2 75 - 41
 75 - Consumable Products
16 - Sealant

16 - Sealant

Contents Page No.

75-16-00 General ........................................................................................................................... 75-43

75 - 42 9813/7000-2 75 - 42
 75 - Consumable Products
16 - Sealant
00 - General

00 - General Introduction
Introduction .................................................... 75-43 All sealants should be used at all times in line
Technical Data ............................................... 75-44 with the manufacturer’s recommendations. Sealants
are used mainly for the sealing of screwed joints,
sealing flanges and flat surfaces and where gap
filling properties are required.

Types of Sealant
Various types of sealant are specified in JCB
Standards:

1. Those for the sealing of screwed joints.

2. Sealants for joining flanges and flat surfaces.
(Flange size and likelihood of dismantling
require consideration when selecting this type of
sealant).
3. Sealants for use where gap filling properties are
required. (The gap dimensions, joint movement
if any, type of materials being joined and
aesthetic appearance require consideration
when selecting this type of sealant).

Approved Sealants
The table shown in Technical Data are the approved
sealants available to use on JCB machines. The
table also provides basic details to help with selection
of sealants. More up to date information can be found
on the manufacturer’s website.

75 - 43 9813/7000-2 75 - 43
 75 - Consumable Products
16 - Sealant
00 - General

Technical Data

Table 618. Sealants Approved Product Information

Subsec- Com- Product Colour Shelf Technical Comments
tion mercial Number life data
name
High Loctite 4102/0500 Green 730d 250bar Non drip formulation, used on larger fittings,
strength 275(1) (3,623.2psi) coarse threads.
Per- torque
mabond strength
A140 (on M8)
High Forge- 4102/3100 Yellow 270d 25bar Can be painted over with some 2 pack
strength way (362.3psi) paint. Maximum width of joint =35mm, min-
240FC
(1)
breaking imum width =2mm, minimum depth =2mm.
strength Recommended depth of joint = width of
joint.
Medium Loctite 4102/3500 Green - More than Used for locating pins in radiator assem-
to high 620 241bar blies, sleeves into pump housings and
strength (3,492.7psi) bearings in auto transmissions. Not suitable
shear for plastics. Diametrical clearance: up to
strength 0.2mm
Medium Loc- 4102/2000 Red, flu- 365d 90bar Typically used as form-in-place gasket on
strength tite 518 ores- (1,304.3psi) rigid flanged connections.
Gasket cent tensile
Elimina- strength
tor
Medium Loctite 4102/4100 Red gel, - 80bar It is manufactured to minimise air bubbles
strength 5182 fluores- (1,159.4psi) in the package. Used to seal gaskets, hous-
cent shear ings, cases and covers. It can also be used
strength to repair and replace cut gaskets (up to
0.08mm in thickness).
Medium Loctite 4102/2500 Clear 365d 6mm gap Formulated to withstand weathering and
strength 595 filling extreme temperature cycling. Used for pot-
ting, coating and sealing. Can be applied
horizontal, vertical and overhead.
Medium Loctite 4102/1900 Yellow 365d 170bar A fast curing thread sealant used on coarse
strength 577
(1)
(2,463.8psi) threads and pipe fittings up to 75mm thread
Per- breakaway size. Clearance for gap filling 0.8mm.
mabond torque
A1044
Medium Loctite 4102/2700 Blue 365d 140– Taper thread sealant, non-fluorescing to
strength 2431 340bar see oil leaks. Suitable for all taper fittings
(2,029.0– up to M36.
4,927.5psi)
breakaway
torque
Low Clayton 4102/2200 White 12h Maximum Seals pipes and plugs against leakage of
strength Dewan- opaque full seal pres- air, fuels, lubricants and coolants. Hardens
dre air cure sure 29bar to a tough seal resistant to shock and vibra-
brake (420.3psi) tion. Easily dismantled.
sealant
SC1252
Low Red 4102/0800 - - Resistant Non-hardening paste jointing for joints reg-
strength Her- to oil ularly opened for servicing.
metite

75 - 44 9813/7000-2 75 - 44
 75 - Consumable Products
16 - Sealant
00 - General

Subsec- Com- Product Colour Shelf Technical Comments

tion mercial Number life data
name
Low Loctite 4102/1100 White 730d 40–100bar Used where slow cure is required to permit
strength 572 opaque (579.7– component alignment. PTFE (Polytetrafluo-
1,449.3psi) roethylene) filler.
breakaway
torque
Gas- Loc- 4102/3200 Blue to 0.2mm 72h full Easy disassembly, used as form-in-place
keting tite 509 green gap strength on gasket.
medium Gasket filling steel
strength Elimi-
nator
Flange
Sealant
Gas- Loctite 4102/1200 Red 730d 2h working Does not creep or relax after curing, no bolt
keting 574
(1)
strength re-tightening is required. Oil resistant. Ideal
medium Per- for formed in-situ gaskets.
strength mabond
A136
Sealant Loctite 4102/2600 Black 365d Resists Used to dress new or worn gaskets. Dries
for gas- FAG 2 / pres- slowly, sets to pliable film for easy disman-
kets Loctite sures up tling.
5922 to 345bar
(5,000.0psi)
Rubber Dow 4102/0900 Clear or 270d 16.7bar A synthetic rubber joint sealant suitable for
jointing corning translu- (242.0psi) joints between non-porous surfaces such
com- 781 cent tensile as glass and metal, metal and metal where
pound Loc- strength relatively large gap filling properties are re-
tite su- quired. Suitable for vertical and overhead
perflex applications under normal atmospheric con-
clear ditions. Joint movement approx.+/-12.5%.
RTV3 Cure time to 6mm depth in 24h.
EVO-
stick
stan-
dard in-
dustri-
al clear
silicone
sealant
Dun-
lop high
modulus
silicone
sealant
DP2205
Epoxy Loc- 4102/2400 Slightly - - 0.05L container requires special bi-mixer
resin tite fast coloured / (gun) so it is mixed as dispensed, 0.024L is
epoxy trans- mixed by hand.
sealant parent
Room Loctite 4102/3400 Metal- - Dry to Designed for flange sealing, good resis-
tempera- 5910, lic black touch in tance to oils and allows high joint move-
ture vul- Flange paste 40min ment.
canising sealant,
RTV Sil-
icon

75 - 45 9813/7000-2 75 - 45
 75 - Consumable Products
16 - Sealant
00 - General

Subsec- Com- Product Colour Shelf Technical Comments

tion mercial Number life data
name
Room Loctite 4102/4200 Black 730d 18bar Used for gaskets. Excellent resistance to
tempera- 5970 (260.9psi) engine oils. Typical applications include
ture vul- tensile stamped sheet metal covers (timing covers
canising strength and oil sumps) where good oil resistance
and the ability to withstand high joint-move-
ment are required.
Room Loc- 4102/2900 Black 270d 16bar Thixotropic allowing easy application, hori-
tempera- tite su- (231.9psi) zontal, vertical and overhead. Seals against
ture vul- perflex tensile water and many solvents.
canising black strength
silicone
Room Loctite 4102/3700 Grey 730d 14bar Designed specifically for on line, low pres-
tempera- 5901 (202.9psi) sure tests carried out before product be-
ture vul- shear gins to cure. Product exhibits excellent re-
canising strength sistance to automotive engine oils. Primari-
ly for flange sealing, it withstands high joint-
movement requirements.
Room Loctite 4102/3900 Black 730d 20bar Generally used for sealing applications, but
tempera- 5368 paste (289.9psi) also for bonding and for high temperature
ture vul- tensile protection.
canising strength
Room Loctite 4102/4000 Clear 730d 20bar Designed specifically for use as a bond-
tempera- 5366 paste (289.9psi) ing agent to ensure perfect sealing, as
ture vul- shear well as bonding and protection. Examples
canising strength are sealing side windows in trains, seal-
ing heat sources (heat exchangers and wa-
ter heaters) and for protection/insulation of
electrical boxes.
Room Hylomar 332/D5695 Black 540d 40bar A special purpose adhesive and sealant
tempera- 607 paste (579.7psi) that can be used for a variety of applica-
ture vul- tensile tions. It has good resistance to oils and
canising strength aqueous anti-freeze agents, and is particu-
larly suitable for high strength applications
in odour sensitive environments.
Joining Loctite 4102/3800 Black 730d 14bar JCB Service ONLY. Introduced for joining
oil pan to 5900 paste (202.9psi) the oil pan to the bedplate face during ser-
bedplate shear vice. High resistance to engine oils. The
strength joint should be clamped to spread the ad-
hesive and allowed to cure for 7d before
heavy service duty.
Anti-cor- To mil- 4102/4300 Yellow - Type 1 Used to coat surfaces of dissimilar metals
rosive itary Class C prior to assembly to prevent corrosion. Zinc
spec chromate containing substance ideal for ap-
TT- plication to joints between aluminium and
P-1757B steel to prevent corrosion and seizure. FOR
1CY USE ON MILITARY VEHICLES ONLY.
Gas- Bondloc 4102/4500 Clear/ - Full cure B555 is an anaerobic gasket sealant. It
keting B555 Opaque time 24h. seals close fitting joints between rigid metal
medium 50bar faces and flanges. Tensile strength to ISO
strength (724.6psi) 6922.
tensile
strength

75 - 46 9813/7000-2 75 - 46
 75 - Consumable Products
16 - Sealant
00 - General

Subsec- Com- Product Colour Shelf Technical Comments

tion mercial Number life data
name
Seam Terolan 4102/4600 Light 90d - Serves as a seam sealant between sheet
sealant 3412 grey metal butt and overlap joints (interior
AA-25 seems) on vehicle bodies. Can be cured at
temperatures of minimum 140°C (283.8°F)
(effective metal temperature) for 15min.
The material is applied to electro-dip coated
steel sheets.
Direct Sikaflex 4102/2800 Yellow - - Direct glazing one component polyurethane
glazing 221 based adhesive and sealant compound.
(use Tack free time of 50min.
4102/4800)
Direct Sikaflex 4102/2300 Black - - A one component polyurethane pre-poly-
glazing 252 mer based sealant. For sealing glass to
(use frames. A mastic sealant which reacts with
4102/4700)
(1)
atmospheric moisture to form a rubber like
solid.
Direct Teroson 4102/4700 - 365d - The substrates must be clean, dry, oil and
glazing PU92 in grease free. Skin formation time: approx.
CT orig- 20min Cure rate: approx. 4mm/24h
inal
pack-
aging
Direct 930 4102/4800 Yellow 365d - The substrates must be clean, dry, oil and
glazing JCB in grease free. It can be necessary to rough-
Branded orig- en the surface or to use a primer/adhe-
yellow inal sion promoter to provide optimum adhe-
CT pack- sion. When manufacturing of plastics, ex-
aging ternal release agents are often used; these
agents must be absolutely removed prior.
Skin formation time : approx. 20min Cure
rate : approx. 4mm/24h
Direct Terostat 4102/4900 Black - - Isocyanate free solution. Designed for use
glazing 8597 without primer or activator. When you use
CT this sealant on operator station, it should be
used with Teroson PU 8519P black primer
(and Teroson 450 clear adhesion promoter
when specified specially). Cross compatible
with all OEM / OES / AAM DGX sealants,
including MS and PU chemistry (any re-
maining bead must be fully cured before
application).
Silicone Si- 4102/5100 Black - - High modulus permanently flexible 100%
sealant - ka/Ever- silicone. Temperature resistant up to 300°C
Heat re- build (571.6°F). Ideal for sealing industrial and
sistant Heat high performance gaskets, oven doors etc.
Mate
Gas- Loctite 4102/6100 Opaque - - Introduced for Heavy products India (swing
ket and 510 pink motor/ gearbox face).
sealing
(1) This is a non preferred product.

75 - 47 9813/7000-2 75 - 47
 75 - Consumable Products
18 - Fuel

18 - Fuel

Contents Page No.

75-18-00 General ........................................................................................................................... 75-49

75 - 48 9813/7000-2 75 - 48
 75 - Consumable Products
18 - Fuel
00 - General

00 - General Health and Safety

Health and Safety .......................................... 75-49 Fuel
Technical Data ............................................... 75-50 Fuel is flammable, keep naked flames away from the
fuel system. Stop the engine immediately if a fuel
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel
which could cause a fire. There could be a fire and
injury if you do not follow these precautions.
WARNING! Do not use petrol in this machine. Do not
mix petrol with the diesel fuel. In storage tanks the
petrol will form flammable vapours.

75 - 49 9813/7000-2 75 - 49
 75 - Consumable Products
18 - Fuel
00 - General

Technical Data

Notice: No warranty liability whatsoever will be where the failure is attributed to the quality and
accepted for failure of fuel injection equipment grade of the fuel used.

Table 619. Acceptable Fuels

Fuel Specification Applicable Engines Service Requirements
EN590 Diesel fuel types - Auto/C0/ All Obey the usual routine mainte-
C1/C2/C3/C4 nance schedules and procedures.
BS2869 Class A2
ASTM D975-076 2-D, US DF1, US
DF2, US DFA
JIS K2204 Grades 1, 2, 3 and Spe-
cial Grade 3
ASTM D975-076 1-D All (engines operated with these Obey the usual routine mainte-
MIL T38219 JP7 fuels may have a reduced service nance schedules and procedures.
life) Fuel additives are recommended
NATO F63
for use with low sulphur fuels.
(1)

French EN590 (RME5) with 5%

maximum
AVTURFSII, NATO F34, JP8, MIL All (engines operated with these Obey the usual routine mainte-
T83133, DERD 2463, DEF STAN fuels may have a reduced service nance schedules and procedures.
91-87 life) Fuel additives must be used.
AVCAT FSII, NATO F44, JP5, MIL
T5624, DERD 2452, AVTOR
NATO F35, JET A1, DEF STAN
91-91, DERD 2494, XF63
AVCAT, NATO F43 (obsolete),
JP5 without additives
JET A (ASTM D1655)
ASTM D3699 Kerosene
B5 Biodiesel - RME content blend- Tier 3 only
(2)
You must obey special routine
ed with mineral derived diesel (5% maintenance schedules and proce-
maximum) - ASTM D6751, DIN dures.
51606, ISO 14214
(1) Use a fuel additive (where instructed) to make sure that the fuel meets the minimum lubricity requirement.
(2) Refer to Typical Engine Identification Number.

Additives • Paradyne 7505 (from Infineum). Dosage 500

ppm (0.05%).
The additives listed below are advertised as being
suitable for bringing the lubricity levels of kerosene/ These products are given as examples only. The
low sulphur fuels up to those of diesel fuels. They information is derived from the manufacturers data.
must be used as specified by your fuel supplier who The products are not recommended or endorsed by
will understand the concentration level necessary. JCB.

The lubricity wear scar diameter must not be more Service Requirements for use of B5
than 460 microns, as tested on a high frequency Biodiesel
reciprocating rig at 60°C (139.9°F). Refer to ISO
12156-1. • The engine oil must be a grade CH4 as
minimum specification.
• Elf 2S 1750. Dosage 1000-1500 parts per • Do not leave unused B5 biodiesel in the fuel
million (0.1–0.15%), specifically for Indian tank for extended periods (top up each day).
Superior Kerosene (SKO) but may be • Make sure that 1 in 5 fuel tank fills use standard
applicable to other fuels. diesel to EN590 specification, this will help to
• Lubrizol 539N. Dosage (on Swedish low prevent 'gumming'.
sulphur fuel) 250 parts per million.

75 - 50 9813/7000-2 75 - 50
 75 - Consumable Products
18 - Fuel
00 - General

• Make sure regular oil sampling is completed High sulphur content can cause engine wear. High
(look for excessive unburnt fuel content, water sulphur fuel is not normally found in North America,
or wear particles. Europe or Australia. If you have to use high sulphur
• Change the engine oil and filter more frequently fuel you must change the engine oil more frequently.
(as a minimum half the recommended
intervals), or as indicated by oil sampling. Low sulphur fuels must have the appropriate fuel
• Change the fuel filters more frequently (as a lubricity additives, these lubricity improvers must not
minimum half the recommended intervals), or if create residual deposits that block the fuel system,
there are engine performance related issues. for example injectors, filters etc. Contact your fuel
• Make sure the fuel is stored correctly, care must supplier.
be taken to make sure no water enters the
machine fuel tank (or the storage tank). Water Table 620. Sulphur Content
will encourage mico-bacterial growth. Percentage of sulphur Oil Change Interval
• Make sure that the fuel pre-filter is drained daily in the fuel
(not every week as currently advised).
Less than 0.5% Normal
• Only Tier 3 engines (factory filled with CH4 oil)
- this is not approved with other manufacturers. 0.5–1% 75% of normal
• Use heater kits in low ambient temperature More than 1% 50% of normal
territories.
• The biodiesel must meet the following Effects of Fuel Contaminates
standards: ASTM D6751, DIN 51606, ISO
14214. The effect of dirt, water and other contaminants in
diesel can be disastrous for injection equipment:
If necessary use a test kit to confirm the fuel
specification. Testing kits are available (not from JCB Dirt: A severely damaging contaminant. Finely
currently), use the internet as a source for the kits. machined and mated surfaces such as delivery
valves and distributor rotors are susceptible to the
If performance related issues are to be reported abrasive nature of dirt particles - increased wear will
to JCB Service, and the engine has been run on almost inevitably lead to greater leakage, uneven
biodiesel, then the fuel system must be filled with running and poor fuel delivery.
standard diesel (at least 2 x tank fills) to EN590
specification and relevant stall speeds recorded prior Water: Water can enter fuel through poor storage
to making the report. or careless handling, and will almost inevitably
condense in fuel tanks. The smallest amounts of
Warranty water can result in effects that are just as disastrous
to the fuel injection pump as dirt, causing rapid
JCB have shown a commitment to support the wear, corrosion and in severe cases, even seizure.
environment by approving the use of biodiesel It is vitally important that water is prevented from
blended fuels. reaching the fuel injection equipment. The filter/water
trap must be drained regularly.
Using a B5 blend of biodiesel requires caution and
additional servicing of the engine is required. Wax: Wax is precipitated from diesel when the
ambient temperature falls below that of the fuel's
Failure to follow the additional recommended service cloud point, causing a restriction in fuel flow resulting
requirements may lead to a warranty claim being in rough engine running. Special winter fuels may be
declined. available for engine operation at temperatures below
0°C (32.0°F). These fuels have a lower viscosity and
Failures resulting by the incorrect use of biodiesels limit wax formation.
or other fuel additives are not defects of the engine
workmanship and therefore will not be supported by
JCB Warranty.

Sulphur Content
CAUTION A combination of water and sulphur will
have a corrosive chemical effect on fuel injection
equipment. It is essential that water is eradicated
from the fuel system when high sulphur fuels are
used.

75 - 51 9813/7000-2 75 - 51
Notes:

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 75 - Consumable Products
Contents Page No.

Acronyms Glossary .................................................................................................................................... 75-2

75-00 Consumable Products

75-00-00 General ............................................................................................................................. 75-3
75-00-03 Parts List ........................................................................................................................ 75-12
75-03 Oil
75-03-00 General ........................................................................................................................... 75-15
75-03-03 Engine ............................................................................................................................ 75-16
75-03-21 Refrigerant ...................................................................................................................... 75-18
75-06 Grease
75-06-00 General ........................................................................................................................... 75-21
75-09 Fluids
75-09-00 General ........................................................................................................................... 75-25
75-09-03 Antifreeze ....................................................................................................................... 75-26
75-10 Locking Fluids
75-10-00 General ........................................................................................................................... 75-29
75-14 Solvents and Primers
75-14-00 General ........................................................................................................................... 75-33
75-15 Adhesive
75-15-00 General ........................................................................................................................... 75-37
75-16 Sealant
75-16-00 General ........................................................................................................................... 75-43
75-18 Fuel
75-18-00 General ........................................................................................................................... 75-49

9813/7000-2
2018-01-17
Acronyms Glossary

2WD Two Wheel Drive

2WS Two Wheel Steer
4WD Four Wheel Drive
4WS Four Wheel Steer
DEF Diesel Exhaust Fluid
LSD Limited Slip Differential
PTFE Polytetrafluoroethylene
SAE Society of Automotive Engineers

9813/7000-2
2018-01-17
 75 - Consumable Products
00 - Consumable Products

00 - Consumable Products

Contents Page No.

75-00-00 General ............................................................................................................................. 75-3

75-00-03 Parts List ........................................................................................................................ 75-12

75 - 1 9813/7000-2 75 - 1
Notes:

75 - 2 9813/7000-2 75 - 2
 75 - Consumable Products
00 - Consumable Products
00 - General

00 - General Introduction
Introduction ...................................................... 75-3 JCB recommend that you use the JCB lubricants
Health and Safety ........................................... 75-4 shown as they have been verified by JCB for use
Technical Data ................................................. 75-6 on JCB machines. However, you could use other
lubricants that are equivalent to the JCB standards
and quality or offer the same machine component
protection.

Before you start work, make sure that:

• All safety precautions are observed in

accordance with the information contained
within the relevant support documentation.
• The consumables are used in accordance with
the manufacturer's recommendations.
• The consumables shown are available in the
correct quantity.

Consumables other than those listed may be

required. It is expected that general consumables will
be available in any well equipped workshop or be
available locally.

75 - 3 9813/7000-2 75 - 3
 75 - Consumable Products
00 - Consumable Products
00 - General

Health and Safety

Oil Waste Disposal

Oil is toxic. If you swallow any oil, do not induce CAUTION It is illegal to pollute drains, sewers
vomiting, seek medical advice. Used engine oil or the ground. Clean up all spilt fluids and/or
contains harmful contaminants which can cause skin lubricants.
cancer. Do not handle used engine oil more than
necessary. Always use barrier cream or wear gloves Used fluids and/or lubricants, filters and
to prevent skin contact. Wash skin contaminated with contaminated materials must be disposed of in
oil thoroughly in warm soapy water. Do not use petrol, accordance with local regulations. Use authorised
diesel fuel or paraffin to clean your skin. waste disposal sites.
Fluid Under Pressure CAUTION Damaged or spent batteries and any
residue from fires or spillage must be put in a
Fine jets of fluid at high pressure can penetrate the suitable closed receptacle and must be disposed
skin. Keep face and hands well clear of fluid under of in accordance with local environmental waste
pressure and wear personal protective equipment. regulations.
Hold a piece of cardboard close to suspected
leaks and then examine the cardboard for signs of
fluid. If fluid penetrates your skin, get medical help All waste products must be disposed of in
immediately. accordance with all the relevant regulations.
Fuel The collection and disposal of used oil must be in
Fuel is flammable, keep naked flames away from the accordance with any local regulations. Never pour
fuel system. Stop the engine immediately if a fuel used engine oil into sewers, drains or on the ground.
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the Handling
engine running. Completely wipe off any spilt fuel
CAUTION The temperature of the hydraulic oil
which could cause a fire. There could be a fire and
will be high soon after stopping the machine. Wait
injury if you do not follow these precautions.
until it cools before beginning maintenance.
Hygiene
New Oil
JCB lubricants are not a health risk when used
correctly for their intended purposes. There are no special precautions needed for the
handling or use of new oil, beside the normal care
However, excessive or prolonged skin contact can and hygiene practices.
remove the natural fats from your skin, causing
dryness and irritation. Used Oil
Low viscosity oils are more likely to do this, so take Used engine crankcase lubricants contain harmful
special care when handling used oils, which might be contaminants.
diluted with fuel contamination.
Here are precautions to protect your health when
Whenever you are handling oil products you must handling used engine oil:
maintain good standards of care and personal and
plant hygiene. For details of these precautions we • Avoid prolonged, excessive or repeated skin
advise you to read the relevant publications issued contact with used oil
by your local health authority, plus the following. • Apply a barrier cream to the skin before
handling used oil. Note the following when
Storage removing engine oil from skin:
• Wash your skin thoroughly with soap and
Always keep lubricants out of the reach of children. water
• Using a nail brush will help
Never store lubricants in open or unlabelled • Use special hand cleansers to help clean
containers. dirty hands
• Never use petrol, diesel fuel, or paraffin for
washing
• Avoid skin contact with oil soaked clothing
• Don't keep oily rags in pockets
• Wash dirty clothing before re-use

75 - 4 9813/7000-2 75 - 4
 75 - Consumable Products
00 - Consumable Products
00 - General

• Throw away oil-soaked shoes Battery

Warning Symbols
The following warning symbols may be found on the
battery.

Figure 1903.
A B C D E F

A Keep away from children B Shield eyes

C No smoking, no naked flames, no sparks D Explosive gas
E Battery acid F Note operating instructions

First Aid - Oil Swallowing

Eyes Do not induce vomiting. Drink large quantities of

water or milk. Then drink milk of magnesia, beaten
In the case of eye contact, flush with water for 15min. egg or vegetable oil. Get medical help.
If irritation persists, get medical attention.
Skin
Swallowing
Flush with water, remove affected clothing. Cover
If oil is swallowed do not induce vomiting. Get burns with a sterile dressing then get medical help.
medical advice.
First Aid - DEF (if applicable)
Skin
Do not drink or inhale DEF (Diesel Exhaust Fluid).
In the case of excessive skin contact, wash with soap If large quantities of DEF have been swallowed
and water. a doctor should be called immediately. Do not
induce vomiting unless directed to do so by medical
Spillage personnel. Never give anything by mouth to an
unconscious person.
Absorb with sand or a locally approved brand of
absorbent granules. Scrape up and remove to a Avoid prolonged or repeated skin contact. After
chemical disposal area. contact with skin wash thoroughly with plenty of soap
and water. If irritation develops seek medical advice.
Fires
Avoid contact with eyes, skin and clothing. Wear
WARNING Do not use water to put out an oil fire. chemical resistant gloves, overalls and safety
This will only spread it because oil floats on water. goggles complying with an approved standard. If
Extinguish oil and lubricant fires with carbon in contact with eyes, rinse immediately with plenty
dioxide, dry chemical or foam. of clean water. If irritation occurs seek medical
attention. Always wash hands and arms thoroughly
after handling before eating, drinking, smoking or
First Aid - Electrolyte using the lavatory.

Eyes
In the case of eye contact, flush with water for 15min.
always get medical attention.

75 - 5 9813/7000-2 75 - 5
 75 - Consumable Products
00 - Consumable Products
00 - General

Technical Data

For: 3CX [T2/T3], 4CX [T2/T3], UK Tier 2/3 Do not weld near the affected area during the
..................................................... Page 75-6 drying period. Take the same precautions as for
For: 5CX [T2/T3] ......................... Page 75-8 oil to keep Waxoyl off your skin. Do not breathe
For: 3CX [T2/T3], Brazil Tier 2/3, India Tier the fumes. Apply in a well-ventilated area.
2/3 ............................................... Page 75-9
JCB recommend that you use the JCB lubricants
(For: 3CX [T2/T3], 4CX [T2/T3], UK Tier shown as they have been verified by JCB for use
on JCB machines. However, you could use other
2/3) lubricants that are equivalent to the JCB standards
CAUTION Waxoyl contains turpentine substitute and quality or offer the same machine component
which is flammable. Keep flames away when protection.
applying Waxoyl. Waxoyl can take a few weeks
to dry completely. Keep flames away during the No warranty liability will be accepted for engine
drying period. failures where unacceptable fuel grades (or their
equivalent) have been used at any stage.

Table 598.
Item Capacity Fluid/Lubricant JCB Part
Container Specification
Number
Size
(1)

Fuel tank 160L Diesel oil - -

Engine (oil)
(2)
Minimum JCB engine oil EP 15W/40 -10°C 4001/1805 20L API CH-4/SJ,
12L Maxi- (14.0°F) to 50°C (121.9°F) ACEA E5, E3,
mum 15L JCB cold climate engine oil EP 4001/2705 20L B3, A3
5W/40 -20°C (-4.0°F) to 50°C
(121.9°F)
JCB cold climate engine oil FE 4001/3305 20L
5W30 -30°C (-22.0°F) to -40°C
(-39.9°F) certain markets only -
consult your JCB dealer
Engine (coolant)
(3)
20.5L Wet JCB antifreeze HP coolant/ water 4006/1120 20L ASTM D3306,
21.5L Dry ASTM D4985,
ASTM D6210,
SAE (Soci-
ety of Auto-
motive Engi-
neers) J1034,
BS6580
(1992),
AFNOR NF
R15- 601
Syncro shut- 14.4L Dry JCB extreme performance EP
tle (2WD (Two
Wheel Drive))
(4)

10L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)
Syncro shut- 15.4L Dry JCB extreme performance EP
tle (4WD (Four
Wheel Drive))
(3)

11L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
11L Wet SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)

75 - 6 9813/7000-2 75 - 6
 75 - Consumable Products
00 - Consumable Products
00 - General

Item Capacity Fluid/Lubricant JCB Part Container Specification

Number Size
(1)

Powershift 6 16L Dry JCB extreme performance EP

speed
(3)

11.5L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)
Powershift 4 15.5L Dry JCB extreme performance EP
speed
(3)

11L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)
Front axle (4WD) JCB gear oil HP90 (without LSD 4000/0305 20L
(Limited Slip Differential))
Housing 2WS 13L JCB gear oil HP plus (with LSD) 4000/2205 20L
(Two Wheel
Steer)
Housing (4WS 18L JCB gear oil LS plus (with LSD) 4000/3905 20L
(Four Wheel
Steer))
(5)

Hubs (x2) 2L JCB gear oil HP90 4000/0305 20L

Rear axle (4WS) JCB gear oil HP plus 4000/2205 20L
Housing
(6)
16.5L JCB gear oil LS plus (with LSD) 4000/3905 20L
Hubs (x2) 1.9L JCB gear oil HP90 4000/0305 20L
Rear axle (2WS) 21L JCB gear oil HP90 (without LSD) 4000/0305 20L
JCB gear oil HP plus (with LSD) 4000/2205 20L
Brake system - Uses hydraulic system oil - -
Hydraulic system 130L JCB hydraulic fluid HP46 above 4002/0805 20L
(gear pump ma- 38°C (100.3°F)
chines)
(7)
JCB hydraulic fluid HP32 below 4002/1025 20L
38°C (100.3°F)
Hydraulic system 130L JCB Optimum Performance hy- 4002/2005 20L
(variable pump draulic fluid 46
machines)
Grease points - JCB special HP grease 4003/2017 0.4kg x24
- JCB special MPL-EP grease
(8)
4003/1501 0.4kg x24
Extending dipper - JCB waxoyl 4004/0502 5L

75 - 7 9813/7000-2 75 - 7
 75 - Consumable Products
00 - Consumable Products
00 - General

Item Capacity Fluid/Lubricant JCB Part Number Container Size

(1)

SAE30 -5°C 4000/2605 20L

(23.0°F) to 46°C
(114.7°F)
Front axle (4WD) 18L JCB Gear Oil HP90 4000/0305 20L
(without LSD)
Housing (4WS)
(4)
JCB Gear Oil LS 4000/3905 20L
Plus (with LSD)
Hubs (x2)

75 - 9 9813/7000-2 75 - 9
 75 - Consumable Products
00 - Consumable Products
00 - General

and quality or offer the same machine component No warranty liability will be accepted for engine
protection. failures where unacceptable fuel grades (or their
equivalent) have been used at any stage.

Table 600.
Item Capacity Fluid/Lubricant JCB Part Container Specification
Number Size
(1)

Fuel tank 127L Diesel oil - -

Engine (oil)
(2)
Minimum JCB engine oil EP 5W/40 -30°C 4001/2705 20L API CH-4/
12L Maxi- (-22.0°F) to 46°C (114.7°F) CG-4,
mum 15L CF-4,CF,SJ.ACEA,
E2, B3, A3
JCB engine oil EP 15W/40 -15°C 4001/1805 API CH-4/SJ,
(5.0°F) to 46°C (114.7°F) ACEA E5, E3,
B3, A3
Engine (coolant)
(3)
20.5L Wet JCB antifreeze HP coolant/ water 4006/1120 20L ASTM D3306,
21.5L Dry ASTM D4985,
ASTM D6210,
SAE J1034,
BS6580
(1992),
AFNOR NF
R15- 601
Syncro shuttle 14.4L Dry JCB extreme performance EP
(2WD)
(4)

10L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)
Syncro shuttle 15.4L Dry JCB extreme performance EP
(4WD)
(3)

11L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
11L Wet SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)
Powershift 6 16L Dry JCB extreme performance EP
speed
(3)

11.5L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)
Powershift 4 15.5L Dry JCB extreme performance EP
speed
(3)

11L Wet 10W -32°C (-25.6°F) to 40°C 4000/2505 20L

(103.9°F)
SAE30 -5°C (23.0°F) to 46°C 4000/2605 20L
(114.7°F)
Front axle (4WD) JCB gear oil HP90 (without LSD) 4000/0305 20L
Housing 2WS 13L JCB gear oil HP plus (with LSD) 4000/2205 20L
Hubs (x2) 2L JCB gear oil HP90 4000/0305 20L
Rear axle (2WS) 21L JCB gear oil HP90 (without LSD) 4000/0305 20L
JCB gear oil HP plus (with LSD) 4000/2205 20L
Housing
(6)
16.5L JCB gear oil LS plus (with LSD) 4000/3905 20L
Hubs (x2) 1.9L JCB gear oil HP90 4000/0305 20L
Brake system 1L JCB Hydraulic Fluid HP15 4002/0503 1L

75 - 10 9813/7000-2 75 - 10
 75 - Consumable Products
00 - Consumable Products
00 - General

Item Capacity Fluid/Lubricant JCB Part Container Specification

Number Size
(1)

Hydraulic system 130L JCB hydraulic fluid HP46 above 4002/0805 20L
(gear pump ma- 38°C (100.3°F)
chines)
(7)
JCB hydraulic fluid HP32 below 4002/1025 20L
38°C (100.3°F)
Hydraulic system 130L JCB optimum performance hy- 4002/2005 20L
(variable pump draulic fluid
machines)
Grease points - JCB special HP grease 4003/2017 0.4kg
- JCB special MPL-EP grease
(8)
4003/1501 0.4kg
Extending dipper - JCB waxoyl 4004/0502 5L
Electrical connec- - As a corrosion and moisture in- - -
tions hibitor all exposed connections
should be coated liberally with pe-
troleum jelly
(1) For information about the different container sizes that are available (and their part numbers), contact your
JCB dealer.
(2) Caution - Do not use ordinary engine oil.
(3) It is recommended that the cooling system be filled at a maximum rate of 10 litres per minute. If the fill rate
is any higher than this there is a possibility of air becoming trapped in the system.
(4) The figure quoted is total system capacity. Use the minimum and maximum marks on the dipstick when
filling the system.
(6) Must be used with oil immersed brakes and LSD (Limited Slip Differentials).
(7) The total hydraulic system capacity depends on the equipment being used. Fill with all rams closed. Watch
level indicator on hydraulic tank.
(8) JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing
must be carried out more frequently.

75 - 11 9813/7000-2 75 - 11
 75 - Consumable Products
00 - Consumable Products
03 - Parts List

03 - Parts List Introduction

Consumables
Description Part No. Size
Antifreeze HP/Coolant ASTM D6210 Concentrate 4006/1101 5L
4006/1120 20L
4006/1103 200L
Black Polyurethane Sealant 4102/2310 0.31L
Black Primer/Activator 4104/2304 0.1L
Cleaner/Degreaser - General purpose solvent based parts cleaner 4104/1557 0.4L
Clear Silicone Sealant 4102/0901 0.31L
EP Hammer Grease 4003/2107 0.4kg
4003/2106 12.5kg
Extreme Performance Moly Grease 4003/1327 0.4kg
4003/1326 12.5kg
Glass Replacement Kit 993/55701 -
Hand Cleaner 4104/1310 -
JCB Activator 4104/0251 0.2L
4104/0253 1L
JCB Autogrease 4003/2305 0.5kg
JCB Gear Oil HP 4000/0505 20L
4000/0503 200L
JCB Glass Cleaner 4006/3175 0.75L
JCB High Strength Threadlocker 4102/0551 0.05L
JCB Hydraulic Fluid HP 46 4002/0801 5L
4002/0805 20L
4002/0803 200L
JCB Liquid Maintenance 993/99166 0.4L
JCB Multi-Gasket 4102/1212 0.05L
JCB Threadlocker and Sealer (High Strength) 4101/0550 0.01L
4101/0552 0.2L
JCB Threadlocker and Sealer (Medium Strength) 4101/0250 0.01L
4101/0251 0.05L
JCB Threadseal 4102/1951 0.05L
JCB Transmission Fluid EP SAE 30 4000/2601 5L
4000/2605 20L
4000/2603 200L
Polyurethane Adhesive 4103/2110 0.31L
Special HP Grease 4003/2017 0.4kg
4003/2006 12.5kg
4003/2005 50kg
Special Hammer Grease 4003/1119 0.4kg
Special MPL-EP Grease 4003/1501 0.4kg
4003/1506 12.5kg
4003/1510 50kg
Special Slew Pinion Grease 4003/1619 0.4kg
Special Slide Grease 4003/1115 0.4kg
Surface Cleaning Fluid 4103/1204 1L
Threaded Insert (M10 x 23mm) 826/01104 -
Threaded Insert (M10 x 26mm) 826/01105A -

75 - 12 9813/7000-2 75 - 12
 75 - Consumable Products
00 - Consumable Products
03 - Parts List

Description Part No. Size

Threaded Insert (M6 x 16mm) 826/01099 -
Threaded Insert (M6 x 19mm) 826/01101 -
Threaded Insert (M8 x 18mm) 826/01102 -
Threaded Insert (M8 x 21mm) 826/01103 -
Waxoyl 4004/0501A 0.4L
4004/0502 5L
4004/0505 200L
Wiring Splice (0.5-1.5mm Red, contains 50 off) 892/00351 -
Wiring Splice (1.5-2.5mm Blue, contains 50 off) 892/00352 -
Wiring Splice (3-6mm Yellow, contains 50 off) 892/00353 -

75 - 13 9813/7000-2 75 - 13
 75 - Consumable Products
03 - Oil

03 - Oil

Contents Page No.

75-03-00 General ........................................................................................................................... 75-15

75-03-03 Engine ............................................................................................................................ 75-16
75-03-21 Refrigerant ...................................................................................................................... 75-18

75 - 14 9813/7000-2 75 - 14
 75 - Consumable Products
03 - Oil
00 - General

00 - General

Introduction

New Oil
There are no special precautions needed for the
handling or use of new oil, besides the normal
health and safety practices mentioned in the relevant
section of this service manual.

Used Oil
Used engine crankcase lubricants contain harmful
contaminants. Here are precautions to protect your
health when handling used engine oil:

1. Avoid prolonged, excessive or repeated skin

contact with used oil.
2. Apply a barrier cream to the skin before handling
used oil.
3. Note the following when removing engine oil from
skin:
3.1. Wash your skin thoroughly with soap and
water.
3.2. Using a nail brush will help.
3.3. Use special hand cleansers to help clean
dirty hands.
3.4. Never use petrol, diesel fuel, or paraffin for
washing.
4. Avoid skin contact with oil soaked clothing.
5. Don't keep oily rags in pockets.
6. Wash dirty clothing before re-use.
7. Throw away oil-soaked shoes.

First Aid
EYES - In the case of eye contact, flush with water for
15 minutes. If irritation persists, get medical attention.

SWALLOWING - If oil is swallowed do not induce

vomiting. Get medical advice.

SKIN - In the case of excessive skin contact, wash

with soap and water.

SPILLAGE - Absorb on sand or a locally approved

brand of absorbent granules. Scrape up and remove
to a chemical disposal area.

FIRES - Extinguish with carbon dioxide, dry chemical

or foam. Firefighters should use self-contained
breathing apparatus.

75 - 15 9813/7000-2 75 - 15
 75 - Consumable Products
03 - Oil
03 - Engine

03 - Engine Introduction
Introduction .................................................... 75-16 New engines DO NOT require a running-in period.
Technical Data ............................................... 75-17 The engine/machine should be used in a normal
work cycle immediately, glazing of the piston cylinder
bores, resulting in excessive oil consumption, could
occur if the engine is gently run-in. Under no
circumstances should the engine be allowed to idle
for extended periods; (e.g. warming up without load).

The choice of lubricant viscosity should be made

based on the lowest ambient temperature at which
the machine will be started and the maximum
ambient temperature at which it will operate.

The technical data section provides guidance as to

the temperature range that can be accommodated
by standard oil viscosities and can be used to select
an appropriate grade.

When selecting the oil viscosity grade, make

sure that the oil conforms with or exceeds the
recommended specification.

75 - 16 9813/7000-2 75 - 16
 75 - Consumable Products
03 - Oil
03 - Engine

Technical Data

Table 601.
Engine Code Oil API Specifica- Viscosity Minimum Maximum
tion Temperature°C (°F) Temperature°C (°F)
SA, SB, SC, SK, CF/ CH-4 SAE 5W30 -30°C (-22.0°F) 30°C (86.0°F)
SG, SD, SE, SF, CH-4 SAE 15W40 -5°C (23.0°F) 50°C (121.9°F)
DA, DB, DC, DE, CH-4 SAE 10W40 -15°C (5.0°F) 46°C (114.7°F)
DG, DD, DK, DF,
EC, EE, EF, EK CH-4 SAE 5W40 -30°C (-22.0°F) 46°C (114.7°F)

Table 602.
Engine Code Oil API Specifica- Viscosity Minimum Maximum
tion Temperature°C (°F) Temperature°C (°F)
CH-4 SAE 5W40 -30°C (-22.0°F) 46°C (114.7°F)

75 - 17 9813/7000-2 75 - 17
 75 - Consumable Products
03 - Oil
21 - Refrigerant

21 - Refrigerant Introduction
Introduction .................................................... 75-18 Refrigerants are the basic ingredient of all air
Health and Safety .......................................... 75-19 conditioning systems and are used to transfer the
heat energy around the system. Refrigerant type
R134a is used in the air conditioning system. It's
full chemical name is: 1, 1, 1, 2 - Tetrafluoroethane
(CH²FCF²).

R134a is a HFC (Hydrofluorocarbon) and is non-

toxic, non-flammable and non-explosive at normal
atmospheric temperature and pressure. It can be
flammable under certain pressure and air mixtures.

Due to environmental concerns, the use of ozone

depleting chlorofluorocarbons (CFCs) in the air
conditioning systems is being gradually phased
out. The R-12 refrigerant used in some systems
contains CFCs. Air conditioning systems using
R-134a refrigerant are not compatible with systems
using R-12 refrigerant. No attempt should be made
to charge R-134a systems with R- 12 refrigerant.

Important: Refer to the safety procedures within the

Air conditioning section before handling refrigerants.

Good installation practice is required to avoid

the release of refrigerant into the atmosphere.
Refrigerant R134a contains no chlorine and has an
Ozone Depleting Potential (ODP) of zero, and a
Global Warming Potential (GWP) of 0.1.

PAG Type Refrigerant Oil

The system requires a PAG type refrigerant oil to
lubricate the compressor. The oil mixes with the
refrigerant and is carried around the system.

It is important that the recommended grade of

refrigerant oil is used. Mineral oil is not suitable for
R134a refrigerant systems. Do not mix oil types.

The compressor is supplied with an oil charge, but

additional oil will be required when the receiver drier
is replaced. The oil is added to the compressor
through the oil filling plug before the evacuation
procedure is started.

Only use fresh, unused oil. Oil that has been exposed
to the air will have absorbed water.

75 - 18 9813/7000-2 75 - 18
 75 - Consumable Products
03 - Oil
21 - Refrigerant

Health and Safety

CAUTION Polyalkylene Glycol (PAG) type oil is
an irritant. It can cause skin irritation. Breathing
PAG vapour can cause irritation of the eyes,
nose and lungs. Prolonged inhalation can cause
drowsiness.
WARNING Polyalkylene Glycol (PAG) type oil
vapour is extremely flammable. Do not smoke
or eat near PAG contaminated material. Exercise
caution when working around hot and moving
engine parts.

75 - 19 9813/7000-2 75 - 19
 75 - Consumable Products
06 - Grease

06 - Grease

Contents Page No.

75-06-00 General ........................................................................................................................... 75-21

75 - 20 9813/7000-2 75 - 20
 75 - Consumable Products
06 - Grease
00 - General

00 - General Consumable: JCB Autogrease

6. JCB EP Hammer Grease
Introduction Consumable: EP Hammer Grease
Special Tools 7. JCB Special Hammer Grease
Description Part No. Qty.
Consumable: Special Hammer Grease
Grease Gun 892/00913 1
Attachment 8. JCB Special Slew Pinion Grease
Grease Gun 992/11300 1
Consumable: Special Slew Pinion Grease
Consumables
Description Part No. Size Greasing Procedure
EP Hammer Grease 4003/2107 0.4kg 1. Make the machine safe.
4003/2106 12.5kg
Extreme Performance 4003/1327 0.4kg 2. If necessary, install any maintenance or
Moly Grease articulation struts.
4003/1326 12.5kg
JCB Autogrease 4003/2305 0.5kg 3. Make a note of the following:
Special HP Grease 4003/2017 0.4kg 3.1. The machine must always be greased after
4003/2006 12.5kg pressure washing or steam cleaning.
4003/2005 50kg
3.2. Greasing must be done with a grease gun.
Special Hammer 4003/1119 0.4kg Normally, two strokes of the gun should be
Grease sufficient.
Special MPL-EP 4003/1501 0.4kg
Special Tool: Grease Gun (Qty.: 1)
Grease 4003/1506 12.5kg Special Tool: Grease Gun Attachment (Qty.:
4003/1510 50kg 1)
Special Slew Pinion 4003/1619 0.4kg 3.3. Stop greasing when fresh grease appears
Grease at the joint.
Special Slide Grease 4003/1115 0.4kg
3.4. Use only the recommended type of grease.
There are various greasing points on the machine. 3.5. Do not mix different types of grease, keep
You must grease the machine regularly to keep them separate.
it working efficiently. Regular greasing will also
lengthen the machine's working life. You must grease 4. Count off the grease points as you grease each
the machine as stated in the maintenance schedule. one.
Refer to: PIL 78-24-06.
5. Install the dust caps after greasing (if installed).
JCB grease is manufactured to provide significant
load protection for your machine. It is recommended JCB Special HP Grease
to use only JCB grease on your machine because
they are specifically designed for the particular JCB Special HP grease is a premium quality,
application. The list of JCB greases comprises: extreme pressure grease. It is recommended
for use in arduous operating conditions, such
1. JCB Special HP Grease as high temperatures, excessive loading and
Consumable: Special HP Grease extensive exposure to water. The sophisticated
additive package combines with excellent adhesive
2. JCB Special MPL-EP Grease properties to give high performance protection to
your machine.
Consumable: Special MPL-EP Grease
Table 605. JCB Special HP Grease Properties
3. JCB Extreme Performance Moly Grease
Description Data
Consumable: Extreme Performance Moly
Grease Colour Blue
Soap type Lithium complex
4. JCB Special Slide Grease Drop point 245°C (472.7°F)
Consumable: Special Slide Grease Working temperature -20–150°C (-4.0–
range 301.8°F)
5. JCB Autogrease

75 - 21 9813/7000-2 75 - 21
 75 - Consumable Products
06 - Grease
00 - General

JCB Special MPL-EP Grease JCB Autogrease

JCB Special MPL-EP grease is a true multipurpose JCB Autogrease is for use with the automatic
grease. It is recommended for a wide range of greasing system. It is a mineral oil based paste.
lubricating applications, such as pivot pins and wheel It contains an aluminium complex soap and solid
bearings, where excellent anti wear and anti rust lubricants. It is suitable for use under water or in
performance is required. Its EP additive makes it high ambient temperatures. The specially designed
particularly suitable for the shock load and vibrating cartridges screw into the automatic greasing system
conditions found on machines. installed on the machine.

Table 606. JCB Special The clear cartridge allows the operator to easily
MPL-EP Grease Properties monitor the grease usage from inside of the operator
station.
Description Data
Colour Brown Table 609. JCB Autogrease
Soap type Lithium Description Data
Drop point 180°C (355.7°F) Colour Black
Working temperature -20–130°C (-4.0– Soap type Aluminium complex, sol-
range 265.8°F) id lubricants
Drop point 260°C (499.6°F)
JCB Extreme Performance Moly Grease
Working temperature -20–110°C (-4.0–
JCB Extreme Performance Moly grease is an range 229.8°F)
advanced performance, multipurpose grease. It is
recommended for heavily loaded bearing surfaces JCB EP Hammer Grease
and in particular where limited or oscillating
motion causes fretting. The addition of molybdenum JCB EP Hammer grease is a unique formulation
disulphide provides extra protection against scoring aluminium complex grease for use where extremes
and wear. This grease is ideal for automotive, of pressure and temperature are likely to be
industrial, agricultural and earthmoving equipment. encountered. It is suitable for the hammer
applications where resistance to water washing and
Table 607. JCB Extreme migration may be critical.
Performance Moly Grease Properties
Table 610. JCB EP Hammer Grease
Description Data
Colour Grey Black Description Data
Soap type Lithium Colour Black
Drop point 185°C (364.7°F) Soap type Aluminium complex
Working temperature -20–120°C (-4.0– Drop point 250°C (481.6°F)
range 247.8°F) Working temperature -20–160°C (-4.0–
range 319.8°F)
JCB Special Slide Grease
JCB Special Hammer Grease
JCB Special Slide grease is formulated to provide
excellent protection under heavy load and extreme JCB Special Hammer grease provides a highly
pressure, where water and dirt are prevalent. It effective lubricant on slow moving slides and an
maintains a film of lubrication on slow moving slides. excellent corrosion resistant property. It combines
It has an excellent resistance to squeeze out and the self healing action of oils and the resistance to
superb corrosion resistance. drip of viscous compounds.

Table 608. JCB Special Slide Grease Properties Table 611. JCB Special Hammer Grease
Description Data Description Data
Colour Dark grey Colour Dark grey
Soap type Lithium Soap type Lithium
Drop point 180°C (355.7°F) Drop point 185°C (364.7°F)
Working temperature -20–120°C (-4.0– Working temperature -15–120°C (5.0–
range 247.8°F) range 247.8°F)

75 - 22 9813/7000-2 75 - 22
 75 - Consumable Products
06 - Grease
00 - General

JCB Special Slew Pinion Grease

JCB Special Slew Pinion grease is a soft, black and
tenacious grease. It is designed specifically for the
lubrication of large and heavy duty open gears. It has
an excellent corrosion protection and load carrying
properties throughout a large temperature range.

Table 612. JCB Special Slew Pinion Grease

Description Data
Colour Black
Soap type Organically modified
clay
Working temperature -40–100°C (-39.9–
range 211.9°F)

75 - 23 9813/7000-2 75 - 23
 75 - Consumable Products

09 - Fluids

Contents Page No.

75 - 24 9813/7000-2 75 - 24
 75 - Consumable Products
09 - Fluids
00 - General

00 - General

Introduction

It is most important that you read and understand this

information and the publications referred to. Make
sure all your colleagues who are concerned with
lubricants read it too.

Hygiene
JCB lubricants are not a health risk when used
properly for their intended purposes.

However, excessive or prolonged skin contact can

remove the natural fats from your skin, causing
dryness and irritation.

Low viscosity oils are more likely to do this, so take

special care when handling used oils, which might be
diluted with fuel contamination.

Whenever you are handling oil products you should

maintain good standards of care and personal and
plant hygiene. For details of these precautions we
advise you to read the relevant publications issued
by your local health authority, plus the following.

Storage
Always keep lubricants out of the reach of children.
Never store lubricants in open or unlabelled
containers.

Waste Disposal
All waste products should be disposed of in
accordance with all the relevant regulations.

The collection and disposal of used oil should be in

accordance with any local regulations. Never pour
used engine oil into sewers, drains or on the ground.

75 - 25 9813/7000-2 75 - 25
 75 - Consumable Products
09 - Fluids
03 - Antifreeze

03 - Antifreeze Introduction
Introduction .................................................... 75-26
Health and Safety .......................................... 75-27
Coolant Mixtures
Technical Data ............................................... 75-27 Check the strength of the coolant mixture at least
once a year, preferably at the start of the cold period.
Do not use solutions of more than 60% or damage to
the engine may occur. Replace the coolant mixture
according to the intervals shown in the machine's
maintenance schedule.

You must dilute full strength antifreeze with clean

water before use. Use clean water of no more
than a moderate hardness (pH value 8.5). If this
cannot be obtained, use de-ionized water. For further
information advice on water hardness, contact your
local water authority.

The correct concentration of antifreeze protects the

engine against frost damage in winter and provides
year round protection against corrosion. Always
renew the antifreeze every two years.

The protection provided by High Performance

Antifreeze and Inhibitor is shown below. If any
other antifreeze is used, refer to the manufacturer's
instructions and make sure that a corrosion inhibitor
is included.

Table 613.
Solution Maintains cir- Protects
culation down against dam-
to: age down to:
50% Concen- -33°C (-27.4°F) -40°C (-39.9°F)
tration (Stan-
dard)
60% Concen- -42°C (-43.5°F) -56°C (-68.7°F)
tration (Stan-
dard)

Important: Do not exceed a 60% concentration, as

the freezing protection provided reduces beyond this
point.

If you use any other brand of antifreeze:

• Make sure that the antifreeze complies with

International Specification ASTM D6210.
• Always read and understand the
manufacturer's instructions.
• Make sure that a corrosion inhibitor is included.
Serious damage to the cooling system can
occur if corrosion inhibitors are not used.
• Make sure that the antifreeze is ethylene
glycol based and does not use Organic Acid
Technology (OAT).

75 - 26 9813/7000-2 75 - 26
 75 - Consumable Products
09 - Fluids
03 - Antifreeze

Health and Safety Technical Data

CAUTION The cooling system is pressurised
when the coolant is hot. When you remove the Table 614.
cap, hot coolant can spray out and burn you. Item Fluid
Make sure that the engine is cool before you work
on the cooling system. Engine coolant Antifreeze HP/Coolant
ASTM D6210
CAUTION Antifreeze can be harmful. Obey the
manufacturer's instructions when handling full
strength or diluted antifreeze.

75 - 27 9813/7000-2 75 - 27
 75 - Consumable Products
10 - Locking Fluids

10 - Locking Fluids

Contents Page No.

75-10-00 General ........................................................................................................................... 75-29

75 - 28 9813/7000-2 75 - 28
 75 - Consumable Products
10 - Locking Fluids
00 - General

00 - General Introduction
Introduction .................................................... 75-29 All locking fluids should be used at all times in line
Technical Data ............................................... 75-30 with the manufacturer’s recommendations.

Locking fluids are used for the locking of threaded

fasteners and for the retention of ball & roller
bearings and similar cylindrical items on to shafts and
into housings. These fluids consist of an anaerobic
resin in a liquid form which hardens when confined
between closely fitting metal to metal and many
metal to non-metal surfaces.

The fluids available possess a wide span of

break-loose strengths, viscosities and gap filling
properties and are marketed for a variety of locking
and retaining purposes requiring different strength
grades. Some of the sealants in use in JCB are
also of anaerobic resin type and only differ from
the locking fluids in respect of viscosity and other
technical details.

Strength grades
Various strength grades of fluid are available,
the highest strength type for permanent locking
where disassembly is unlikely, medium strength
for permanent locking but allowing disassembly
with ordinary tools and low strength for locking
of components where frequent adjustment or easy
dismantling is required.

It is recommended that trials be carried out before

scheduling locking fluids for any new type of
application that has not been already proved as
satisfactory in production or when use at elevated
temperatures is intended.

Additional technical information is normally available

from the product manufacturers.

Approved locking fluids

The table shown in Technical Data shows the
approved locking fluids available to use on JCB
machines. The table also provides basic details to
help with selection of locking fluids. More up to
date information can be found on the manufacturer’s
website.

75 - 29 9813/7000-2 75 - 29
 75 - Consumable Products
10 - Locking Fluids
00 - General

Technical Data

Table 615. Locking Fluids Approved Product Information

Subsec- Commer- Product Colour Shelf Strength Comments
tion cial name Number life
High Loctite 4101/0100 Green 365d 80–120bar For the retention of threads up to M20 di-
strength 270
(1)
fluores- (1,159.4– ameter where disassembly is unlikely and
cent 1,739.1psi) for locking bearings etc. onto shafts and
R.A.S. Red breakaway into housing. Has a maximum gap fill of
threadlock strength 0.05mm.
for studs
(1)

High Loctite 4101/1400 Green, 365d More than Maximum gap fill of 0.25mm. Maximum
strength 638 UV fluo- 250bar strength at room temperature.
rescent (3,623.2psi)
compres-
sive shear
strength
High Per- 4101/0500 Red, flu- 365d 100–150bar Fast curing (10–15min) thread locking up
strength mabond ores- (1,449.3– to M20, especially for use on oily surfaces,
A115
(1)
cent 2,173.9psi) plated and clean parts.
Loctite prevailing
262 strength
High Loctite 4101/0600 Green, 365d More than Designed for holding gears and sprockets
strength 648(1) fluores- 250bar onto gearbox shafts and rotors on electric
Per- cent (3,623.2psi) motor shafts.
mabond compres-
A118 sive shear
strength
High Loctite 4101/1700 Green 365d 260–500bar Designed for permanent locking and seal-
strength 2701 (3,768.1– ing of threaded fasteners. Particularly suit-
7,246.3psi) ed for use on inactive substrates and/or
breakaway where maximum resistance to hot oil is re-
torque quired.
Medium Loctite 4101/1100 Blue 365d 140–340bar Suitable for all nuts, bolts, screws up to
to high 243 (2,029.0– M36.
4,927.5psi)
breakaway
torque
Medium Per- 4101/0900 Blue 365d 80–120bar Maximum gap fill of 0.25mm. Handling
strength mabond (1,159.4– strength in 10–15min.
A119
(1)
1,739.1psi)
static shear
strength
Medium Loctite 4101/1200 Green, 365d 150–330bar Product has a slow cure rate, used on parts
strength 640 fluores- (2,173.9– unlikely to be disassembled.
cent 4,782.6psi)
static shear
strength
Medium Loctite 4101/0200 Blue, 365d 80–120bar Suitable for all nuts, bolts and screws up to
strength 242(1) fluores- (1,159.4– M36 and hydraulic fittings up to 25mm in di-
Per- cent 1,739.1psi) ameter. Permabond A113 and A1042 are
mabond static shear the preferred choices. The difference be-
A1042 strength tween A113 and A1042 is timing for han-
dling and working strength. A113 handling
Per- time 10–25min, working strength 1h. A1042
mabond handling time 5–10min, working strength
A113 30min.

75 - 30 9813/7000-2 75 - 30
 75 - Consumable Products
10 - Locking Fluids
00 - General

Subsec- Commer- Product Colour Shelf Strength Comments

tion cial name Number life
Low Loctite 4101/0300 Purple, 365d 15–40bar For screwed fasteners up to M20 that re-
strength 222 fluores- (217.4– quire easy disassembly or frequent ad-
cent 579.7psi) justment. Maximum gap fill of 0.05mm.
Achieves handling strength in 10–30min.
Low Per- 4101/1500 Blue 365d 120bar Allows dismantling of parts for mainte-
strength mabond (1,739.1psi) nance. Suitable for sealing small hydraulic
A1098 shear and pneumatic fittings. Handling strength in
strength 5–10min.
Low Loctite 4101/1600 Off- 365d 17bar For the locking and sealing of metal ta-
strength 567 white (246.4psi) pered threads and fittings. High lubricat-
breakaway ing properties prevent galling on stainless
torque steel, aluminium and all other metal pipe
threads and fittings.
Very low Loctite 4101/0400 Brown/ 365d 7–18bar Can be disassembled with hand tools. 10–
strength 932(1) red (101.4– 30min cure time for handling strength. Used
Per- 260.9psi) on large diameter screw threads bigger
mabond average than 50mm.
A011 shear
strength
(1) This is a non preferred product.

75 - 31 9813/7000-2 75 - 31
 75 - Consumable Products
14 - Solvents and Primers

14 - Solvents and Primers

Contents Page No.

75-14-00 General ........................................................................................................................... 75-33

75 - 32 9813/7000-2 75 - 32
 75 - Consumable Products
14 - Solvents and Primers
00 - General

00 - General Introduction
Introduction .................................................... 75-33 This section contains information on primers,
Technical Data ............................................... 75-34 solvents, cleaning solutions etc. that are in use at
JCB.

All primers and solvents should be used at all times

in line with the manufacturer’s recommendations.

Approved primers and solvents

The table shown in Technical Data shows the
approved primers and solvents available to use on
JCB machines. The table also provides basic details
to help with the selection of primers and solvents.
More up to date information can be found on the
manufacturer’s website.

75 - 33 9813/7000-2 75 - 33
 75 - Consumable Products
14 - Solvents and Primers
00 - General

Technical Data

Table 616. Primers and Solvents Approved Product Information

Subsec- Commer- Product Colour Shelf Drying Comments
tion cial name Number life Time
Activa- Loctite 332/U7901 Colour- 365d Less than Used to make low energy surfaces suit-
tor/Primer 770 less 5s able for bonding with cyanocrylate adhe-
sives. It is recommended for polyethylene,
polypropylene, PTFE and thermoplastic
rubber materials. Can be used with Loctite
406 (332/U7899).
Activator Loctite 4104/1700 Clear 730d Apply and HIGHLY FLAMMABLE. Organic accelera-
7455 amber leave to dry tor, non CFC solvent based surface activa-
for 30s be- tor. Designed to promote the speed of cure
fore apply- of cyanoacrylic adhesives.
ing adhe-
sive
Activator Loctite 4104/0200 Colour- 365d 1–3min Used with anaerobic products it increases
7471 less cure speed. Recommended for inert sur-
Per- faces and large bond gaps.
mabond
A905
Water Loctite 4104/0500 - - - A water proofing solution for protecting
proofing water joints made using cyanoacrylate adhesive.
proofing Apply to Loctite 495 (4103/0900).
Solvent Loctite 4104/1500 Colour- 365d 1min at HIGHLY FLAMMABLE, cleaner and de-
7063 less 20°C greaser. Removes grease, oil and dirt from
(68.0°F) electrical parts, tools and precision equip-
ment.
Cleaning Loctite 4101/2200 Colour- 365d No wipe Cleaning treatment to remove most greas-
fluid 7070 less 5–10min, es, oils, lubrication fluids and metal cuttings
post wipe
1–2min
Cleaning Simple 332/E9240 Colour- 365d - An all purpose cleaner and degreaser used
fluid green ex- less diluted in water for direct, spray and dip
treme tank procedures.
Applica- A4GBCJCB4104/3300 Blue 730d - Vinyl labels application fluid for use with the
tion fluid insignia/livery labels.
Gasket Loctite 4104/3200 Colour- 730d Allow 10– This is a product to aid the removal of
cleaner 7200 less 15min for cured chemical gaskets. Apply for time
gasket, specified and remove gasket with soft
30min for scraper.
silicone
gasket.
Hand Loctite 4104/3100 Light 540d - Is a heavy duty hand cleaner, specially for-
cleaner 7855 grey mulated for the most difficult to remove
soils like polyurethane, paints, primers, ad-
hesives etc. The product is free from sil-
icone and harsh solvents. Can be used
without water.
Hand Sika hand 4104/1300 Off - - A non-abrasive hand cleaner for use when
cleaner cleaner white using direct glazing materials.

75 - 34 9813/7000-2 75 - 34
 75 - Consumable Products
14 - Solvents and Primers
00 - General

Subsec- Commer- Product Colour Shelf Drying Comments

tion cial name Number life Time
Direct Sika acti- 4104/2100 Clear 365d 10min mini- HIGHLY FLAMMABLE. A cleaning and acti-
glazing vator mum drying vating agent specifically formulated for the
time treatment of bonded faces in direct glaz-
ing applications prior to applying the direct
glazing adhesive.
Direct Sika re- 4104/1900 Trans- - - A cleaning agent for removing contami-
glazing mover parent nates on painted surfaces and glass.
208 (use
4104/3600)
Direct Sika 4104/1200 Clear - - A cleaning agent for removing contami-
glazing cleaner nates on painted surfaces and glass.
205 (use
4104/3600)
Direct Sika 4104/2300 Black 270d Application Used to prime painted surfaces and plas-
glazing primer tempera- tic substrates prior to bonding with Sikaflex
209 (use ture 10– products.
4104/3500) 35°C (50.0–
95.0°F)
Direct Sika akti- 4104/2400 Clear 365d 10min Used to clean and give improved adhe-
glazing vator at more sion on glass, ceramic-coated glass, the cut
than 15°C face of old polyurethane adhesive beads,
(59.0°F) polyurethane coated windows glass and
or 30min paints.
at less
than 15°C
(59.0°F)
Active Tero- 4104/3400 Colour- 270d Minimum Applied with a clean cloth to the surface,
wipe for stat 8560 less 30s and the adhesive may then be applied after the
surface AC-25 maximum drying time. Applied to glass or ceramic
1h coating but only in the bonding area.
Direct Terostat 4102/3500 Black 0.1L Approx. Used to promote adhesion in direct glazing
glazing 8519 P bot- 2min to glass and glass ceramics.
tle =
365d.
0.01L
and
0.035L
bot-
tle =
540d
Cleaner Teroson 4104/3600 Clear 730d Depend- Used for degreasing and cleaning of sub-
FL clean- ing on con- strates prior to application of adhesives and
er ditions be- sealants.
tween 2–
10min.

75 - 35 9813/7000-2 75 - 35
 75 - Consumable Products
15 - Adhesive

15 - Adhesive

Contents Page No.

75-15-00 General ........................................................................................................................... 75-37

75 - 36 9813/7000-2 75 - 36
 75 - Consumable Products
15 - Adhesive
00 - General

00 - General Introduction
Introduction .................................................... 75-37 All adhesives should be used at all times in line with
Technical Data ............................................... 75-38 the manufacturer’s recommendations.

Adhesives are used for the bonding of a number

of engineering materials used in production at JCB.
Many types are available on the market but in the
interests of variety reduction and economy only a
limited selection is purchased for regular use.

Types of adhesive
Various types of adhesive are covered by JCB
Standards:

1. General purpose adhesives for bonding

laminated plastics, wood, rubber etc. to
themselves and to each other.
2. The more expensive cyanoacrylate adhesives
for use where high strength, resistance to many
chemicals and fast cure times are required.
3. Adhesives specially developed for bonding of
foam rubber to painted metal surfaces.

Additional health and safety for

cyanoacrylates
These adhesives require very careful handling on
account of their exceptional properties. They bond
together strongly and rapidly to most surfaces
including body tissue, the curing process being
initiated by surface moisture. For further information
on cyanoacrylates refer to the Manufacturer’s
recommendations.

Approved adhesives
The tables shown in Technical Data are the approved
adhesives available to use on JCB machines. The
tables also provide basic details to help with the
selection of adhesives. More up to date information
can be found on the manufacturer’s website.

75 - 37 9813/7000-2 75 - 37
 75 - Consumable Products
15 - Adhesive
00 - General

Technical Data

Table 617. Adhesives Approved Product Information

Subsec- Commer- Product Colour Shelf Technical Comments
tion cial name Number life data
High Per- 4103/3100 Mixed 730d 3–5min for Two part adhesive mixed in equal parts. A
strength mabond grey handling toughened adhesive system which bonds
5002 strength metals, plastics, wood, glass, ceramics and
composites; even plated or coated surfaces
can be securely fastened.
High Loctite 4103/1000 Green 365d 16–30bar This product is a single component anaero-
strength 601 fluores- (231.9– bic adhesive. Used to bond cylindrical fitting
cent 434.8psi) parts, particularly where low viscosity is re-
static shear quired. Maximum gap fill is 0.15mm.
strength
Cyano- Loctite 4103/3500 Colour- - 18–26bar Suitable for most materials including plas-
acrylate 424 less to (260.9– tic and rubber. Takes 30s to cure to working
straw 376.8psi) strength.
shear
strength
Cyano- Loctite 4103/2300 Colour- 180d 18–26bar Designed for general purpose use. For use
acrylate 401 less (260.9– on acidic and porous surfaces, reaching
376.8psi) handling strength in seconds. Materials in-
tensile clude plated metals, composite materials,
strength wood, cork, foam, leather and paper.
Cyano- Loctite 332/U7899 Colour- 180d 18–26bar Designed for bonding of plastics and elas-
acrylate 406 less (260.9– tomeric materials where very fast fixturing
376.8psi) is required. Can be used with Loctite 770
lap shear as a primer (332/U7901)
strength
Cyano- Loctite 4103/2400 Black 120d 22bar 0.2mm, gap fill. A rubber toughened ethyl
acrylate 410 (318.8psi) cyanoacrylate adhesive with enhanced re-
lap shear sistance to peel and shock. Bonds rubber,
strength metals and plastics for use in difficult condi-
tions.
Cyano- Loctite 4103/3800 Black - 22–30bar A rubber toughened adhesive with in-
acrylate 480 (318.8– creased flexibility and peel strength along
434.8psi) with enhanced resistance to shock.
lap shear
strength
Cyano- Loctite 4103/0900 Colour- 270d 12h maxi- High speed bonding, suitable for rubber to
acrylate 495 less mum cure itself and other materials reaching handling
Per- time strength in a matter of seconds. Joint must
mabond be waterproofed with Loctite water proofing
C2 (4104/0500).
Low Dunlop 4103/1100 Clear 90d - Sprayable adhesive, non-structural appli-
strength 1727 to light cations. For the bonding of flexible foam
British vita straw to themselves, wood, painted metal, chip-
company board, fibreglass, hessian, felt etc.
VB 165
Acrylic 3M 4941P 4103/3900 Dark 730d Peel ad- High bond acrylic double sided foam tape.
foam grey hesion Its allows more complete bond contact area
strip ad- 350N/ when bonding rigid or irregular materials
hesive 100mm due to its conformability. Its core adhesive
composition makes the product well suited
to many paints and primers.

75 - 38 9813/7000-2 75 - 38
 75 - Consumable Products
15 - Adhesive
00 - General

Subsec- Commer- Product Colour Shelf Technical Comments

tion cial name Number life data
General Araldite 4103/1400 Clear / 730d 560bar Two part, equal parts by weight. Wear pad
purpose XD 580 cream (8,115.9psi)
fixing to castings and telescopic compo-
gap fill- flexural nents, alignments of fixings pads without
ing ma- strength expensive machining. This product is a
terial general purpose gap-filling material. Cure
time 2h at 25°C (77.0°F).
Methacry- Loctite 4103/3600 Cream - - This is a sag resistant, two component,
late Speed- to light equal parts, methacrylate adhesive system
bonder yellow formulated to bond automotive grade cold
H3151 rolled steel without the use of an external
primer. Suitable for bonding a wide variety
of plastic and metal substrates. Provides a
long open time (40–60min) for correct align-
ing of parts.
Methacry- Plexus 4103/3700 Off- 365d 186– Two part methacrylate adhesive for struc-
late MA420 white or 206bar tural bonding of thermoplastic, metal and
blue (2,695.6– composite assemblies. Combined at 10:1
2,985.5psi) ratio. It has a working time of 4–6min.
Structur- Scotch- 332/S7420 Black 180d - Two part acrylic based adhesive (10:1 ra-
al plastic weld tio by vol.) that can bond many low surface
structural energy plastics, including many grades of
plastic ad- polypropylene, polyethylene and TPO’s
hesive without special surface preparation.
Non-pre- Evo-Stick 4103/0800 None- 365d HIGHLY A thin even film of adhesive should be ap-
ferred 528 pre- FLAMMA- plied to both surfaces being bonded and al-
adhesive ferred BLE lowed to become touch dry. This is a con-
tact adhesive and coated surfaces can-
not therefore be slid into position since the
bond forms on contact. It is often conve-
nient to align the parts along an edge and
then bring the two areas into contact.
Direct Sika 4103/2100 Black - - A one component polyurethane pre-poly-
glazing 250PC mer based adhesive. A mastic adhesive
Sikat- which reacts with atmospheric moisture to
ack Ultra- form a rubber like solid.
fast (use
4103/4000
or
4102/4900)
Direct Sika 4103/2200 Black - - For bonding glass to cab frames. A mas-
glazing 255FC tic adhesive which reacts with atmospheric
(use moisture to form a rubber like solid. When
4102/5000) using this product ensure both surfaces
are clean and dry. Use Sika cleaner 205
(4104/1200).
Direct Sikaflex 4103/3200 Black - - A high performance, elastic, gap, filling one
glazing 552 (use part structural adhesive cures on exposure
4102/5000) to atmospheric moisture to form a durable
elastomer. Contains no isocyanate.

75 - 39 9813/7000-2 75 - 39
 75 - Consumable Products
15 - Adhesive
00 - General

Subsec- Commer- Product Colour Shelf Technical Comments

tion cial name Number life data
Industri- Loctite 333/Y7062 Light - 307bar Single component, heat activated formu-
al grade Hysol Grey (4,449.3psi) lation develops tough, strong, structur-
epoxy E-214 HP Paste tensile al bonds which provide excellent peel re-
adhesive strength sistance and impact strength. When ful-
ly cured, the product offers superior ther-
mal shock resistance, excellent mechan-
ical and electrical resistance properties
and withstands exposure to a wide vari-
ety of solvents and chemicals. Bonds to a
wide variety of materials, including metals,
glass, ceramics and plastics. Cure at 120°C
(247.8°F) or above until completely firm.
Heat up to 150°C (301.8°F) for 2h, to maxi-
mize properties.
Anaero- Scotch- 333/L9575 Green 365d - Single component anaerobic adhesives de-
bic ad- weld signed to secure cylindrical metal assem-
hesive RT-20 blies such as bearings on shafts, bush-
(Dimethacry- ings, sleeves, housings, and keyways.
late) Help prevent loosening, corrosion and leak-
age caused by shock and vibration. Full
cure time 24h. Temperature range = -54°C
(129.1°F) to 450°C (841.4°F). Not recom-
mended for use on most plastics due to po-
tential cracking of plastic parts.
Direct Terostat 4102/4900 Black 540d - Cure rate: approx. 3–4mm/24h. Glazing
glazing 8597 CT in time: maximum 20min (period of time be-
orig- tween beginning of material application until
inal inserting of the pane).
pack-
aging
Direct Teroson 4102/5000 Black, 365d - Skin formation time: approx. 10min. Cure
glazing 939CT / off- in rate: approx. 3mm/24h.
Terostat white, orig-
MS939 grey, inal
black pack-
aging
Direct Terostat 4103/4000 Black 180d 80bar One component, pumpable adhe-
glazing 8900 HV (1,159.4psi)sive/sealant based on polyurethane, which
tensile cures by reaction with moisture to an elas-
strength tic rubber. The skin formation and curing
time are dependent on humidity, tempera-
ture and depth of joint. High temperature
and high moisture reduces curing time.
Sag resistant, temperature range of -40°C
(103.9°F) to 90°C (193.9°F).
Direct Tero- 4103/4100 Black 270d 85bar Single component, moisture curing, ad-
glazing stat 8594 (1,231.9psi) hesive/sealant for repair. Product with
HMLC tensile high shear modulus and low conductivity.
strength Suitable for all applications that require very
high electrical insulation of the adhesive
used for the bonding of windows. Sag resis-
tant.

75 - 40 9813/7000-2 75 - 40
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00 - General

Subsec- Commer- Product Colour Shelf Technical Comments

tion cial name Number life data
Direct Terostat 4103/4200 Black 365d 80bar One component, pumpable adhe-
glazing 8900 LV in (1,159.4psi) sive/sealant based on polyurethane, which
car- tensile cures by reaction with moisture to an elas-
tridges.strength tic rubber. The skin formation and curing
180d time are dependent on humidity, tempera-
in ture and depth of joint. High temperature
sausage and high moisture reduces curing time.
pack. Sag resistant, temperature range of -40°C
180d (103.9°F) to 90°C (193.9°F) short exposure
in (up to 1h) of 130°C (265.8°F).
hob-
bocks
and
drums
Direct Sika 295 4103/4300 Black, 365d - Direct glazing adhesive for plastic glaz-
glazing UV white ing panels. One component polyurethane
adhesive of paste like consistency. 60min
tack free time, 1d cure time (4mm at 23°C
(73.4°F)). Good UV, fresh water and sea-
water resistance. Do not apply below tem-
peratures of 10°C (50.0°F) or above 35°C
(95.0°F).

75 - 41 9813/7000-2 75 - 41
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16 - Sealant

16 - Sealant

Contents Page No.

75-16-00 General ........................................................................................................................... 75-43

75 - 42 9813/7000-2 75 - 42
 75 - Consumable Products
16 - Sealant
00 - General

00 - General Introduction
Introduction .................................................... 75-43 All sealants should be used at all times in line
Technical Data ............................................... 75-44 with the manufacturer’s recommendations. Sealants
are used mainly for the sealing of screwed joints,
sealing flanges and flat surfaces and where gap
filling properties are required.

Types of Sealant
Various types of sealant are specified in JCB
Standards:

1. Those for the sealing of screwed joints.

2. Sealants for joining flanges and flat surfaces.
(Flange size and likelihood of dismantling
require consideration when selecting this type of
sealant).
3. Sealants for use where gap filling properties are
required. (The gap dimensions, joint movement
if any, type of materials being joined and
aesthetic appearance require consideration
when selecting this type of sealant).

Approved Sealants
The table shown in Technical Data are the approved
sealants available to use on JCB machines. The
table also provides basic details to help with selection
of sealants. More up to date information can be found
on the manufacturer’s website.

75 - 43 9813/7000-2 75 - 43
 75 - Consumable Products
16 - Sealant
00 - General

Technical Data

Table 618. Sealants Approved Product Information

Subsec- Com- Product Colour Shelf Technical Comments
tion mercial Number life data
name
High Loctite 4102/0500 Green 730d 250bar Non drip formulation, used on larger fittings,
strength 275(1) (3,623.2psi) coarse threads.
Per- torque
mabond strength
A140 (on M8)
High Forge- 4102/3100 Yellow 270d 25bar Can be painted over with some 2 pack
strength way (362.3psi) paint. Maximum width of joint =35mm, min-
240FC
(1)
breaking imum width =2mm, minimum depth =2mm.
strength Recommended depth of joint = width of
joint.
Medium Loctite 4102/3500 Green - More than Used for locating pins in radiator assem-
to high 620 241bar blies, sleeves into pump housings and
strength (3,492.7psi) bearings in auto transmissions. Not suitable
shear for plastics. Diametrical clearance: up to
strength 0.2mm
Medium Loc- 4102/2000 Red, flu- 365d 90bar Typically used as form-in-place gasket on
strength tite 518 ores- (1,304.3psi) rigid flanged connections.
Gasket cent tensile
Elimina- strength
tor
Medium Loctite 4102/4100 Red gel, - 80bar It is manufactured to minimise air bubbles
strength 5182 fluores- (1,159.4psi) in the package. Used to seal gaskets, hous-
cent shear ings, cases and covers. It can also be used
strength to repair and replace cut gaskets (up to
0.08mm in thickness).
Medium Loctite 4102/2500 Clear 365d 6mm gap Formulated to withstand weathering and
strength 595 filling extreme temperature cycling. Used for pot-
ting, coating and sealing. Can be applied
horizontal, vertical and overhead.
Medium Loctite 4102/1900 Yellow 365d 170bar A fast curing thread sealant used on coarse
strength 577
(1)
(2,463.8psi) threads and pipe fittings up to 75mm thread
Per- breakaway size. Clearance for gap filling 0.8mm.
mabond torque
A1044
Medium Loctite 4102/2700 Blue 365d 140– Taper thread sealant, non-fluorescing to
strength 2431 340bar see oil leaks. Suitable for all taper fittings
(2,029.0– up to M36.
4,927.5psi)
breakaway
torque
Low Clayton 4102/2200 White 12h Maximum Seals pipes and plugs against leakage of
strength Dewan- opaque full seal pres- air, fuels, lubricants and coolants. Hardens
dre air cure sure 29bar to a tough seal resistant to shock and vibra-
brake (420.3psi) tion. Easily dismantled.
sealant
SC1252
Low Red 4102/0800 - - Resistant Non-hardening paste jointing for joints reg-
strength Her- to oil ularly opened for servicing.
metite

75 - 44 9813/7000-2 75 - 44
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00 - General

Subsec- Com- Product Colour Shelf Technical Comments

tion mercial Number life data
name
Low Loctite 4102/1100 White 730d 40–100bar Used where slow cure is required to permit
strength 572 opaque (579.7– component alignment. PTFE (Polytetrafluo-
1,449.3psi) roethylene) filler.
breakaway
torque
Gas- Loc- 4102/3200 Blue to 0.2mm 72h full Easy disassembly, used as form-in-place
keting tite 509 green gap strength on gasket.
medium Gasket filling steel
strength Elimi-
nator
Flange
Sealant
Gas- Loctite 4102/1200 Red 730d 2h working Does not creep or relax after curing, no bolt
keting 574
(1)
strength re-tightening is required. Oil resistant. Ideal
medium Per- for formed in-situ gaskets.
strength mabond
A136
Sealant Loctite 4102/2600 Black 365d Resists Used to dress new or worn gaskets. Dries
for gas- FAG 2 / pres- slowly, sets to pliable film for easy disman-
kets Loctite sures up tling.
5922 to 345bar
(5,000.0psi)
Rubber Dow 4102/0900 Clear or 270d 16.7bar A synthetic rubber joint sealant suitable for
jointing corning translu- (242.0psi) joints between non-porous surfaces such
com- 781 cent tensile as glass and metal, metal and metal where
pound Loc- strength relatively large gap filling properties are re-
tite su- quired. Suitable for vertical and overhead
perflex applications under normal atmospheric con-
clear ditions. Joint movement approx.+/-12.5%.
RTV3 Cure time to 6mm depth in 24h.
EVO-
stick
stan-
dard in-
dustri-
al clear
silicone
sealant
Dun-
lop high
modulus
silicone
sealant
DP2205
Epoxy Loc- 4102/2400 Slightly - - 0.05L container requires special bi-mixer
resin tite fast coloured / (gun) so it is mixed as dispensed, 0.024L is
epoxy trans- mixed by hand.
sealant parent
Room Loctite 4102/3400 Metal- - Dry to Designed for flange sealing, good resis-
tempera- 5910, lic black touch in tance to oils and allows high joint move-
ture vul- Flange paste 40min ment.
canising sealant,
RTV Sil-
icon

75 - 45 9813/7000-2 75 - 45
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16 - Sealant
00 - General

Subsec- Com- Product Colour Shelf Technical Comments

tion mercial Number life data
name
Room Loctite 4102/4200 Black 730d 18bar Used for gaskets. Excellent resistance to
tempera- 5970 (260.9psi) engine oils. Typical applications include
ture vul- tensile stamped sheet metal covers (timing covers
canising strength and oil sumps) where good oil resistance
and the ability to withstand high joint-move-
ment are required.
Room Loc- 4102/2900 Black 270d 16bar Thixotropic allowing easy application, hori-
tempera- tite su- (231.9psi) zontal, vertical and overhead. Seals against
ture vul- perflex tensile water and many solvents.
canising black strength
silicone
Room Loctite 4102/3700 Grey 730d 14bar Designed specifically for on line, low pres-
tempera- 5901 (202.9psi) sure tests carried out before product be-
ture vul- shear gins to cure. Product exhibits excellent re-
canising strength sistance to automotive engine oils. Primari-
ly for flange sealing, it withstands high joint-
movement requirements.
Room Loctite 4102/3900 Black 730d 20bar Generally used for sealing applications, but
tempera- 5368 paste (289.9psi) also for bonding and for high temperature
ture vul- tensile protection.
canising strength
Room Loctite 4102/4000 Clear 730d 20bar Designed specifically for use as a bond-
tempera- 5366 paste (289.9psi) ing agent to ensure perfect sealing, as
ture vul- shear well as bonding and protection. Examples
canising strength are sealing side windows in trains, seal-
ing heat sources (heat exchangers and wa-
ter heaters) and for protection/insulation of
electrical boxes.
Room Hylomar 332/D5695 Black 540d 40bar A special purpose adhesive and sealant
tempera- 607 paste (579.7psi) that can be used for a variety of applica-
ture vul- tensile tions. It has good resistance to oils and
canising strength aqueous anti-freeze agents, and is particu-
larly suitable for high strength applications
in odour sensitive environments.
Joining Loctite 4102/3800 Black 730d 14bar JCB Service ONLY. Introduced for joining
oil pan to 5900 paste (202.9psi) the oil pan to the bedplate face during ser-
bedplate shear vice. High resistance to engine oils. The
strength joint should be clamped to spread the ad-
hesive and allowed to cure for 7d before
heavy service duty.
Anti-cor- To mil- 4102/4300 Yellow - Type 1 Used to coat surfaces of dissimilar metals
rosive itary Class C prior to assembly to prevent corrosion. Zinc
spec chromate containing substance ideal for ap-
TT- plication to joints between aluminium and
P-1757B steel to prevent corrosion and seizure. FOR
1CY USE ON MILITARY VEHICLES ONLY.
Gas- Bondloc 4102/4500 Clear/ - Full cure B555 is an anaerobic gasket sealant. It
keting B555 Opaque time 24h. seals close fitting joints between rigid metal
medium 50bar faces and flanges. Tensile strength to ISO
strength (724.6psi) 6922.
tensile
strength

75 - 46 9813/7000-2 75 - 46
 75 - Consumable Products
16 - Sealant
00 - General

Subsec- Com- Product Colour Shelf Technical Comments

tion mercial Number life data
name
Seam Terolan 4102/4600 Light 90d - Serves as a seam sealant between sheet
sealant 3412 grey metal butt and overlap joints (interior
AA-25 seems) on vehicle bodies. Can be cured at
temperatures of minimum 140°C (283.8°F)
(effective metal temperature) for 15min.
The material is applied to electro-dip coated
steel sheets.
Direct Sikaflex 4102/2800 Yellow - - Direct glazing one component polyurethane
glazing 221 based adhesive and sealant compound.
(use Tack free time of 50min.
4102/4800)
Direct Sikaflex 4102/2300 Black - - A one component polyurethane pre-poly-
glazing 252 mer based sealant. For sealing glass to
(use frames. A mastic sealant which reacts with
4102/4700)
(1)
atmospheric moisture to form a rubber like
solid.
Direct Teroson 4102/4700 - 365d - The substrates must be clean, dry, oil and
glazing PU92 in grease free. Skin formation time: approx.
CT orig- 20min Cure rate: approx. 4mm/24h
inal
pack-
aging
Direct 930 4102/4800 Yellow 365d - The substrates must be clean, dry, oil and
glazing JCB in grease free. It can be necessary to rough-
Branded orig- en the surface or to use a primer/adhe-
yellow inal sion promoter to provide optimum adhe-
CT pack- sion. When manufacturing of plastics, ex-
aging ternal release agents are often used; these
agents must be absolutely removed prior.
Skin formation time : approx. 20min Cure
rate : approx. 4mm/24h
Direct Terostat 4102/4900 Black - - Isocyanate free solution. Designed for use
glazing 8597 without primer or activator. When you use
CT this sealant on operator station, it should be
used with Teroson PU 8519P black primer
(and Teroson 450 clear adhesion promoter
when specified specially). Cross compatible
with all OEM / OES / AAM DGX sealants,
including MS and PU chemistry (any re-
maining bead must be fully cured before
application).
Silicone Si- 4102/5100 Black - - High modulus permanently flexible 100%
sealant - ka/Ever- silicone. Temperature resistant up to 300°C
Heat re- build (571.6°F). Ideal for sealing industrial and
sistant Heat high performance gaskets, oven doors etc.
Mate
Gas- Loctite 4102/6100 Opaque - - Introduced for Heavy products India (swing
ket and 510 pink motor/ gearbox face).
sealing
(1) This is a non preferred product.

75 - 47 9813/7000-2 75 - 47
 75 - Consumable Products
18 - Fuel

18 - Fuel

Contents Page No.

75-18-00 General ........................................................................................................................... 75-49

75 - 48 9813/7000-2 75 - 48
 75 - Consumable Products
18 - Fuel
00 - General

00 - General Health and Safety

Health and Safety .......................................... 75-49 Fuel
Technical Data ............................................... 75-50 Fuel is flammable, keep naked flames away from the
fuel system. Stop the engine immediately if a fuel
leak is suspected. Do not smoke while refuelling or
working on the fuel system. Do not refuel with the
engine running. Completely wipe off any spilt fuel
which could cause a fire. There could be a fire and
injury if you do not follow these precautions.
WARNING! Do not use petrol in this machine. Do not
mix petrol with the diesel fuel. In storage tanks the
petrol will form flammable vapours.

75 - 49 9813/7000-2 75 - 49
 75 - Consumable Products
18 - Fuel
00 - General

Technical Data

Notice: No warranty liability whatsoever will be where the failure is attributed to the quality and
accepted for failure of fuel injection equipment grade of the fuel used.

Table 619. Acceptable Fuels

Fuel Specification Applicable Engines Service Requirements
EN590 Diesel fuel types - Auto/C0/ All Obey the usual routine mainte-
C1/C2/C3/C4 nance schedules and procedures.
BS2869 Class A2
ASTM D975-076 2-D, US DF1, US
DF2, US DFA
JIS K2204 Grades 1, 2, 3 and Spe-
cial Grade 3
ASTM D975-076 1-D All (engines operated with these Obey the usual routine mainte-
MIL T38219 JP7 fuels may have a reduced service nance schedules and procedures.
life) Fuel additives are recommended
NATO F63
for use with low sulphur fuels.
(1)

French EN590 (RME5) with 5%

maximum
AVTURFSII, NATO F34, JP8, MIL All (engines operated with these Obey the usual routine mainte-
T83133, DERD 2463, DEF STAN fuels may have a reduced service nance schedules and procedures.
91-87 life) Fuel additives must be used.
AVCAT FSII, NATO F44, JP5, MIL
T5624, DERD 2452, AVTOR
NATO F35, JET A1, DEF STAN
91-91, DERD 2494, XF63
AVCAT, NATO F43 (obsolete),
JP5 without additives
JET A (ASTM D1655)
ASTM D3699 Kerosene
B5 Biodiesel - RME content blend- Tier 3 only
(2)
You must obey special routine
ed with mineral derived diesel (5% maintenance schedules and proce-
maximum) - ASTM D6751, DIN dures.
51606, ISO 14214
(1) Use a fuel additive (where instructed) to make sure that the fuel meets the minimum lubricity requirement.
(2) Refer to Typical Engine Identification Number.

Additives • Paradyne 7505 (from Infineum). Dosage 500

ppm (0.05%).
The additives listed below are advertised as being
suitable for bringing the lubricity levels of kerosene/ These products are given as examples only. The
low sulphur fuels up to those of diesel fuels. They information is derived from the manufacturers data.
must be used as specified by your fuel supplier who The products are not recommended or endorsed by
will understand the concentration level necessary. JCB.

The lubricity wear scar diameter must not be more Service Requirements for use of B5
than 460 microns, as tested on a high frequency Biodiesel
reciprocating rig at 60°C (139.9°F). Refer to ISO
12156-1. • The engine oil must be a grade CH4 as
minimum specification.
• Elf 2S 1750. Dosage 1000-1500 parts per • Do not leave unused B5 biodiesel in the fuel
million (0.1–0.15%), specifically for Indian tank for extended periods (top up each day).
Superior Kerosene (SKO) but may be • Make sure that 1 in 5 fuel tank fills use standard
applicable to other fuels. diesel to EN590 specification, this will help to
• Lubrizol 539N. Dosage (on Swedish low prevent 'gumming'.
sulphur fuel) 250 parts per million.

75 - 50 9813/7000-2 75 - 50
 75 - Consumable Products
18 - Fuel
00 - General

• Make sure regular oil sampling is completed High sulphur content can cause engine wear. High
(look for excessive unburnt fuel content, water sulphur fuel is not normally found in North America,
or wear particles. Europe or Australia. If you have to use high sulphur
• Change the engine oil and filter more frequently fuel you must change the engine oil more frequently.
(as a minimum half the recommended
intervals), or as indicated by oil sampling. Low sulphur fuels must have the appropriate fuel
• Change the fuel filters more frequently (as a lubricity additives, these lubricity improvers must not
minimum half the recommended intervals), or if create residual deposits that block the fuel system,
there are engine performance related issues. for example injectors, filters etc. Contact your fuel
• Make sure the fuel is stored correctly, care must supplier.
be taken to make sure no water enters the
machine fuel tank (or the storage tank). Water Table 620. Sulphur Content
will encourage mico-bacterial growth. Percentage of sulphur Oil Change Interval
• Make sure that the fuel pre-filter is drained daily in the fuel
(not every week as currently advised).
Less than 0.5% Normal
• Only Tier 3 engines (factory filled with CH4 oil)
- this is not approved with other manufacturers. 0.5–1% 75% of normal
• Use heater kits in low ambient temperature More than 1% 50% of normal
territories.
• The biodiesel must meet the following Effects of Fuel Contaminates
standards: ASTM D6751, DIN 51606, ISO
14214. The effect of dirt, water and other contaminants in
diesel can be disastrous for injection equipment:
If necessary use a test kit to confirm the fuel
specification. Testing kits are available (not from JCB Dirt: A severely damaging contaminant. Finely
currently), use the internet as a source for the kits. machined and mated surfaces such as delivery
valves and distributor rotors are susceptible to the
If performance related issues are to be reported abrasive nature of dirt particles - increased wear will
to JCB Service, and the engine has been run on almost inevitably lead to greater leakage, uneven
biodiesel, then the fuel system must be filled with running and poor fuel delivery.
standard diesel (at least 2 x tank fills) to EN590
specification and relevant stall speeds recorded prior Water: Water can enter fuel through poor storage
to making the report. or careless handling, and will almost inevitably
condense in fuel tanks. The smallest amounts of
Warranty water can result in effects that are just as disastrous
to the fuel injection pump as dirt, causing rapid
JCB have shown a commitment to support the wear, corrosion and in severe cases, even seizure.
environment by approving the use of biodiesel It is vitally important that water is prevented from
blended fuels. reaching the fuel injection equipment. The filter/water
trap must be drained regularly.
Using a B5 blend of biodiesel requires caution and
additional servicing of the engine is required. Wax: Wax is precipitated from diesel when the
ambient temperature falls below that of the fuel's
Failure to follow the additional recommended service cloud point, causing a restriction in fuel flow resulting
requirements may lead to a warranty claim being in rough engine running. Special winter fuels may be
declined. available for engine operation at temperatures below
0°C (32.0°F). These fuels have a lower viscosity and
Failures resulting by the incorrect use of biodiesels limit wax formation.
or other fuel additives are not defects of the engine
workmanship and therefore will not be supported by
JCB Warranty.

Sulphur Content
CAUTION A combination of water and sulphur will
have a corrosive chemical effect on fuel injection
equipment. It is essential that water is eradicated
from the fuel system when high sulphur fuels are
used.

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