JCB 403 Wheel Loading Shovel Repair Service Manual

Download Ebook


(S/N: 1070000 to 1070499)

This service manual PDF download for the 403 JCB Wheel Loading Shovel has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.

APPLICABLE MODELS :

JCB Wheeled Loader / Loading Shovel
JCB 403 – from S/N: 1070000 to 1070499

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Maintenance
Section A – Attachments
Section B – Body and Framework
Section C – Electrics
Section E – Hydraulics
Section K – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes –
P/N : 9803-9490-1
Total Pages : 187

This service manual / repair manual / workshop manual PDF download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

More Info : http://www.sitelux.com

9803-9490
JCB 403
Section 1 – General Information
Section 1
Section 1
General Information
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Manual – JCB 403
Service Manual – JCB 403
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Maintenance
Section 3 – Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
<GRAPHIC
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Notes:
<TABLE BODY
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
About this Manual
About this Manual
Introduction
Introduction
Using the Service Manual
Using the Service Manual
This publication is designed for the benefit of JCB Distributor Service Engineers who are receiving, or have received, training by JCB Technical Training Department.
These personnel should have a sound knowledge of workshop practice, safety procedures, and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment.
The illustrations in this publication are for guidance only. Where the machines differ, the text and/or the illustration will specify.
General warnings in Section 2 are repeated throughout the manual, as well as specific warnings. Read all safety statements regularly, so you do not forget them.
Renewal of oil seals, gaskets, etc., and any component showing obvious signs of wear or damage is expected as a matter of course…
Where a torque setting is given as a single figure it may be varied by plus or minus 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third.
The manufacturer’s policy is one of continuous improvement. The right to change the specification of the machine without notice …
Finally, please remember above all else safety must come first!
Units of Measurement
Units of Measurement
In this publication, the S.I. system of units is used. For example, liquid capacities are given in litres. The Imperial units follow in parentheses ( ) eg 28 litres (6 gal).
Section Numbering
Section Numbering
The manual is compiled in sections, the first three are numbered and contain information as follows:
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
1
1
General Information – includes torque settings and service tools.
<TABLE ROW
2
2
Care and Safety – includes warnings and cautions pertinent to aspects of workshop procedures etc.
<TABLE ROW
3
3
Maintenance – includes service schedules and recommended lubricants for all the machine.
The remaining sections are alphabetically coded and deal with Dismantling, Overhaul etc. of specific components, for example:
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
A
A
Attachments
<TABLE ROW
B
B
Body and Framework, etc.
Section contents, technical data, circuit descriptions, operation descriptions etc. are inserted at the beginning of each alphabetically coded section.
Cross References
Cross References
In this publication, page cross references are made by presenting the subject title printed in bold, italic and underlined. It i…
K Cross References ( T 1-1)
Using the Machine
Using the Machine
To use the machine efficiently and safely you must know the machine and have the skill to use it. You must abide by all relevant…
Hydraulic Schematic Colour Codes
Hydraulic Schematic Colour Codes
The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publications.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Red
Red
Full Pressure: Pressure generated from operation of a service. Depending on application this may be anything between neutral circuit pressure and MRV operating pressure.
Full Pressure:
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pink
Pink
Pressure: Pressure that is above neutral circuit pressure but lower than that denoted by Red.
Pressure:
<TABLE ROW
<GRAPHIC
<GRAPHIC
Orange
Orange
Servo: Oil pressure used in controlling a device (servo).
Servo:
<TABLE ROW
<GRAPHIC
<GRAPHIC
Blue
Blue
Neural: Neutral circuit pressure.
Neural:
<TABLE ROW
<GRAPHIC
<GRAPHIC
Green
Green
Exhaust
Exhaust
<TABLE ROW
<GRAPHIC
<GRAPHIC
Light Green
Light Green
Cavitation: Oil subjected to a partial vacuum due to a drop in pressure (cavitation).
Cavitation:
<TABLE ROW
<GRAPHIC
<GRAPHIC
Yellow
Yellow
Lock Up: Oil trapped within a chamber or line, preventing movement of components (lock up).
Lock Up:
Identifying the Machine
Identifying the Machine
Serial Numbers
Serial Numbers
Machine Model and Serial Number
Machine Model and Serial Number
This manual provides information for the following machines :
403 from machine serial number 1070000 to 1070499.
Data Plate
Data Plate
Your machine has a Data Plate. The serial numbers of the machine, engine and transmission unit
<GRAPHIC
<GRAPHIC
Fig 1.
Typical Vehicle Identification Number (VIN)
Typical Vehicle Identification Number (VIN)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
1
2
3
4
5
<TABLE BODY
<TABLE ROW
SLP
403
7
E
1070000
1 World Manufacturer Identification (SLP = JCB)
1 World Manufacturer Identification (SLP = JCB)
2 Machine Type (403)
3 Year of Manufacture (1 = 2001, 2 = 2002, 3 = 2003, 4 = 2004, 5 = 2005, 6 = 2006, 7=2007)
4 Manufacturers Location (E = England)
5 Machine Serial Number (1070000)
Typical Engine Identification Number
Typical Engine Identification Number
If the engine is replaced by a new one, the data plate serial number will be wrong. Either stamp the new number on the plate or stamp out the old one. This will prevent the wrong number being quoted when you order replacement parts.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
a
b
c
d
e
<TABLE BODY
<TABLE ROW
AB
50316
J
000001
2
a Engine Type (AB= 4 cylinder turbo)
a Engine Type (AB= 4 cylinder turbo)
a Engine Type (AB= 4 cylinder turbo)
a Engine Type (AB= 4 cylinder turbo)
b Engine Parts List
c Country of Manufacture
d Engine Serial Number
e Year of Manufacture
Standard Torque Settings
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Introduction
Some external fasteners on JCB machines are manufactured using an improved type of corrosion resistant finish. This type of finish is called Dacromet and replaces the original Zinc and Yellow Plating used on earlier machines.
The two types of fasteners can be readily identified by colour and part number suffix.
K Table 1. Fastener Types ( T 1-4)
Table 1. Fastener Types
Table 1. Fastener Types
<TABLE
<TABLE HEADING
<TABLE ROW
Fastener Type
Colour
Part No. Suffix
<TABLE BODY
<TABLE ROW
Zinc and Yellow
Golden finish
‘Z’ (e.g. 1315/3712Z)
<TABLE ROW
Dacromet
Mottled silver finish
‘D’ (e.g. 1315/3712D)
As the Dacromet fasteners have a lower torque setting than the Zinc and Yellow fasteners, the torque figures used must be relevant to the type of fastener.
A Dacromet bolt should not be used in conjunction with a Zinc or Yellow plated nut, as this could change the torque characteristics of the torque setting further. For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt.
All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
Dacromet bolts, due to their high corrosion resistance are used in areas where rust could occur. Dacromet bolts are only used for external applications. They are not used in applications such as gearbox or engine joint seams or internal applications.
Bolts and Screws
Bolts and Screws
Use the following torque setting tables only where no torque setting is specified in the text.
Dacromet fasteners are lubricated as part of the plating process, do not lubricate.
Torque settings are given for the following conditions:
Condition 1
Condition 1
– Un-lubricated fasteners
– Un-lubricated fasteners
– Zinc fasteners
– Yellow plated fasteners
Condition 2
Condition 2
– Zinc flake (Dacromet) fasteners
– Zinc flake (Dacromet) fasteners
– Lubricated zinc and yellow plated fasteners
– Where there is a natural lubrication. For example, cast iron components
Verbus Ripp Bolts
Verbus Ripp Bolts
<GRAPHIC
<GRAPHIC
Fig 2.
Torque settings for these bolts are determined by the application. Refer to the relevant procedure for the required settings.
Table 2. Torque Settings – UNF Grade ‘S’ Fasteners
Table 2. Torque Settings – UNF Grade ‘S’ Fasteners
<TABLE
<TABLE HEADING
<TABLE ROW
Bolt Size
Hexagon (A/F)
Condition 1
Condition 2
<TABLE ROW
in.
mm
in.
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
1/4
6.3
7/16
11.2
1.1
8.3
10.0
1.0
7.4
<TABLE ROW
5/16
7.9
1/2
22.3
2.3
16.4
20.0
2.0
14.7
<TABLE ROW
3/8
9.5
9/16
40.0
4.1
29.5
36.0
3.7
26.5
<TABLE ROW
7/16
11.1
5/8
64.0
6.5
47.2
57.0
5.8
42.0
<TABLE ROW
1/2
12.7
3/4
98.00
10.0
72.3
88.0
9.0
64.9
<TABLE ROW
9/16
14.3
13/16
140.0
14.3
103.2
126.0
12.8
92.9
<TABLE ROW
5/8
15.9
15/16
196.0
20.0
144.6
177.0
18.0
130.5
<TABLE ROW
3/4
19.0
1 1/8
343.0
35.0
253.0
309.0
31.5
227.9
<TABLE ROW
7/8
22.2
1 15/16
547.0
55.8
403.4
492.0
50.2
362.9
<TABLE ROW
1
25.4
1 1/2
814.0
83.0
600.4
732.0
74.6
539.9
<TABLE ROW
1 1/8
31.7
1 7/8
1181.0
120.4
871.1
1063.0
108.4
784.0
<TABLE ROW
1 1/4
38.1
2 1/4
1646.0
167.8
1214.0
1481.0
151.0
1092.3
Table 3. Torque Settings – Metric Grade 8.8 Fasteners
Table 3. Torque Settings – Metric Grade 8.8 Fasteners
<TABLE
<TABLE HEADING
<TABLE ROW
Bolt Size
Hexagon (A/F)
Condition 1
Condition 2
<TABLE ROW
ISO Metric Thread
mm
mm
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
M5
5
8
5.8
0.6
4.3
5.2
0.5
3.8
<TABLE ROW
M6
6
10
9.9
1.0
7.3
9.0
0.9
6.6
<TABLE ROW
M8
8
13
24.0
2.4
17.7
22.0
2.2
16.2
<TABLE ROW
M10
10
17
47.0
4.8
34.7
43.0
4.4
31.7
<TABLE ROW
M12
12
19
83.0
8.5
61.2
74.0
7.5
54.6
<TABLE ROW
M16
16
24
205.0
20.9
151.2
184.0
18.8
135.7
<TABLE ROW
M20
20
30
400.0
40.8
295.0
360.0
36.7
265.5
<TABLE ROW
M24
24
36
690.0
70.4
508.9
621.0
63.3
458.0
<TABLE ROW
M30
30
46
1372.0
139.9
1011.9
1235.0
125.9
910.9
<TABLE ROW
M36
36
55
2399.0
244.6
1769.4
2159.0
220.0
1592.4
Table 4. Metric Grade 10.9 Fasteners
Table 4. Metric Grade 10.9 Fasteners
<TABLE
<TABLE HEADING
<TABLE ROW
Bolt Size
Hexagon (A/F)
Condition 1
Condition 2
<TABLE ROW
ISO Metric Thread
mm
mm
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
M5
5
8
8.1
0.8
6.0
7.3
0.7
5.4
<TABLE ROW
M6
6
10
13.9
1.4
10.2
12.5
1.3
9.2
<TABLE ROW
M8
8
13
34.0
3.5
25.0
30.0
3.0
22.1
<TABLE ROW
M10
10
17
67.0
6.8
49.4
60.0
6.1
44.2
<TABLE ROW
M12
12
19
116.0
11.8
85.5
104.0
10.6
76.7
<TABLE ROW
M16
16
24
288.0
29.4
212.4
259.0
26.4
191.0
<TABLE ROW
M20
20
30
562.0
57.3
414.5
506.0
51.6
373.2
<TABLE ROW
M24
24
36
971.0
99.0
716.9
874.0
89.1
644.6
<TABLE ROW
M30
30
46
1930.0
196.8
1423.5
1737.0
177.1
1281.1
<TABLE ROW
M36
36
55
3374.0
344.0
2488.5
3036.0
309.6
2239.2
Table 5. Metric Grade 12.9 Fasteners
Table 5. Metric Grade 12.9 Fasteners
<TABLE
<TABLE HEADING
<TABLE ROW
Bolt Size
Hexagon (A/F)
Condition 1
Condition 2
<TABLE ROW
ISO Metric Thread
mm
mm
Nm
kgf m
lbf ft
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
M5
5
8
9.8
1.0
7.2
8.8
0.9
6.5
<TABLE ROW
M6
6
10
16.6
1.7
12.2
15.0
1.5
11.1
<TABLE ROW
M8
8
13
40.0
4.1
29.5
36.0
3.7
26.5
<TABLE ROW
M10
10
17
80.0
8.1
59.0
72.0
7.3
53.1
<TABLE ROW
M12
12
19
139.0
14.2
102.5
125.0
12.7
92.2
<TABLE ROW
M16
16
24
345.0
35.2
254.4
311.0
31.7
229.4
<TABLE ROW
M20
20
30
674.0
68.7
497.1
607.0
61.9
447.7
<TABLE ROW
M24
24
36
1165.0
118.8
859.2
1048.0
106.9
773.0
<TABLE ROW
M30
30
46
2316.0
236.2
1708.2
2084.0
212.5
1537.1
<TABLE ROW
M36
36
55
4049.0
412.9
2986.4
3644.0
371.6
2687.7
Table 6. Torque Settings – Rivet Nut Bolts/Screws
Table 6. Torque Settings – Rivet Nut Bolts/Screws
<TABLE
<TABLE HEADING
<TABLE ROW
Bolt Size
Nm
kgf m
lbf ft
<TABLE ROW
ISO Metric Thread
mm
<TABLE BODY
<TABLE ROW
M3
3
1.2
0.1
0.9
<TABLE ROW
M4
4
3.0
0.3
2.0
<TABLE ROW
M5
5
6.0
0.6
4.5
<TABLE ROW
M6
6
10.0
1.0
7.5
<TABLE ROW
M8
8
24.0
2.5
18.0
<TABLE ROW
M10
10
48.0
4.9
35.5
<TABLE ROW
M12
12
82.0
8.4
60.5
Table 7. Torque Settings – Internal Hexagon Headed Cap Screws (Zinc)
Table 7. Torque Settings – Internal Hexagon Headed Cap Screws (Zinc)
<TABLE
<TABLE HEADING
<TABLE ROW
Bolt Size
Nm
kgf m
lbf ft
<TABLE ROW
ISO Metric Thread
<TABLE BODY
<TABLE ROW
M3
2.0
0.2
1.5
<TABLE ROW
M4
6.0
0.6
4.5
<TABLE ROW
M5
11.0
1.1
8.0
<TABLE ROW
M6
19.0
1.9
14.0
<TABLE ROW
M8
46.0
4.7
34.0
<TABLE ROW
M10
91.0
9.3
67.0
<TABLE ROW
M12
159.0
16.2
117.0
<TABLE ROW
M16
395.0
40.0
292.0
<TABLE ROW
M18
550.0
56.0
406.0
<TABLE ROW
M20
770.0
79.0
568.0
<TABLE ROW
M24
1332.0
136.0
983.0
Hydraulic Connections
Hydraulic Connections
‘O’ Ring Face Seal System
‘O’ Ring Face Seal System
Adaptors Screwed into Valve Blocks
Adaptors Screwed into Valve Blocks
Adaptor screwed into valve blocks, seal onto an ‘O’ ring which is compressed into a 45˚ seat machined into the face of the tapped port.
Table 8. Torque Settings – BSP Adaptors
Table 8. Torque Settings – BSP Adaptors
<TABLE
<TABLE HEADING
<TABLE ROW
BSP Adaptor Size
Hexagon (A/F)
Nm
kgf m
lbf ft
<TABLE ROW
in.
mm
<TABLE BODY
<TABLE ROW
1/4
19.0
18.0
1.8
13.0
<TABLE ROW
3/8
22.0
31.0
3.2
23.0
<TABLE ROW
1/2
27.0
49.0
5.0
36.0
<TABLE ROW
5/8
30.0
60.0
6.1
44.0
<TABLE ROW
3/4
32.0
81.0
8.2
60.0
<TABLE ROW
1
38.0
129.0
13.1
95.0
<TABLE ROW
1 1/4
50.0
206.0
21.0
152.0
Table 9. Torque Settings – SAE Connections
Table 9. Torque Settings – SAE Connections
<TABLE
<TABLE HEADING
<TABLE ROW
SAE Tube Size
SAE Port Thread Size
Hexagon (A/F)
Nm
kgf m
lbf ft
<TABLE ROW
mm
<TABLE BODY
<TABLE ROW
4
7/16 – 20
15.9
20.0 – 28.0
2.0 – 2.8
16.5 – 18.5
<TABLE ROW
6
9/16 – 18
19.1
46.0 – 54.0
4.7 – 5.5
34.0 – 40.0
<TABLE ROW
8
3/4 – 16
22.2
95.0 – 105.0
9.7 – 10.7
69.0 – 77.0
<TABLE ROW
10
7/8 – 14
27.0
130.0 – 140.0
13.2 – 14.3
96.0 – 104.0
<TABLE ROW
12
1 1/16 – 12
31.8
190.0 – 210.0
19.4 – 21.4
141.0 – 155.0
<TABLE ROW
16
1 5/16 – 12
38.1
290.0 – 310.0
29.6 – 31.6
216.0 – 230.0
<TABLE ROW
20
1 5/8
47.6
280.0 – 380.0
28.5 – 38.7
210.0 – 280.0
Hoses Screwed into Adaptors
Hoses Screwed into Adaptors
<GRAPHIC
<GRAPHIC
Fig 3.
Hoses
3-B
3
3-A
3
3-C
3
Dimension
3-D
3
Table 10. BSP Hose – Torque Settings
Table 10. BSP Hose – Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
BSP Hose Size
Hexagon (A/F)
Nm
kgf m
lbf ft
<TABLE ROW
in.
mm
<TABLE BODY
<TABLE ROW
1/8
14.0
14.0 – 16.00
1.4 – 1.6
10.3 – 11.8
<TABLE ROW
1/4
19.0
24.0 – 27.0
2.4 – 2.7
17.7 – 19.9
<TABLE ROW
3/8
22.0
33.0 – 40.0
3.4 – 4.1
24.3 – 29.5
<TABLE ROW
1/2
27.0
44.0 – 50.0
4.5 – 5.1
32.4 – 36.9
<TABLE ROW
5/8
30.0
58.0 – 65.0
5.9 – 6.6
42.8 – 47.9
<TABLE ROW
3/4
32.0
84.0 – 92.0
8.6 – 9.4
61.9 – 67.8
<TABLE ROW
1
38.0
115.0 – 126.0
11.7 – 12.8
84.8 – 92.9
<TABLE ROW
1 1/4
50.0
189.0 – 200.0
19.3 – 20.4
139.4 – 147.5
<TABLE ROW
1 1/2
55.0
244.0 – 260.0
24.9 – 26.5
180.0 – 191.8
Adaptors into Component Connections with Bonded Washers
Adaptors into Component Connections with Bonded Washers
Table 11. BSP Adaptors with Bonded Washers – Torque Settings
Table 11. BSP Adaptors with Bonded Washers – Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
BSP Size
Nm
kgf m
lbf ft
<TABLE ROW
in.
<TABLE BODY
<TABLE ROW
1/8
20.0
2.1
15.0
<TABLE ROW
1/4
34.0
3.4
25.0
<TABLE ROW
3/8
75.0
7.6
55.0
<TABLE ROW
1/2
102.0
10.3
75.0
<TABLE ROW
5/8
122.0
12.4
90.0
<TABLE ROW
3/4
183.0
18.7
135.0
<TABLE ROW
1
203.0
20.7
150.0
<TABLE ROW
1 1/4
305.0
31.0
225.0
<TABLE ROW
1 1/2
305.0
31.0
225.0
‘Torque Stop’ Hose System
‘Torque Stop’ Hose System
<GRAPHIC
<GRAPHIC
Fig 4.
`Torque Stop’ Hoses
4-B
4
4-A
4
4-C
4
4-D
4
Minimum dimension
4-E
4
4-D
4
Table 12. BSP `Torque Stop’ Hose – Torque Settings
Table 12. BSP `Torque Stop’ Hose – Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
BSP Hose Size
Hexagon (A/F)
Nm
kgf m
lbf ft
<TABLE ROW
in.
mm
<TABLE BODY
<TABLE ROW
1/8
14.0
14.0
1.4
10.0
<TABLE ROW
1/4
19.0
27.0
2.7
20.0
<TABLE ROW
3/8
22.0
40.0
4.1
30.0
<TABLE ROW
1/2
27.0
55.0
5.6
40.0
<TABLE ROW
5/8
30.0
65.0
6.6
48.0
<TABLE ROW
3/4
32.0
95.0
9.7
70.0
<TABLE ROW
1
38.0
120.0
12.2
89.0
<TABLE ROW
1 1/4
50.0
189.0
19.3
140.0
<TABLE ROW
1 1/2
55.0
244.0
24.9
180.0
Service Tools
Service Tools
Numerical List
Numerical List
The tools listed in the table are special tools required for removal and replacement of Body and Framework parts. These tools are available from JCB Service.
Tools other than those listed will be required. It is expected that such general tools will be available in any well equipped workshop or be available locally from any good tool supplier.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Part Number
Description
Tool Detail Reference
<TABLE BODY
<TABLE ROW
1406/0011
Bonded Washer
K Fig 17. ( T 1-19)
K Fig 17. ( T 1-19)
<TABLE ROW
1406/0014
Bonded Washer
K Fig 17. ( T 1-19)
K Fig 17. ( T 1-19)
<TABLE ROW
1406/0018
Bonded Washer
K Fig 17. ( T 1-19)
K Fig 17. ( T 1-19)
<TABLE ROW
1406/0021
Bonded Washer
K Fig 17. ( T 1-19)
K Fig 17. ( T 1-19)
<TABLE ROW
1406/0029
Bonded Washer
K Fig 17. ( T 1-19)
K Fig 17. ( T 1-19)
<TABLE ROW
1604/0003A
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
1604/0004A
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
1604/0006A
Adapter
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
1604/2055
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
1606/0004
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
1606/0007A
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
1606/0008
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
1606/0009
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
1606/0012
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
1606/0014
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
1606/0015
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
1606/0016
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
1606/0017
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
1606/2052
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
1612/2054
Adapter
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
816/00017
Adapter
K Fig 13. ( T 1-19)
K Fig 13. ( T 1-19)
<TABLE ROW
816/00189A
Blanking Cap
K Fig 15. ( T 1-19)
K Fig 15. ( T 1-19)
<TABLE ROW
816/00190A
Blanking Cap
K Fig 15. ( T 1-19)
K Fig 15. ( T 1-19)
<TABLE ROW
816/00439
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
816/00440
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
816/15007A
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
816/15008
Adapter
K Fig 10. ( T 1-18)
K Fig 10. ( T 1-18)
<TABLE ROW
816/15118
Adapter
K Fig 11. ( T 1-18)
K Fig 11. ( T 1-18)
<TABLE ROW
816/20008
Adapter
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
816/20013
Adapter
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
816/50005
Adapter
K Fig 13. ( T 1-19)
K Fig 13. ( T 1-19)
<TABLE ROW
816/50043
Adapter
K Fig 13. ( T 1-19)
K Fig 13. ( T 1-19)
<TABLE ROW
816/55038
Adapter
K Fig 12. ( T 1-18)
K Fig 12. ( T 1-18)
<TABLE ROW
816/55040
Adapter
K Fig 12. ( T 1-18)
K Fig 12. ( T 1-18)
<TABLE ROW
816/55045
Adapter
K Fig 12. ( T 1-18)
K Fig 12. ( T 1-18)
<TABLE ROW
816/60096
Adapter
K Fig 13. ( T 1-19)
K Fig 13. ( T 1-19)
<TABLE ROW
816/90022
Blanking Cap
K Fig 15. ( T 1-19)
K Fig 15. ( T 1-19)
<TABLE ROW
816/90045
Blanking Cap
K Fig 15. ( T 1-19)
K Fig 15. ( T 1-19)
<TABLE ROW
816/90205
Blanking Cap
K Fig 15. ( T 1-19)
K Fig 15. ( T 1-19)
<TABLE ROW
816/90274
Blanking Cap
K Fig 15. ( T 1-19)
K Fig 15. ( T 1-19)
<TABLE ROW
826/01099
Rivet Nut
K Fig 6. ( T 1-16)
K Fig 6. ( T 1-16)
<TABLE ROW
826/01101
Rivet Nut
K Fig 6. ( T 1-16)
K Fig 6. ( T 1-16)
<TABLE ROW
826/01102
Rivet Nut
K Fig 6. ( T 1-16)
K Fig 6. ( T 1-16)
<TABLE ROW
826/01103
Rivet Nut
K Fig 6. ( T 1-16)
K Fig 6. ( T 1-16)
<TABLE ROW
826/01104
Rivet Nut
K Fig 6. ( T 1-16)
K Fig 6. ( T 1-16)
<TABLE ROW
826/01105A
Rivet Nut
K Fig 6. ( T 1-16)
K Fig 6. ( T 1-16)
<TABLE ROW
892/00047
Adapter
K Fig 13. ( T 1-19)
K Fig 13. ( T 1-19)
<TABLE ROW
892/00048
Adapter
K Fig 13. ( T 1-19)
K Fig 13. ( T 1-19)
<TABLE ROW
892/00049
Adapter
K Fig 13. ( T 1-19)
K Fig 13. ( T 1-19)
<TABLE ROW
892/00055A
Blanking Cap
K Fig 14. ( T 1-19)
K Fig 14. ( T 1-19)
<TABLE ROW
892/00056A
Blanking Cap
K Fig 14. ( T 1-19)
K Fig 14. ( T 1-19)
<TABLE ROW
892/00057
Blanking Cap
K Fig 14. ( T 1-19)
K Fig 14. ( T 1-19)
<TABLE ROW
892/00058A
Blanking Cap
K Fig 14. ( T 1-19)
K Fig 14. ( T 1-19)
<TABLE ROW
892/00059A
Blanking Cap
K Fig 14. ( T 1-19)
K Fig 14. ( T 1-19)
<TABLE ROW
892/00060
Blanking Cap
K Fig 14. ( T 1-19)
K Fig 14. ( T 1-19)
<TABLE ROW
892/00051
Adapter
K Fig 13. ( T 1-19)
K Fig 13. ( T 1-19)
<TABLE ROW
892/00074
Connector
K Fig 16. ( T 1-19)
K Fig 16. ( T 1-19)
<TABLE ROW
892/00075
Connector
K Fig 16. ( T 1-19)
K Fig 16. ( T 1-19)
<TABLE ROW
892/00076
Connector
K Fig 16. ( T 1-19)
K Fig 16. ( T 1-19)
<TABLE ROW
892/00077
Connector
K Fig 16. ( T 1-19)
K Fig 16. ( T 1-19)
<TABLE ROW
892/00078
Connector
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
892/00137
Hose
K Fig 21. ( T 1-21)
K Fig 21. ( T 1-21)
<TABLE ROW
892/00201
Replacement Gauge
K Fig 19. ( T 1-20)
K Fig 19. ( T 1-20)
<TABLE ROW
892/00202
Replacement Gauge
K Fig 19. ( T 1-20)
K Fig 19. ( T 1-20)
<TABLE ROW
892/00203
Replacement Gauge
K Fig 19. ( T 1-20)
K Fig 19. ( T 1-20)
<TABLE ROW
892/00223
Hand Pump
K Fig 21. ( T 1-21)
K Fig 21. ( T 1-21)
<TABLE ROW
892/00254
Replacement Hose
K Fig 20. ( T 1-21)
K Fig 20. ( T 1-21)
<TABLE ROW
892/00255
Adapter
K Fig 11. ( T 1-18)
K Fig 11. ( T 1-18)
<TABLE ROW
892/00256
Adapter
K Fig 11. ( T 1-18)
K Fig 11. ( T 1-18)
<TABLE ROW
892/00257
Adapter
K Fig 11. ( T 1-18)
K Fig 11. ( T 1-18)
<TABLE ROW
892/00258
Adapter
K Fig 11. ( T 1-18)
K Fig 11. ( T 1-18)
<TABLE ROW
892/00259
Adapter
K Fig 11. ( T 1-18)
K Fig 11. ( T 1-18)
<TABLE ROW
892/00260
Adapter
K Fig 11. ( T 1-18)
K Fig 11. ( T 1-18)
<TABLE ROW
892/00261
Adapter
K Fig 11. ( T 1-18)
K Fig 11. ( T 1-18)
<TABLE ROW
892/00263
Adapter
K Fig 12. ( T 1-18)
K Fig 12. ( T 1-18)
<TABLE ROW
892/00264
Adapter
K Fig 12. ( T 1-18)
K Fig 12. ( T 1-18)
<TABLE ROW
892/00265
Adapter
K Fig 12. ( T 1-18)
K Fig 12. ( T 1-18)
<TABLE ROW
892/00266
Adapter
K Fig 12. ( T 1-18)
K Fig 12. ( T 1-18)
<TABLE ROW
892/00267
Adapter
K Fig 12. ( T 1-18)
K Fig 12. ( T 1-18)
<TABLE ROW
892/00268
Flow Monitoring Unit
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
892/00269
Sensor Head
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
892/00270
Load Valve
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
892/00271
Adapter
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
892/00272
Adapter
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
892/00273
Sensor Head
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
892/00274
Adapter
K Fig 15. ( T 1-19)
K Fig 15. ( T 1-19)
<TABLE ROW
892/00275
Adapter
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
892/00276
Adapter
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
892/00277
Adapter
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
892/00278
Gauge
K Fig 21. ( T 1-21)
K Fig 21. ( T 1-21)
<TABLE ROW
892/00279
Gauge
K Fig 21. ( T 1-21)
K Fig 21. ( T 1-21)
<TABLE ROW
892/00280
Gauge
K Fig 20. ( T 1-21)
K Fig 20. ( T 1-21)
<TABLE ROW
892/00284
Tachometer
K Fig 9. ( T 1-17)
K Fig 9. ( T 1-17)
<TABLE ROW
892/00285
Hydraulic Oil Temperature Probe
K Fig 8. ( T 1-17)
K Fig 8. ( T 1-17)
<TABLE ROW
892/00293
Connector Pipe
K Fig 18. ( T 1-20)
K Fig 18. ( T 1-20)
<TABLE ROW
892/00298
Fluke Meter
K Fig 7. ( T 1-17)
K Fig 7. ( T 1-17)
<TABLE ROW
892/00347
Connector
K Fig 19. ( T 1-20)
K Fig 19. ( T 1-20)
<TABLE ROW
892/00706
Test Probe
K Fig 19. ( T 1-20)
K Fig 19. ( T 1-20)
<TABLE ROW
993/68101
Slide Hammer
K Fig 5. ( T 1-16)
K Fig 5. ( T 1-16)
<TABLE ROW
993/68102
End Stops
K Fig 5. ( T 1-16)
K Fig 5. ( T 1-16)
<TABLE ROW
993/68103
Adapter
K Fig 5. ( T 1-16)
K Fig 5. ( T 1-16)
<TABLE ROW
993/68104
Adapter
K Fig 5. ( T 1-16)
K Fig 5. ( T 1-16)
<TABLE ROW
993/68105
Adapter
K Fig 5. ( T 1-16)
K Fig 5. ( T 1-16)
<TABLE ROW
993/68106
Adapter
K Fig 5. ( T 1-16)
K Fig 5. ( T 1-16)
<TABLE ROW
993/68107
Bar
K Fig 5. ( T 1-16)
K Fig 5. ( T 1-16)
<TABLE ROW
993/68108
Adapter
K Fig 5. ( T 1-16)
K Fig 5. ( T 1-16)
<TABLE ROW
993/68109
Adapter
K Fig 5. ( T 1-16)
K Fig 5. ( T 1-16)
<TABLE ROW
993/68110
Adapter
K Fig 5. ( T 1-16)
K Fig 5. ( T 1-16)
<TABLE ROW
993/68111
Adapter
K Fig 5. ( T 1-16)
K Fig 5. ( T 1-16)
Tool Detail Reference
Tool Detail Reference
Section B – Body and Framework
Section B – Body and Framework
Not all service tools are illustrated.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 5. 993/68100 Slide Hammer Kit
<TABLE ROW
1
1
993/68101
Slide Hammer
7
7
993/68107
Bar – M20 x M20 X 800 mm
<TABLE ROW
2
2
993/68102
End Stops
8
8
993/68108
Adaptor – M20 x 7/8″ UNF
<TABLE ROW
3
3
993/68103
Adaptor – M20 x 5/8″ UNF
9
9
993/68109
Adaptor – M20 x M12
<TABLE ROW
4
4
993/68104
Adaptor – M20 x 1″ UNF
10
10
993/68110
Adaptor – M20 x 5/8″ UNF (Shoulder)
<TABLE ROW
5
5
993/68105
Adaptor – M20 x M20
11
11
993/68111
Adaptor – M20 x 1/2″ UNF
<TABLE ROW
6
6
993/68106
Adaptor – M20 x M24
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 6. Rivet Nut Tool
1
1
826/01099
M6 x 16 mm Rivet Nut
<TABLE ROW
826/01101
M6 x 19 mm Rivet Nut
<TABLE ROW
826/01102
M8 x 18 mm Rivet Nut
<TABLE ROW
826/01103
M8 x 21 mm Rivet Nut
<TABLE ROW
826/01104
M10 x 23 mm Rivet Nut
<TABLE ROW
826/01105A
M10 x 26 mm Rivet Nut
<TABLE ROW
2
2

Installation Tool available from: Bollhoff Fastenings Ltd (www.bollhof.com)
www.bollhof.com
Section C – Electrics
Section C – Electrics
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 7. 892/00298 Fluke Meter
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 8. 892/00285 Hydraulic Temperature Probe
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 9. 892/00284 Venture Microtach Digital Tachometer
Section E – Hydraulics
Section E – Hydraulics
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 10. Male Adaptors
Male Adapters – BSP x BSP
<TABLE ROW
1606/2052
3/8 in. x 1/4 in.
<TABLE ROW
1604/0003A
3/8 in. x 3/8 in.
<TABLE ROW
892/00071
3/8 in. x 3/8 in. taper
<TABLE ROW
1606/0004
1/2 in. x 1/4 in.
<TABLE ROW
1606/0007A
1/2 in. x 3/8 in.
<TABLE ROW
1604/0004A
1/2 in. x 1/2 in.
<TABLE ROW
1606/0017
5/8 in. x 1/2 in.
<TABLE ROW
1606/0008
3/4 in. x 3/8 in.
<TABLE ROW
Male Adapters – BSP x NPT (USA only)
1606/0009
3/4 in. x 1/2 in.
<TABLE ROW
816/00439
3/8 in. x 1/4 in.
1604/2055
3/4 in. x 3/4 in.
<TABLE ROW
816/00440
1/2 in. x 1/4 in.
1606/0012
3/4 in. x 1 in.
<TABLE ROW
816/15007A
3/8 in. x 3/8 in.
1606/0014
3/4 in. x 1.1/4 in.
<TABLE ROW
816/15008
1/2 in. x 3/8 in.
1606/0015
1 in. x 1.1/4 in.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 11. Pressure Test Adapters
892/00255
1/4 in. BSP x Test Point
<TABLE ROW
892/00256
3/8 in. BSP x Test Point
<TABLE ROW
892/00257
1/2 in. BSP x Test Point
<TABLE ROW
892/00258
5/8 in. BSP x Test Point
<TABLE ROW
816/15118
3/4 in. BSP x Test Point
<TABLE ROW
892/00259
1 in BSP x Test Point
<TABLE ROW
892/00260
1.1/4 in. BSP x Test Point
<TABLE ROW
892/00261
5/8 in. UNF x Test Point
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 12. Pressure Test ‘T’ Adapters
816/55045
1/4 in. M BSP x 1/4 in. F BSP x Test Point
<TABLE ROW
816/55038
3/8 in. M BSP x 3/8 in. F BSP x Test Point
<TABLE ROW
816/55040
1/2 in. M BSP x 1/2 in. F BSP x Test Point
<TABLE ROW
892/00263
5/8 in. M BSP x 5/8 in. F BSP x Test Point
<TABLE ROW
892/00264
3/4 in. M BSP x 3/4 in. F BSP x Test Point
<TABLE ROW
892/00265
1 in. M BSP x 1 in. F BSP x Test Point
<TABLE ROW
892/00266
1.1/4 in. M BSP x 1.1/4 in. F BSP x Test Point
<TABLE ROW
892/00267
1.1/4 in. M BSP x 1.1/2 in. F BSP x Test Point
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 13. ‘T’ Adapters
892/00047
3/8 in. BSP (A) x 1/4 in. BSP (B)
A
B
<TABLE ROW
892/00048
1/2 in. BSP (A) x 1/4 in. BSP (B)
A
B
<TABLE ROW
892/00049
5/8 in. BSP (A) x 1/4 in. BSP (B)
A
B
<TABLE ROW
816/50043
3/4 in. BSP (A) x 1/4 in. BSP (B)
A
B
<TABLE ROW
892/00051
1 in. BSP (A) x 1/4 in. BSP (B)
A
B
<TABLE ROW
816/50005
1/2 in. BSP (A) x 1/2 in. BSP (B)
A
B
<TABLE ROW
816/60096
3/4 in. BSP (A) x 3/4 in. BSP (B)
A
B
<TABLE ROW
816/00017
1 in. BSP (A) x 1 in. BSP (B)
A
B
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 14. Female Blanking Caps
892/00055A
1/4 in. BSP
<TABLE ROW
892/00056A
3/8 in. BSP
<TABLE ROW
892/00057
1/2 in. BSP
<TABLE ROW
892/00058A
5/8 in. BSP
<TABLE ROW
892/00059A
3/4 in. BSP
<TABLE ROW
892/00060
1 in. BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 15. Male Cone Blanking Caps
816/90045
1/4 in. BSP
<TABLE ROW
816/00189A
3/8 in. BSP
<TABLE ROW
816/00190A
1/2 in. BSP
<TABLE ROW
816/90022
5/8 in. BSP
<TABLE ROW
816/90274
3/4 in. BSP
<TABLE ROW
816/90205
1 in. BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 16. Female Connectors
892/00074
3/8 in. BSP x 3/8 in. BSP
<TABLE ROW
892/00075
1/2 in. BSP x 1/2 in. BSP
<TABLE ROW
892/00076
5/8 in. BSP x 5/8 in. BSP
<TABLE ROW
892/00077
3/4 in. BSP x 3/4 in. BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 17. Bonded Washers
1406/0011
1/4 in. BSP
<TABLE ROW
1406/0018
1/2 in. BSP
<TABLE ROW
1406/0014
5/8 in. BSP
<TABLE ROW
1406/0021
3/4 in. BSP
<TABLE ROW
1406/0029
1.1/4 in. BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 18. Flow Test Equipment
892/00268
Flow Monitoring Unit
<TABLE ROW
892/00269
Sensor Head 0 – 100 l/min (0 – 22 UK gal/min)
<TABLE ROW
892/00273
Sensor Head 0 – 380 l/min (0 – 85.5 UK gal/min)
<TABLE ROW
892/00293
Connector Pipe
<TABLE ROW
892/00270
Load Valve
<TABLE ROW
1406/0021
Bonded Washer
<TABLE ROW
1604/0006A
Adapter 3/4 in M x 3/4 in M BSP
<TABLE ROW
1612/2054
Adapter 3/4 in F x 3/4 in M BSP
<TABLE ROW
892/00271
Adapter 3/4 in F x 5/8 in M BSP
<TABLE ROW
892/00272
Adapter 5/8 in F x 3/4 in M BSP
<TABLE ROW
816/20008
Adapter 3/4 in F x 1/2 in M BSP
<TABLE ROW
892/00275
Adapter 1/2 in F x 3/4 in M BSP
<TABLE ROW
892/00276
Adapter 3/4 in F x 3/8 in M BSP
<TABLE ROW
892/00277
Adapter 3/8 in F x 3/4 in M BSP
<TABLE ROW
1606/0015
Adapter 1.1/4 in M BSP x 1 in M BSP
<TABLE ROW
892/00078
Connector 1 in F x 1 in F BSP
<TABLE ROW
1604/0008
Adapter 1 in M x 1 in M BSP
<TABLE ROW
1604/0008
Adapter 1 in M x 3/4 in M BSP
<TABLE ROW
816/20013
Adapter 3/4 in F x 1 in M BSP
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 19. 892/ 00253 Hydraulic Circuit Pressure Test Kit
892/00201
Replacement Gauge 0-20 bar (0-300 lbf/in2)
2
<TABLE ROW
892/00202
Replacement Gauge 0-40 bar (0-600 lbf/in2)
2
<TABLE ROW
892/00203
Replacement Gauge 0-400 bar (0-6000 lbf/in2)
2
<TABLE ROW
892/00254
Replacement Hose
<TABLE ROW
993/69800
Seal Kit for 892/00254 (can also be used with probe 892/00706)
<TABLE ROW
892/00706
Test Probe
<TABLE ROW
892/00347
Connector – Hose to gauge
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 20. Hydraulic Circuit Test Gauges and Connections
892/00280
Pressure Gauge 0-600 bar (0-9000 lbf/in2)
2
<TABLE ROW
892/00279
Pressure Gauge 0-400 bar (0-6000 lbf/in2)
2
<TABLE ROW
892/00346
Pressure Gauge 0-70 bar (0-1000 lbf/in2)
2
<TABLE ROW
892/00347
Connector
<TABLE ROW
892/00254
Hose
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fig 21. Hand Pump Equipment
892/00223
Hand Pump
<TABLE ROW
892/00137
Micro-bore Hose 1/4 in BSP x 3 metres
<TABLE ROW
892/00274
Adapter 1/4 in M BSP x 3/8 in M BSP Taper
<TABLE ROW
892/00262
1/4 in M BSP x 1/4 in F BSP x Test Point
<TABLE ROW
892/00706
Test Probe
<TABLE ROW
892/00278
Gauge 0 – 40 bar (0 – 600 lbf/in2)
2
<TABLE ROW
892/00279
Gauge 0 – 400 bar (0 – 6000 lbf/in2)
2
Moving a Disabled Machine
Moving a Disabled Machine
Towing or Winching
Towing or Winching
It is only possible to tow or winch the machine very slowly for a short distance. If at all possible repair the disabled machine where it stands.
If the machine needs to be returned to the workshop for repair, it must be winched or lifted onto a trailer.
The machine is normally prevented from moving by hydraulic oil locked up in the transmission circuit. The procedure in Section E of this manual must be carried out before attempting to move the machine. See
Preparation for Towing or Winching (Section E)
Page left intentionally blank
Service Consumables
Service Consumables
Sealing and Retaining Compounds
Sealing and Retaining Compounds
Table 13.
Table 13.
<TABLE
<TABLE HEADING
<TABLE ROW
Type
Description
Part No.
Quantity
<TABLE BODY
<TABLE ROW
JCB Multi-Gasket
A medium strength sealant suitable for all sizes of gasket flanges, and for hydraulic fittings of 25-65 mm diameter.
4102/1212
50 ml
<TABLE ROW
JCB High Strength Threadlocker
A high strength locking fluid for use with threaded components. Gasketing for all sizes of flange where the strength of the joint is important.
4102/0551
50 ml
<TABLE ROW
JCB Retainer (High Strength)
For all retaining parts which are unlikely to be dismantled.
4101/0651
50 ml
<TABLE ROW
JCB Threadlocker and Sealer
A medium strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter.
4101/0250
10 ml
<TABLE ROW
4101/0251
50 ml
<TABLE ROW
JCB Threadlocker and Sealer (High Strength)
A high strength locking fluid for sealing and retaining nuts, bolts, and screws up to 50 mm diameter, and for hydraulic fittings up to 25 mm diameter.
4101/0550
10 ml
<TABLE ROW
4101/0552
200 ml
<TABLE ROW
JCB Threadseal
A medium strength thread sealing compound.
4102/1951
50 ml
<TABLE ROW
JCB Activator
A cleaning primer which speeds the curing rate of anaerobic products.
4104/0251
200 ml (Aerosol)
<TABLE ROW
4104/0253
1 ltr (Bottle)
<TABLE ROW
JCB Cleaner/Degreaser
For degreasing components prior to use of anaerobic adhesives and sealants.
4104/1557
400 ml (Aerosol)
<TABLE ROW
Direct Glazing Kit
For one pane of glass; comprises of:
– 1 x Ultra Fast Adhesive (310 ml)
– 1 x Ultra Fast Adhesive (310 ml)
– 1 x Active Wipe 205 (30 ml)
– 1 x Black Primer 206J (30 ml)
– plus applicator nozzle etc.
993/55700
<TABLE ROW
Ultra Fast Adhesive
For direct glazing.
4103/2109
310 ml
<TABLE ROW
Active Wipe 205
For direct glazing.
4104/1203
250 ml
<TABLE ROW
Black Primer 206J
For direct glazing.
4201/4906
30 ml
<TABLE ROW
Clear Silicone Sealant
To seal butt jointed glass.
4102/0901
<TABLE ROW
Plastic to Metal Bonder
To seal plastic to metal joints.
4103/0956
50 g
<TABLE ROW
Black Polyurethane Sealant
To finish exposed edges of laminated glass.
4102/2309
310 ml
Section 2 – Care and Safety
Section 2
Section 2
Care and Safety
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Manual – JCB 403
Service Manual – JCB 403
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Maintenance
Section 3 – Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
<GRAPHIC
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Notes:
<TABLE BODY
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
Safety Check List
Safety Check List
Safety First
Safety First
Safety – Yours and Others
Safety – Yours and Others
All machinery can be hazardous. When a machine is correctly operated and properly maintained, it is a safe machine to work with. But when it is carelessly operated or poorly maintained it can become a danger to you (the operator) and others.
In this manual and on the machine you will find warning messages. Read and understand them. They tell you of potential hazards a…
But safety is not just a matter of responding to the warnings. All the time you are working on or with the machine you must be thinking what hazards there might be and how to avoid them.
Do not work with the machine until you are sure that you can control it.
Do not start any job until you are sure that you and those around you will be safe.
If you are unsure of anything, about the machine or the job, ask someone who knows. Do not assume anything.
Remember
BE CAREFUL
BE CAREFUL
BE ALERT
BE SAFE
General Safety
General Safety
Operator Manual
You and others can be injured if you operate or maintain the machine without first studying the Operator Manual. Read the safety…
Care and Alertness
All the time you are working with or on the machine, take care and stay alert. Always be careful. Always be alert for hazards.
Clothing
You can be injured if you do not wear the proper clothing. Loose clothing can get caught in the machinery. Wear protective cloth…
Alcohol and Drugs
It is extremely dangerous to operate machinery when under the influence of alcohol or drugs. Do not consume alcoholic drinks or take drugs before or while operating the machine or attachments. Be aware of medicines which can cause drowsiness.
Feeling Unwell
Do not attempt to operate the machine if you are feeling unwell. By doing so you could be a danger to yourself and those you work with.
Mobile Phones
Switch off your mobile phone before entering an area with a potentially explosive atmosphere. Sparks in such an area could cause an explosion or fire resulting in death or serious injury.
Switch off and do not use your mobile phone when refuelling the machine.
Lifting Equipment
You can be injured if you use faulty lifting equipment. Make sure that lifting equipment is in good condition. Make sure that li…
Raised Equipment
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a …
Raised Machine
NEVER position yourself or any part of your body under a raised machine which is not properly supported. If the machine moves unexpectedly you could become trapped and suffer serious injury or be killed.
Lightning
Lightning can kill you. Do not use the machine if there is lightning in your area.
Machine Modifications
This machine is manufactured in compliance with legislative and other requirements. It should not be altered in any way which could affect or invalidate any of these requirements. For advice consult your JCB Distributor.
Operating Safety
Operating Safety
Controls
You or others can be killed or seriously injured if you operate the control levers from outside the machine. Operate the control levers only when you are correctly seated in the machine.
Machine Condition
A defective machine can injure you or others. Do not operate a machine which is defective or has missing parts. Make sure the maintenance procedures in this manual are completed before using the machine.
Machine Limits
Operating the machine beyond its design limits can damage the machine, it can also be dangerous. Do not operate the machine outside its limits. Do not try to upgrade the machine performance with unapproved modifications.
Engine/Steering Failure
If the engine or steering fails, stop the machine as quickly as possible. Do not operate the machine until the fault has been corrected.
The engine has exposed rotating parts. Switch OFF the engine before working in the engine compartment. Do not use the machine with the engine cover open.
Exhaust Gases
Breathing the machine exhaust gases can harm and possibly kill you. Do not operate the machine in closed spaces without making s…
You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protecti…
Work Sites
Work sites can be hazardous. Inspect the site before working on it. Look for potholes, weak ground, hidden rocks etc. Check for …
Communications
Bad communications can cause accidents. Keep people around you informed of what you will be doing. If you will be working with o…
Parking
An incorrectly parked machine can move without an operator. Follow the instructions in the Operator Manual to park the machine correctly.
Banks and Trenches
Banked material and trenches can collapse. Do not work or drive too close to banks and trenches where there is danger of collapse.
Ramps and Trailers
Water, mud, ice, grease and oil on ramps or trailers can cause serious accidents. Make sure ramps and trailers are clean before driving onto them. Use extreme caution when driving onto ramps and trailers.
Safety Barriers
Unguarded machines in public places can be dangerous. In public places, or where your visibility is reduced, place barriers around the work area to keep people away.
Sparks
Explosions and fire can be caused by sparks from the exhaust or the electrical system. Do not use the machine in closed areas where there is flammable material, vapour or dust.
Hazardous Atmospheres
This machine is designed for use in normal out door atmospheric conditions. It should not be used in an enclosed area without ad…
Regulations
Obey all laws, work site and local regulations which affect you and your machine.
Practice
You or others can be killed or seriously injured if you do unfamiliar operations without first practising them. Practise away fr…
Reversing
Reversing at high speeds can cause accidents. Do not reverse in a high gear with full throttle. Always drive at a safe speed to suit working conditions.
Airborne particles of light combustible material such as straw, grass, wood shavings, etc. must not be allowed to accumulate wit…
Keep the machine controls clean and dry. Your hands and feet could slide off slippery controls. If that happens you could lose control of the machine.
Visibility
Accidents can be caused by working in poor visibility. Use your lights to improve visibility. Keep the road lights, windows and mirrors clean.
Do not operate the machine if you cannot see clearly.
Electrical Power Cables
You could be electrocuted or badly burned if you get the machine or its attachments too close to electrical power cables.
You are strongly advised to make sure that the safety arrangements on site comply with the local laws and regulations concerning work near electric power lines.
Before you start using the machine, check with your electricity supplier if there are any buried power cables on the site.
There is a minimum clearance required for working beneath overhead power cables. You must obtain details from your local electricity supplier.
If you have an attachment which is not covered in the Operator Manual do not install it, use it or remove it until you have obtained, read and understood the pertinent information. Install attachments only on the machines for which they were designed.
Use only the JCB approved attachments that are specified for your machine. Operating with non- specified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yourself or others.
The use of non-approved attachments could invalidate your warranty.
Maintenance Safety
Maintenance Safety
Communications
Bad communications can cause accidents. If two or more people are working on the machine, make sure each is aware of what the ot…
Repairs
If your machine does not function correctly in any way, get it repaired straight away. Neglect of necessary repairs could result…
Metal Splinters
You can be injured by flying metal splinters when driving metal pins in or out. Use a soft faced hammer or copper pin to remove and fit metal pins. Always wear safety glasses.
Electrical Circuits
Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage.
Do not disconnect the battery while the engine is running, otherwise the electrical circuits may be damaged.
If you try to charge a frozen battery, or jump start and run the engine, the battery could explode. Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery at full charge.
Battery Gases
Batteries give off explosive gases. Keep flames and sparks away from the battery. Do not smoke close to the battery. Make sure t…
Electrolyte
Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery. Keep the electrolyte away from your clothes, skin, mouth and eyes. Wear safety glasses.
Battery Terminals
The machine is negatively earthed. Always connect the negative pole of the battery to earth.
When connecting the battery, connect the earth (-) lead last.
When disconnecting the battery, disconnect the earth (-) lead first.
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear prot…
Hydraulic Pressure
Hydraulic fluid at system pressure can injure you. Before connecting or removing any hydraulic hose, residual hydraulic pressure…
Petrol
Do not use petrol in this machine. Do not mix petrol with the diesel fuel; in storage tanks the petrol will rise to the top and form flammable vapours.
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from the fuel system. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions.
Oil
Oil is toxic. If you swallow any oil, do not induce vomiting, seek medical advice. Used engine oil contains harmful contaminants…
It is illegal to pollute drains, sewers or the ground. Clean up all spilt fluids and/or lubricants.
Used fluids and/or lubricants, filters and contaminated materials must be disposed of in accordance with local regulations. Use authorised waste disposal sites.
Soft Ground
A machine can sink into soft ground. Never work under a machine on soft ground.
Hot Coolant
The cooling system is pressurised when the engine is hot. Hot coolant can spray out when you remove the filler cap. Let the syst…
Always wear safety glasses when dismantling assemblies containing components under pressure from springs. This will protect against eye injury from components accidentally flying out.
Rams
The efficiency of the rams will be affected if they are not kept free of solidified dirt. Clean dirt from around the rams regularly. When leaving or parking the machine, close all rams if possible to reduce the risk of weather corrosion.
Cleaning
Cleaning metal parts with incorrect solvents can cause corrosion. Use only recommended cleaning agents and solvents.
When using cleaning agents, solvents or other chemicals, you must adhere to the manufacturer’s instructions and safety precautions.
‘O’ rings, Seals and Gaskets
Badly fitted, damaged or rotted ‘O’ rings, seals and gaskets can cause leakages and possible accidents. Renew whenever disturbed unless otherwise instructed. Do not use Triochloroethane or paint thinners near ‘O’ rings and seals.
Hydraulic Hoses
Damaged hoses can cause fatal accidents. Inspect the hoses regularly for:
– Damaged hose ends
– Damaged hose ends
– Chafed outer covers
– Ballooned outer covers
– Kinked or crushed hoses
– Embedded armouring in outer covers
– Displaced end fittings.
Waxoyl contains turpentine substitute which is flammable. Keep flames away when applying Waxoyl. Waxoyl can take a few weeks to dry completely. Keep flames away during the drying period.
Do not weld near the affected area during the drying period. Take the same precautions as for oil to keep Waxoyl off your skin. Do not breathe the fumes. Apply in a well-ventilated area.
Working Under the Machine
Make the machine safe before getting beneath it. Ensure that any fitments on the machine are secure; engage the park brake, remove the starter key, disconnect the battery.
Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroelastomeric materials such as Viton, Fluorel …
New fluoroelastomeric components at ambient temperature require no special safety precautions.
Used fluoroelastomeric components whose temperatures have not exceeded 300˚C (572˚F) require no special safety precautions. If e…
Used fluoroelastomeric components subjected to temperatures greater than 300˚C (572˚F) (e.g. engine fire) must be treated using the following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn:
1 Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.
1 Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool to remove burnt remains.
2 Thoroughly wash contaminated area with detergent and water.
3 Contain all removed material, gloves etc. used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.
DO NOT BURN FLUOROELASTOMERIC MATERIALS.
Protect your eyes when grinding metal. Wear safety glasses or goggles. Remove or protect any combustible materials from the area which could be ignited by sparks.
To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a wire brush to clean components.
Arc Welding
To prevent the possibility of damage to electronic components, disconnect the battery and the alternator before arc-welding on the machine or attached implements.
If the machine is equipped with sensitive electrical equipment, i.e. amplifier drivers, electronic control units (E.C.U.s), moni…
Parts of the machine are made from cast iron; welds on cast iron can weaken the structure and break. Do not weld cast iron. Do not connect the welder cable or apply any weld to any part of the engine.
Always connect the welder earth (ground) cable to the same component that is being welded, i.e. boom or dipper, to avoid damage …
Counterweights
Your machine may be fitted with counterweights. They are extremely heavy. Do not attempt to remove them.
Turning the Engine
Do not try to turn the engine by pulling the fan or fan belt. This could cause injury or premature component failure.
Accumulators
The accumulators contain hydraulic fluid and gas at high pressure. Prior to any work being carried out on systems incorporating …
Compressed air is dangerous. Wear suitable eye protection and gloves. Never point a compressed air jet at yourself or others.
Safety Decals
Safety Decals
Decals
Decals on the machine warn you of particular hazards. You can be injured if you do not obey the decal safety instructions.
Each decal is attached close to a part of the machine where there is a possible hazard. Make sure replacement parts include warning decals where necessary.
Keep all decals clean and readable. Replace lost or damaged decals. Each decal has a part number printed on it, use this number to order a new decal from your JCB distributor.
If you need eye-glasses for reading, make sure you wear them when reading the safety decals. Decals are strategically placed aro…
Section 3 – Maintenance
Section 3
Section 3
Maintenance
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Manual – JCB 403
Service Manual – JCB 403
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Maintenance
Section 3 – Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
<GRAPHIC
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Notes:
<TABLE BODY
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
Routine Maintenance
Routine Maintenance
Service Requirements
Service Requirements
Introduction
Introduction
Your machine has been designed and built to give maximum performance, economy and ease of use under a wide variety of operating …
This section of the Manual gives full details of the service requirements necessary to maintain your JCB machine at peak efficiency.
It can be seen from the Service Schedules on the following pages that many essential service checks should only be carried out b…
JCB regularly updates its Distributors advising them of any product developments, changes in specifications and procedures. Therefore only a JCB Distributor is fully able to maintain and service your machine.
A Service Record Sheet or Book is provided which will enable you to plan your service requirements and keep a service history record. It should be dated, signed and stamped by your Distributor each time your machine is serviced.
Remember, if your machine has been correctly maintained, not only will it give you improved reliability but its resale value will be greatly enhanced.
Owner/Operator Support
Owner/Operator Support
JCB together with your Distributor wants you to be completely satisfied with your new JCB machine. If you do encounter a problem however, you should contact your Distributor’s Service Department who are there to help you!
You will have been given the names of the relevant service contacts at your Distributor when the machine was installed.
To get the most from your Distributor please help them to satisfy you by:
1 Giving your name, address and telephone number.
1 Giving your name, address and telephone number.
2 Quoting your machine model and serial number.
3 Date of purchase and hours of work.
4 Nature of the problem.
Remember, only your JCB Distributor has access to the vast resources available at JCB to help support you. In addition, your Dis…
Service/Maintenance Agreements
Service/Maintenance Agreements
To help plan and spread the costs of maintaining your machine, we strongly recommend you take advantage of the many Service and …
Please consult your JCB Distributor for details.
Initial Service and Inspection (100 Hours)
Initial Service and Inspection (100 Hours)
To further protect your machine’s performance it is essential your JCB Distributor carries out an initial service and inspection…
Lifting Regulations – Inspections and Tests
Lifting Regulations – Inspections and Tests
Only your JCB Distributor can fully meet the requirements of the inspection and test parameters to suit UK Health and Safety Executive (H.S.E.) legal requirements along with providing Annual Inspections to meet your Insurance Company Policy conditions.
Only your JCB Distributor has the ability to meet the definition described covering a “Competent Person” to carry out these nece…
Obtaining Replacement Parts
Obtaining Replacement Parts
We recommend you fit only JCB Genuine Parts. A Parts Book will help you identify parts and order them from your JCB distributor.
Your dealer will need to know the exact model, build and serial number of your machine. See
Identifying Your Machine
The data plate also shows the serial numbers of the engine, transmission and axle(s), where applicable. But remember if any of these units have been changed, the serial number on the data plate may be wrong. Check on the unit itself.
Service Schedules
Service Schedules
Introduction
Introduction
A badly maintained machine is a danger to the operator and the people working around him. Make sure that the regular maintenance and lubrication jobs listed in the service schedules are done to keep the machine in a safe and efficient working condition.
Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings to c…
Maintenance must be done only by suitably qualified and competent persons. Before doing any maintenance make sure the machine is safe. It should be correctly parked on firm level ground.
To prevent anyone starting the engine, remove the starter key. Disconnect the battery and block the wheels when you are working beneath the machine.
If you do not take these precautions you could be killed or injured.
Apart from the daily jobs, the schedules are based on machine running hours. Keep a regular check on the hourmeter readings to c…
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Calendar equivalents:
<TABLE BODY
<TABLE ROW
Every 10 Hours = Daily
<TABLE ROW
Every 50 Hours = Weekly
<TABLE ROW
Every 100 Hours = Monthly
<TABLE ROW
Every 500 Hours = Six Months
<TABLE ROW
Every 1000 Hours = 1 Year
<TABLE ROW
Every 2000 Hours = 2 Years
<TABLE ROW
Every 5000 Hours = 5 Years
Services should be carried out at either the hourly interval or calendar interval, whichever occurs first.
How to Use the Service Schedules
How to Use the Service Schedules
In the example shown,
A
B
Services should be carried out at either the hourly interval or calendar interval, whichever occurs first. Refer to
Calendar Equivalents
<GRAPHIC
<GRAPHIC
795390-1
Pre-start Cold Checks, Service Points and Fluid Levels
Pre-start Cold Checks, Service Points and Fluid Levels
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Operation
10
50
500
1000
2000
<TABLE BODY
<TABLE ROW
ENGINE
ENGINE
<TABLE ROW
Oil Level
– Check
<TABLE ROW
Oil and Filter
In arduous conditions, change the oil and filter after every 250 hours or three months (whichever comes first).
– Change
<TABLE ROW
Air Cleaner Dust Valve
Clean more often when working in dusty environments.
– Clean
<TABLE ROW
Air Cleaner Outer Element
Change outer element more frequently in dusty operating environments.
– Change
<TABLE ROW
Air Cleaner Inner Element
– Change
<TABLE ROW
Fuel System for Leaks and Contamination
– Check
<TABLE ROW
Fuel Filter
– Change
<TABLE ROW
Fuel Sedimenter
– Drain and Clean
<TABLE ROW
Fan Belt Tension/Condition
– Check
<TABLE ROW
Fan Belt
– Change
<TABLE ROW
Valve Clearances
– Check and Adjust
<TABLE ROW
Radiator Hoses Condition
– Check
<TABLE ROW
Radiator
– Clean
<TABLE ROW
Coolant Level
– Check
<TABLE ROW
Coolant
– Change
<TABLE ROW
External Oil Leaks
– Check
<TABLE ROW
TRANSMISSION, AXLES AND STEERING
TRANSMISSION, AXLES AND STEERING
<TABLE ROW
Wheel Motor Security
<TABLE ROW
Tyre Pressures/Condition
– Check
<TABLE ROW
Wheel Nut Security
– Check
<TABLE ROW
HYDRAULICS
HYDRAULICS
<TABLE ROW
Oil Level
– Check
<TABLE ROW
Oil
– Change
<TABLE ROW
Oil Filter
– Change
<TABLE ROW
Suction Strainer (Tank)
Strainer located inside hydraulic tank.
– Change
<TABLE ROW
Hoses, Rams and Pipework for Damage and Leaks
– Check
<TABLE ROW
BRAKES
BRAKES
<TABLE ROW
Brake System Fluid Level
– Check
<TABLE ROW
Brake System Fluid
– Change
<TABLE ROW
ELECTRICS
ELECTRICS
<TABLE ROW
Battery Electrolyte Level (if applicable)
– Check
<TABLE ROW
Battery Charge and Condition
– Check
<TABLE ROW
Wiring for Chafing/Routing
– Check
<TABLE ROW
Battery Terminals for Condition and Tightness
– Check
<TABLE ROW
BODYWORK AND CAB
BODYWORK AND CAB
<TABLE ROW
Wing Mirrors Condition and Security
– Check
<TABLE ROW
All Pivot Pins
– Grease
<TABLE ROW
Seat Belt Condition and Security
– Check
<TABLE ROW
ADDITIONAL SERVICE ITEMS
ADDITIONAL SERVICE ITEMS
<TABLE ROW
Engine Cooling System
– Clean
Under dusty conditions, carry out the engine cooling system cleaning procedure more frequently.
The engine timing belt MUST be replaced at 5000 Hours (5 Yearly).
Lubricants and Capacities
Lubricants and Capacities
New engines DO NOT require a running-in period. The engine/machine should be used in a normal work cycle immediately, glazing of…
Table 1.
Table 1.
<TABLE
<TABLE HEADING
<TABLE ROW
ITEM
ITEM
CAPACITY
FLUID/LUBRICANT
FLUID/LUBRICANT
INTERNATIONAL SPECIFICATION
INTERNATIONAL SPECIFICATION
<TABLE BODY
<TABLE ROW
Litres
UK Gal
<TABLE ROW
Fuel Tank
Fuel Tank
42
9.2
Diesel Oil
ASTM D975-66T Nos. 1D, 2D
<TABLE ROW
Engine (Oil)
Engine (Oil)
10.0
2.2
JCB Extreme Performance Engine Oil 15W/40
ACEA A3/B3/E3/ E5 API CH-4/SJ
<TABLE ROW
Coolant
Coolant
6.5
1.4
JCB High Performance Antifreeze and Inhibitor
ASTM D6210
<TABLE ROW
Hydraulic System
Hydraulic System
40
8.8
JCB Super Multigrade Engine Oil 10W/30
ACEA E2 API CF- 4/SG
<TABLE ROW
Grease Points
Grease Points


JCB HP Grease
Lithium complex NLGI No.2 consistency including extreme pressure additives
<TABLE ROW
or JCB MPL EP Grease
JCB MPL EP Grease
JCB HP Grease is the recommended specification grease, if using JCB Special MPL-EP then the greasing must be carried out more frequently.
Lithium based NLGI No.2 consistency including extreme pressure additives
Coolant Mixtures
Coolant Mixtures
Check the strength of the coolant mixture at least once a year, preferably at the start of the cold period.
Replace the coolant mixture according to the intervals shown in the machine’s Service Schedule.
You must dilute full strength antifreeze with clean water before use. Use clean water of no more than a moderate hardness (pH va…
Antifreeze can be harmful. Obey the manufacturer’s instructions when handling full strength or diluted antifreeze.
You must dilute full strength antifreeze with clean water before use. Use clean water of no more than a moderate hardness (pH va…
The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round protection against corrosion.
The protection provided by JCB High Performance Antifreeze and Inhibitor is shown below.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
50% Concentration (Standard)
50% Concentration (Standard)
<TABLE BODY
<TABLE ROW
Protects against damage down to -40 ˚C (-39 ˚F)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
60% Concentration (Extreme Conditions Only)
60% Concentration (Extreme Conditions Only)
<TABLE BODY
<TABLE ROW
Protects against damage down to -56 ˚C (-68 ˚F)
Do not exceed a 60% concentration, as the freezing protection provided reduces beyond this point.
If you use any other brand of antifreeze:
– Ensure that the antifreeze complies with International Specification ASTM D6210.
– Ensure that the antifreeze complies with International Specification ASTM D6210.
– Always read and understand the manufacturer’s instructions.
– Ensure that a corrosion inhibitor is included. Serious damage to the cooling system can occur if corrosion inhibitors are not used.
– Ensure that the antifreeze is ethylene glycol based and does not use Organic Acid Technology (OAT).
Cleaning the Machine
Cleaning the Machine
Clean the machine using water and/or steam. Pay particular attention to the underside. Do not allow mud to build up on the engine or transmission. Make sure the radiator grille is not clogged up.
It is important to note that excessive power washing can cause damage to the seals and bearings. Take care during routine machine washing not to direct high pressure water jets directly at oil seals or universal joints.
The machine should always be greased after pressure washing or steam cleaning.
Avoid using neat detergent – always dilute detergents as per the manufacturer’s recommendations, otherwise damage to the paint finish may occur.
Rinse off all the detergent with water.
Do not steam clean the batteries.
Never use water or steam to clean inside the cab. The use of water or steam could damage the on-board computer and render the machine inoperable. Remove dirt using a brush or damp cloth.
Checking for Damage
Checking for Damage
1 Inspect steelwork for damage. Note damaged paintwork for future repair.
1 Inspect steelwork for damage. Note damaged paintwork for future repair.
2 Make sure all pivot pins are correctly in place and secured by their locking devices.
3 Ensure that the steps and handrails are undamaged and secure.
4 Check for broken or cracked window glass. Replace damaged items.
5 Check all bucket teeth for damage and security.
6 Check all lamp lenses for damage.
7 Inspect the tyres for damage and penetration by sharp objects.
8 Check that all safety decals are in place and undamaged. Fit new decals where necessary.
Seat Belt
Seat Belt
Checking the Seat Belt Condition and Security
Checking the Seat Belt Condition and Security
Inspect the seat belt for signs of fraying and stretching. Check that the stitching is not loose or damaged. Check that the buckle assembly is undamaged and works correctly.
When a seat belt is fitted to your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. Fit a new seat belt every three years.
Inspect the seat belt for signs of fraying and stretching. Check that the stitching is not loose or damaged. Check that the buckle assembly is undamaged and works correctly.
Check that the belt mounting bolts are undamaged, correctly fitted and tightened.
Checking the ROPS Structure
Checking the ROPS Structure
1 Check the structure for damage.
You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS/FOPS. If the Roll Over Protecti…
1 Check the structure for damage.
1 Check the structure for damage.
2 Make sure that all the ROPS mounting bolts are in place and are undamaged.
3 Make sure that the ROPS mounting bolts are tightened to the correct torque setting. This should be 135 Nm (99.5 lbf ft).
Greasing
Greasing
The machine must be greased regularly to keep it working efficiently. Regular greasing will also increase the machine’s working …
Make the machine safe before working underneath it. Park the machine on level ground, lower the attachments to the ground. Apply the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels.
Disconnect the battery, to prevent the engine being started while you are beneath the machine.
The machine must be greased regularly to keep it working efficiently. Regular greasing will also increase the machine’s working …
K Lubricants and Capacities ( T 3-6)
In the following illustrations, the grease points are numbered. Count off the grease points as you apply grease to each one. Refit the dust caps after greasing.
<GRAPHIC
<GRAPHIC
Fig 1.
<GRAPHIC
<GRAPHIC
Fig 2.
Access Panels
Access Panels
Engine Cover
Engine Cover
Opening and Closing the Engine Cover
Opening and Closing the Engine Cover
Opening the Engine Cover
Opening the Engine Cover
1 Apply the parking brake, lower the attachments to the ground, place the transmission in neutral and stop the engine.
The engine has exposed rotating parts. Switch OFF the engine before working in the engine compartment. Do not use the machine with the engine cover open.
1 Apply the parking brake, lower the attachments to the ground, place the transmission in neutral and stop the engine.
1 Apply the parking brake, lower the attachments to the ground, place the transmission in neutral and stop the engine.
2 Unlock the security lock
A
3 Lift the Engine Cover
B
Closing the Engine Cover
Closing the Engine Cover
1 Pull down the engine cover
1 Pull down the engine cover
B
2 Lock the security lock
A
<GRAPHIC
<GRAPHIC
Fig 3.
Electrical System
Electrical System
Battery
Battery
Battery Disconnection/Connection
Battery Disconnection/Connection
Disconnection
Keep metal watch straps and any metal fasteners on your clothes, clear of the positive (+) battery terminal. Such items can short between the terminal and nearby metal work. If it happens you can get burned.
Disconnection
Disconnection
1 Get access to the battery. See
1 Get access to the battery. See
Access Panels
2 Remove the leads. Disconnect the earth (-) terminal first.
Connection
Connection
1 Check the battery.
1 Check the battery.
a If the terminal is dirty, clean the post.
a If the terminal is dirty, clean the post.
<GRAPHIC
<GRAPHIC
Fig 4.
b If the terminal post is corroded and generates white powder wash the terminal with hot water. If considerable corrosion is detected, clean with a wire brush or abrasive paper.
c After cleaning, apply a thin coat of petroleum jelly to the terminal.
2 Re-connect the leads. Connect the earth (-) terminal last.
3 Close and lock the access panels.
Checking the Electrolyte Level
Checking the Electrolyte Level
Maintenance free batteries used in normal temperate climate applications should not need topping up. However, in certain conditi…
1 Get access to the battery. See
1 Get access to the battery. See
Access Panels
2 Disconnect and remove battery. See
Battery Disconnection/Connection.
3 Remove covers
Do not top the battery up with acid. The electrolyte could boil out and burn you.
3 Remove covers
A
<GRAPHIC
<GRAPHIC
Fig 5.
4 Refit battery.
5 Close and lock the access panels.
Jump Starting the Engine
Jump Starting the Engine
1 The park brake should have been engaged when the machine was last parked. If it is not engaged, engage it now. The engine will not start unless the park brake is on.
Do not use a battery if its electrolyte is frozen. To prevent the battery electrolyte from freezing, keep the battery fully charged.
Do not try to charge a frozen battery or jump-start and run the engine, the battery could explode.
Batteries produce a flammable gas, which is explosive; do not smoke when checking the electrolyte levels.
When jump-starting from another vehicle, make sure that the two vehicles do not touch each other. This prevents any chance of sparks near the battery.
Set all the machine switches to their OFF positions before connecting the external power supply. Even with the starter switch set to off some circuits will be energised when the external power supply is connected.
Do not connect the booster (slave) supply directly across the starter motor. Doing this by-passes the neutral gear safety switch. If the machine is in gear, it may ‘runaway’ and kill or injure bystanders.
Use only sound jump leads with securely attached connectors. Connect one jump lead at a time.
The machine has a negative earth electrical system. Check which battery terminal is positive (+) before making any connections.
Keep metal watch straps and jewellery away from the jump lead connectors and the battery terminals – an accidental short could cause serious burns and damage equipment.
Make sure you know the voltage of the machine. The booster (slave) supply must not be higher than that of the machine. Using a higher voltage supply will damage your machine’s electrical system.
If you do not know the voltage of your booster (slave) supply, then contact your JCB dealer for advice. Do not attempt to jump-start the engine until you are sure of the voltage of the booster (slave) supply.
1 The park brake should have been engaged when the machine was last parked. If it is not engaged, engage it now. The engine will not start unless the park brake is on.
1 The park brake should have been engaged when the machine was last parked. If it is not engaged, engage it now. The engine will not start unless the park brake is on.
2 Set all switches in the cab to off.
3 Connect the booster cables as follows:
a Unlock and open the battery cover.
a Unlock and open the battery cover.
b Connect the positive booster cable to the positive (+) terminal on the machine battery. Connect the other end of this cable to the positive (+) terminal of the booster supply.
c Connect the negative (-) booster cable to a good frame earth on the machine, away from and below the battery.
A good frame earth is part of the main frame, free from paint and dirt. Do not use a pivot pin for an earth.
d Connect the other end of this cable to the negative (-) terminal on the booster supply.
5 Start the engine.
6 Disconnect the negative booster cable from the machine frame earth. Then disconnect it from the booster supply.
When the engine is running, there are rotating parts in the engine compartment. Before disconnecting the cables, make sure that you have no loose clothing (cuffs, ties etc.) which could get caught in rotating parts.
6 Disconnect the negative booster cable from the machine frame earth. Then disconnect it from the booster supply.
Disconnect the positive booster cable from the positive (+) terminal on the battery. Then disconnect it from the booster supply.
7 Close and lock the battery cover.
Fuses and Relays
Fuses and Relays
Fuses
Fuses
The electrical circuits are protected by fuses. The fuses are located on the steering column below the ignition switch.
Fuses
Always replace fuses with ones of correct ampere rating to avoid electrical system damage.
The electrical circuits are protected by fuses. The fuses are located on the steering column below the ignition switch.
If a fuse ruptures, find out why and rectify the fault before fitting a new one.
Table 2. Standard Circuits
Table 2. Standard Circuits
<TABLE
<TABLE HEADING
<TABLE ROW
Fuse
Circuit(s) Protected
Rating
<TABLE BODY
<TABLE ROW
A1
Glow Plug Indicator
3A
<TABLE ROW
A2
ESOS
3A
<TABLE ROW
A3
Illumination
5A
<TABLE ROW
A4
Parkbrake
10A
<TABLE ROW
A5
Forward/Reverse
7.5A
<TABLE ROW
A6
Beacon, 12V Socket
15A
<TABLE ROW
A7
Worklights (optional)
20A
<TABLE ROW
A8
Horn
5A
<GRAPHIC
<GRAPHIC
Fig 6.
Table 3. Optional Circuits
Table 3. Optional Circuits
<TABLE
<TABLE HEADING
<TABLE ROW
Fuse
Circuit(s) Protected
Rating
<TABLE BODY
<TABLE ROW
B1
Indicators
5A
<TABLE ROW
B2
Dipped Beam
15A
<TABLE ROW
B3
Fog Lights
5A
<TABLE ROW
B4
Spare

<TABLE ROW
B5
Spare

<TABLE ROW
B6
RH Side Lights
5A
<TABLE ROW
B7
LH Side Lights
5A
<TABLE ROW
B8
Hazards
10A
Relays
Relays
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Relay
Circuit
<TABLE BODY
<TABLE ROW
1
Neutral Start
<TABLE ROW
2
Parkbrake Start Inhibit
<TABLE ROW
3
Parkbrake/Neutral Warning
<TABLE ROW
4
Worklights
<TABLE ROW
5
Roadlights
<TABLE ROW
6
Flasher Unit
<GRAPHIC
<GRAPHIC
Fig 7.
Engine
Engine
Checking the Oil Level
Checking the Oil Level
1 Park the machine on firm level ground and lower the attachments to the ground.
Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.
1 Park the machine on firm level ground and lower the attachments to the ground.
1 Park the machine on firm level ground and lower the attachments to the ground.
2 Stop the engine. Put the transmission into neutral and remove the starter key.
3 Open the engine cover.
4 Check that the oil is between the two marks on the dipstick
A
5 If necessary, add the recommended oil through the filler point
B
K Lubricants and Capacities ( T 3-6)
6 Make sure the filler cap and the dipstick are refitted correctly and are secure.
<GRAPHIC
<GRAPHIC
Fig 8.
Changing the Oil and Filter
Changing the Oil and Filter
1 Do steps 1 to 3 of Checking the Oil Level.
Make the machine safe before working underneath it. Park the machine on level ground, lower the attachments to the ground. Apply the park brake, put the transmission in neutral and stop the engine. Block both sides of all four wheels.
Disconnect the battery, to prevent the engine being started while you are beneath the machine.
1 Do steps 1 to 3 of Checking the Oil Level.
Hot oil and engine components can burn you. Make sure the engine is cool before doing this job.
1 Do steps 1 to 3 of Checking the Oil Level.
1 Do steps 1 to 3 of Checking the Oil Level.
K Checking the Oil Level ( T 3-17)
2 Remove the belly plate for access.
3 Place a suitable container beneath the drain plug (to catch the oil).
4 Remove the drain plug and drain the oil from the sump.
5 Clean and refit the drain plug. Tighten to 55 Nm (40.6 lbf ft).
6 Unscrew the filter canister
A
B
7 Add clean engine oil to the new filter canister. Allow time for the oil to pass through the filter element. Smear seal
C
K Lubricants and Capacities ( T 3-6)
8 Start the engine. Check for leaks. When the engine has cooled, check the oil level. Close and secure the engine cover.
9 Refit the belly panel.
<GRAPHIC
<GRAPHIC
Fig 9.
Fan Belt
Fan Belt
Adjusting the Fan Belt
Adjusting the Fan Belt
1 Park the machine on firm level ground
Make sure the engine cannot be started. Disconnect the battery before doing this job.
1 Park the machine on firm level ground
1 Park the machine on firm level ground
2 Apply the parking brake, put the transmission in neutral and stop the engine.
3 Open the engine compartment cover.
4 Check the fan belt for damage.
5 Loosen screw
A
6 Turn the alternator
B
7 Tighten screw
A
8 Recheck the belt tension.
9 Close and secure the engine compartment cover.
<GRAPHIC
<GRAPHIC
Fig 10.
Checking the Coolant Level
Checking the Coolant Level
1 Park the machine on firm level ground and lower the attachments to the ground.
1 Park the machine on firm level ground and lower the attachments to the ground.
2 Stop the engine. Put the transmission into neutral and remove the starter key.
3 Open the engine cover.
4 Check that the oil is between the two marks on the dipstick
A
5 If necessary, top up the colant systeml through the filler point
B
K Lubricants and Capacities ( T 3-6)
6 Make sure the filler cap is refitted correctly and is secure.
Draining and Refilling the Coolant
Draining and Refilling the Coolant
1 Park the machine on firm level ground and lower the attachments to the ground.
1 Park the machine on firm level ground and lower the attachments to the ground.
2 Stop the engine. Put the transmission into neutral and remove the starter key.
3 Open the engine cover.
4 Carefully loosen the filler cap. Let any pressure escape. Remove the cap.
5 Remove the belly plate.
6 Place a suitable container beneath the radiator bottom hose.
7 Slacken the hose clip, detach the bottom hose and drain the coolant.
8 Flush the system using clean water.
9 Refit and secure the bottom hose.
10 Fill the system slowly with clean water to prevent air locks. Wait 2 to 3 minutes to allow air to be vented and top up the header tank to 1/3 full.
Do not
11 Run the engine for 5 minutes at the normal running temperature. Stop the engine and allow to cool.
12 Drain the cooling system, checking that the coolant is not dirty. If it is, repeat the flushing process (steps
6
12
13 Refill the system as described at step
10
K Coolant Mixtures ( T 3-7)
A 50% antifreeze mixture must be used even if frost protection is not needed. This gives protection against corrosion and raises the coolant’s boiling point.
14 Run the engine for a while to raise the coolant to working temperature and pressure. Stop the engine and check for leaks.
Fuel System
Fuel System
Types of Fuel
Types of Fuel
Use good quality diesel fuel to get the correct power and performance from your engine.
Recommended Fuel Specification
Recommended Fuel Specification
– EN590 Diesel Fuel Types – Auto/Co/C1/C2/C3/C4.
– EN590 Diesel Fuel Types – Auto/Co/C1/C2/C3/C4.
– BS2869 Class A2.
– ASTM D975-91 Class 2-2DA, US DF1, US DF2, US DFA.
– JIS K2204 (1992) Grades 1, 2, 3, and Special Grade 3.
Where low sulphur/low aromatic fuels are used it is important that lubricity additives are used. The additives listed below are …
1 Elf 2S 1750. Dosage 1000-1500 ppm (0.1 – 0.15%), specifically for Indian Superior Kerosene (SKO) but may be applicable to other fuels.
1 Elf 2S 1750. Dosage 1000-1500 ppm (0.1 – 0.15%), specifically for Indian Superior Kerosene (SKO) but may be applicable to other fuels.
2 Lubrizol 539N. Dosage (on Swedish low sulphur fuel) 250 ppm.
3 Paradyne 7505 (from Infineum). Dosage 500 ppm (0.05%).
Consult your fuel supplier or JCB distributor about the suitability of any fuel you are unsure of.
Acceptable Fuel Specification
Acceptable Fuel Specification
– ASTM D975-91 Class 1-1DA.
The fuel specification below is acceptable, however this fuel may reduce the life of the fuel injection equipment. The use of this fuel may also affect the engine performance.
– ASTM D975-91 Class 1-1DA.
– ASTM D975-91 Class 1-1DA.
– JP7, MIL T38219 XF63.
– NATO F63.
Sulphur Content
Sulphur Content
High sulphur content can cause engine wear. (High sulphur fuel is not normally found in North America, Europe or Australia.) If you have to use high sulphur fuel you must change the engine oil more frequently.
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.
High sulphur content can cause engine wear. (High sulphur fuel is not normally found in North America, Europe or Australia.) If you have to use high sulphur fuel you must change the engine oil more frequently.
Table 4.
Table 4.
<TABLE
<TABLE HEADING
<TABLE ROW
Percentage of sulphur in the fuel (%)
Oil Change Interval
<TABLE BODY
<TABLE ROW
Less than 0.5
Normal
<TABLE ROW
0.5 to 1.0
0.75 of normal
<TABLE ROW
More than 1.0
0.50 of normal
Aviation Kerosene Fuels
Aviation Kerosene Fuels
Aviation kerosene fuels are not approved and their use may cause damage to components. Warranty will not be allowed on any component where damage is found to have been caused by the use of aviation kerosene.
Low Temperature Fuels
Low Temperature Fuels
Special winter fuels may be available for engine operation at temperatures below 0˚C (32˚F). These fuels have a lower viscosity….
Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels
Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels
Fuel resources such as Rape Methyl Ester and Soybean Methyl ester, collectively known as Fatty Acid Methyl Esters are being used as alternatives and extenders for mineral oil.
Fatty Acid Methyl Esters must conform to certain standards to be of acceptable quality, just as mineral oils do at present.
Consult your JCB distributor for advice about the use of Fatty Acid Methyl Ester fuels, as improper application may impair engine performance.
Diesel Fuel
Diesel fuel is flammable; keep naked flames away from the fuel system. Do not smoke while refuelling or working on the fuel system. Do not refuel with the engine running. There could be a fire and injury if you do not follow these precautions.
Petrol
Petrol
Petrol
Do not use petrol in this machine. Do not mix petrol with the diesel fuel; in storage tanks the petrol will rise to the top and form flammable vapours.
Changing the Fuel Filter
Changing the Fuel Filter
1 Apply the parking brake, put the transmission into neutral and stop the engine.
1 Apply the parking brake, put the transmission into neutral and stop the engine.
2 Open the engine cover.
3 Remove the belly panel for access
4 Unscrew the filter element
A
5 Clean the filter head
B
6 Fill the new element with fuel (to assist the self bleed system), lubricate the sealing ring
C
7 Start the engine. If the engine does not fire within 20 seconds, wait at least two minutes before cranking the engine again.
Do not operate the starter motor for more than 20 seconds at one time. Let the starter motor cool for at least 2 minutes.
7 Start the engine. If the engine does not fire within 20 seconds, wait at least two minutes before cranking the engine again.
8 Run the engine and check for leaks.
9 Close and secure the engine cover.
10 Refit the belly panel.
<GRAPHIC
<GRAPHIC
Fig 11.
Bleeding the Fuel System
Bleeding the Fuel System
Air in the fuel system could cause misfiring or failure to start. Air will enter the system if any part of it is disconnected or emptied.
Running the engine with air in the system could damage the fuel injection pump. After maintenance, remove air from the fuel system as detailed below.
1 Stop the Engine. Switch off the engine and remove the key.
1 Stop the Engine. Switch off the engine and remove the key.
2 Open the Engine Compartment. Disconnect the Battery. Remove the -ve lead to chassis.
3 Remove the belly panel for access.
4 Prepare for Bleeding. Position a collecting vessel underneath the filter. Loosen the bleed screw.
5 Turn the lever on the fuel pump until the fuel escapes from the bleed screw without any bubbles.
6 Tighten the bleed screw.
7 Wipe up any spilled fuel. Start the engine and check for leaks.
8 Refit the belly panel.
Fuel oil is highly inflammable. Stop the engine immediately if a fuel leak is suspected. Completely wipe off any spilt fuel which could cause a fire.
Hydraulic System
Hydraulic System
Checking the Fluid Level
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear prot…
Checking the Fluid Level
Checking the Fluid Level
1 Apply the parking brake, put the transmission into neutral, lower the attachments to the ground. Make sure the attachment is flat on the ground and switch off the engine.
1 Apply the parking brake, put the transmission into neutral, lower the attachments to the ground. Make sure the attachment is flat on the ground and switch off the engine.
2 Check that the hydraulic fluid is between the two marks on the dipstick
A
3 If necessary, top up with hydraulic fluid, through filler point
B
K Lubricants and Capacities ( T 3-6)
<GRAPHIC
If the fluid is cloudy, then water or air has contaminated the system. This could damage the hydraulic pump. Contact your JCB Distributor immediately.
<GRAPHIC
<GRAPHIC
Fig 12.
Changing the Filter Element
Changing the Filter Element
1 Park the machine on firm level ground. Apply the parking brake, put the transmission in neutral, lower the attachments to the ground. Stop the engine.
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear prot…
1 Park the machine on firm level ground. Apply the parking brake, put the transmission in neutral, lower the attachments to the ground. Stop the engine.
1 Park the machine on firm level ground. Apply the parking brake, put the transmission in neutral, lower the attachments to the ground. Stop the engine.
2 Open the engine cover.
3 Undo the filter assembly cover
A
B
4 Replace the “O” ring
C
The torque setting for the filter cap must not be exceeded.
5 Fold over the lifting handle and screw on the cover. Torque tighten the cap to 40 Nm (29.5 lbf ft).
6 Check the hydraulic fluid level and top up if necessary.
K Checking the Fluid Level ( T 3-24)
7 Close and secure the engine cover.
<GRAPHIC
<GRAPHIC
Fig 13.
Refilling the Hydraulic System
Refilling the Hydraulic System
In order to make sure that the hydraulic fluid is as clean as possible, when refilling or after replacing the pump or motor, the fluid should be added using the following procedure:
1 Apply the parking brake, put the transmission in neutral, lower the attachments to the ground. Make sure the attachments are flat on the ground. Stop the engine.
1 Apply the parking brake, put the transmission in neutral, lower the attachments to the ground. Make sure the attachments are flat on the ground. Stop the engine.
2 Remove the filter element.
K Changing the Filter Element ( T 3-25)
3 Add the hydraulic fluid through the filter housing using a very fine mesh filter, this ensures that the pump is primed before the machine is started. For the correct grade of fluid.
K Lubricants and Capacities ( T 3-6)
4 Refit the filter element.
K Changing the Filter Element ( T 3-25)
Tyres and Wheels
Tyres and Wheels
Tyre Inflation
Tyre Inflation
These instructions are for adding air to a tyre which is already inflated. If the tyre has lost all its air pressure, call in a qualified tyre mechanic. The tyre mechanic should use a tyre inflation cage and the correct equipment to do the job.
1 Prepare the wheel.
An exploding tyre can kill. Inflated tyres can explode if over-heated or over-inflated. Follow the instructions given when inflating the tyres. Do not cut or weld the rims. Use a tyre/wheel specialist for all repair work.
1 Prepare the wheel.
Wheels and tyres are heavy. Take care when lifting or moving them.
Store with care to ensure that they cannot fall and cause injury.
1 Prepare the wheel.
1 Prepare the wheel.
Before you add air to the tyre, make sure it is correctly fitted on the machine or installed in a tyre inflation cage.
K Fig 14. ( T 3-27)
2 Prepare the equipment.
a Use only an air supply system which includes a pressure regulator. Set the regulator no higher than 1.38 bar (20 psi) above the recommended tyre pressure. For recommended tyres and pressures for your machine, see
a Use only an air supply system which includes a pressure regulator. Set the regulator no higher than 1.38 bar (20 psi) above the recommended tyre pressure. For recommended tyres and pressures for your machine, see
Tyre Sizes and Pressures
b Use an air hose fitted with a self-locking air chuck and remote shut-off valve.
3 Add the air.
a Make sure that the air hose is correctly connected to the tyre valve. Clear other people from the area. Stand behind the tread of the tyre while adding the air.
a Make sure that the air hose is correctly connected to the tyre valve. Clear other people from the area. Stand behind the tread of the tyre while adding the air.
b Inflate the tyre to the recommended pressure. Do not over-inflate.
<GRAPHIC
<GRAPHIC
Fig 14.
Checking the Wheel Nut Torques
Checking the Wheel Nut Torques
On new machines, and whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct.
If, for whatever reason, a wheel stud is renewed, all the studs for that wheel must be changed as a set, since the remaining studs may have been damaged.
On new machines, and whenever a wheel has been removed, check the wheel nut torques every two hours until they stay correct.
Every day, before starting work, check that the wheel nuts are tight.
The correct torques are shown in the table below.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Front
Rear
<TABLE ROW
Nm
lbf ft
Nm
lbf ft
<TABLE BODY
<TABLE ROW
200
147
200
147
Page left intentionally blank
Section A – Attachments
Section A
Section A
Attachments
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Manual – JCB 403
Service Manual – JCB 403
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Maintenance
Section 3 – Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
<GRAPHIC
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Notes:
<TABLE BODY
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
General Information
General Information
Introduction
Introduction
A wide range of optional attachments is available to increase the versatility of your machine. Only JCB approved attachments are recommended for use with your machine. Consult your JCB Distributor for the full list of approved attachments available.
Use only the JCB approved attachments that are specified for your machine. Operating with non- specified attachments can overload the machine, causing possible damage and machine instability which could result in injury to yourself or others.
The use of non-approved attachments could invalidate your warranty.
A wide range of optional attachments is available to increase the versatility of your machine. Only JCB approved attachments are recommended for use with your machine. Consult your JCB Distributor for the full list of approved attachments available.
A wide range of optional attachments is available to increase the versatility of your machine. Only JCB approved attachments are recommended for use with your machine. Consult your JCB Distributor for the full list of approved attachments available.
JCB attachments are designed and manufactured specifically to suit the machine’s hydraulic system, mounting arrangements and saf…
This part of the manual includes general information on attachment operation and instructions for installation and removal of attachments.
If you have an attachment which is not covered in the Operator Manual do not install it, use it or remove it until you have obtained, read and understood the pertinent information. Install attachments only on the machines for which they were designed.
This part of the manual includes general information on attachment operation and instructions for installation and removal of attachments.
Some attachments are supplied complete with instructions on safety, installing and removing, operation and maintenance. Read and…
Before using any attachment, read again
Working With The Machine
Practice using attachments off the job before working with them for the first time.
If your machine needs the hydraulic system adapting to facilitate the use of auxiliary attachments, you must consult your distributor. Only suitably qualified personnel must re- route hydraulic hoses.
All optional attachments will have limits on their operation. i.e. lifting capacity, speeds, hydraulic flow rates, etc. Always c…
Some attachments may contact parts of the machine when in the fully folded position. Take extra care to avoid damage to the machine.
Quick Release Couplings
Quick Release Couplings
Connecting and Disconnecting
Connecting and Disconnecting
Flat face quick release couplings allow the operator to remove and install attachments swiftly and efficiently. Generally, your machine pipework will be fitted with a female coupling
A
B
A
B
The quick release couplings should be trouble free and relatively easy to connect and disconnect, provided they are kept clean and used correctly. The recommendations listed below should always apply when using flat face quick release couplings.
Finally, please read the correct fitting and releasing procedures before installing or removing any optional attachment fitted with quick release couplings.
Quick Release Couplings – Do’s and Don’ts
Quick Release Couplings – Do’s and Don’ts
– Do wipe the two faces of the coupling and make sure they are clean before connecting.
– Do wipe the two faces of the coupling and make sure they are clean before connecting.
– Do make sure the outside sleeve (female coupling) is pulled back when disconnecting.
– Do connect and disconnect a new coupling two or three times to ‘work’ the PTFE seals – sometimes a new coupling will stick if the seals have not been ‘worked’.
– Do use a spanner on the hexagon flats of the coupling when fitting adaptors.
– Do use a rubber or hide hammer to disconnect a coupling if it sticks – sticking may occur if there is dirt present in the coupling.
– Don’t attempt to re-connect a damaged half coupling – this will destroy the seals and necessitate replacing both half couplings.
– Don’t leave the coupling where it may be run over by a machine or otherwise crushed – this will distort the coupling sleeve and prevent correct connection and disconnection.
– Don’t clamp on the smooth diameter of the coupling when fitting adaptors – always use the hexagon.
– Don’t try to turn the sleeve (female coupling) when the coupling has been disconnected – the locking ball will wedge underneath the sleeve and destroy the coupling.
– Don’t damage the faces of the couplings – this can prevent connection and disconnection, or damage seals and cause leakage.
– Don’t try to dismantle the couplings – they are non serviceable parts. If a coupling is damaged it should be replaced with a new one.
Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses.
Hydraulic fluid at pressure can injure you. Make the machine safe before connecting or disconnecting quick release couplings; stop the engine and then operate the attachment control a few times to vent residual hydraulic pressure in the attachment hoses
Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses.
The external surfaces of the couplings must be clean before connecting or disconnecting. Ingress of dirt will cause fluid leaks and difficulty in connecting or disconnecting. You could be killed or seriously injured by faulty Quick Release Couplings.
Before connecting or removing any hydraulic hose, residual hydraulic pressure trapped in the service hose line must be vented. Make sure the hose service line has been vented before connecting or removing hoses.
Connecting Quick Release Couplings
Connecting Quick Release Couplings
1 Remove any residual hydraulic pressure trapped in the service line hose.
1 Remove any residual hydraulic pressure trapped in the service line hose.
2 Wipe the two faces of the male and female couplings and make sure they are clean.
3 Make sure that ball
-C
4 Fit the male coupling into the female coupling; To ensure that the coupling is not accidentally released, rotate sleeve
-E
-C
-D
Disconnecting Quick Release Couplings
Disconnecting Quick Release Couplings
1 Remove any residual hydraulic pressure trapped in the service line hose.
1 Remove any residual hydraulic pressure trapped in the service line hose.
2 Align the slot
-D
-C
3 Pull back sleeve
-E
<GRAPHIC
<GRAPHIC
Fig 1.
Page left intentionally blank
Section B – Body and Framework
Section B
Section B
Body and Framework
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Manual – JCB 403
Service Manual – JCB 403
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Maintenance
Section 3 – Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
<GRAPHIC
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Notes:
<TABLE BODY
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
General Information
General Information
Rivet Nuts
Rivet Nuts
A ‘Rivet Nut’ is a one piece fastener installed ‘blind’ from one side of the machine body/framework. The rivet nut
1- A
1
1-B
1
<GRAPHIC
<GRAPHIC
Fig 1.
Rivet nuts are fitted to various parts of the machine body and framework. They are used in a number of applications, for instance, hose clamp and hydraulic valve retention etc.
Various sized rivet nuts are available.
K Table 1. Specifications ( T B-1)
If for any reason a new rivet nut requires fitting, then the correct installation procedure must be followed.
K Fitting Procedure ( T B-2)
In an emergency, and if no installation tool is available, it is possible to fit a rivet nut by using a nut and bolt the same thread diameter as the rivet nut being installed. However, this is not the recommended method.
Table 1. Specifications
Table 1. Specifications
<TABLE
<TABLE HEADING
<TABLE ROW
Rivet Nut Thread Diameter
Rivet Nut Outside Diameter
Material Thickness
Rivet Length (Total)
Drill Hole Dia.
<TABLE BODY
<TABLE ROW
M5
7
0.25 – 3.00
14.00
7.10
<TABLE ROW
3.00 – 5.50
17.00
<TABLE ROW
M6
9
0.50 – 3.00
16.00
9.10
<TABLE ROW
3.00 – 5.50
19.00
<TABLE ROW
M8
11
0.50 – 3.00
18.00
11.10
<TABLE ROW
3.00 – 5.50
21.00
<TABLE ROW
M10
13
1.00 – 3.50
23.00
13.10
<TABLE ROW
3.50 – 6.00
26.00
All dimensions in mm
Fitting Procedure
Fitting Procedure
1 Drill a hole in the machine body/framework where the rivet nut is to be fitted. De-burr hole edges.
1 Drill a hole in the machine body/framework where the rivet nut is to be fitted. De-burr hole edges.
2 Screw the rivet nut onto the mandrel of the installation tool. The bottom of the mandrel should be in line with the bottom of the rivet nut
2-A
2
<GRAPHIC
<GRAPHIC
Fig 2.
3 Wind the body of the installation tool down the threaded mandrel until it touches the head of the rivet nut
3-B
3
<GRAPHIC
<GRAPHIC
Fig 3.
4 Insert the rivet nut (assembled to the tool) into the hole drilled in step
1
5 Hold handle
4-C
4
4-D
4
4-E
4
The thread of the rivet nut must not be stripped, take care when ‘upsetting’ the rivet nut.
<GRAPHIC
<GRAPHIC
Fig 4.
6 Remove the installation tool.
Slide Hammer Kit
Slide Hammer Kit
<GRAPHIC
<GRAPHIC
Fig 5. Typical M/c. Installation
The slide hammer kit is used to remove pivot pins that must be extracted, i.e. cannot be ‘knocked through’. The purpose of this description is to explain how the kit and the various components are used to remove the pivot pins.
The adaptors
5-A
5
5-B
5
5-C
5
Fitting Procedure
Fitting Procedure
1 Prepare the pivot pin, for instance, if fitted, remove the pivot pin retaining bolt.
1 Prepare the pivot pin, for instance, if fitted, remove the pivot pin retaining bolt.
2 Determine the thread size of the pivot pin and then fit the appropriate adaptor
5-A
5
5-D
5
3 Fit an end stop
5-B
5
4 Fit the ‘slide bar’
5-E
5
5 Fit the ‘slide hammer’, item
5-F
5
6 Finally, fit another end stop, item
5-C
5
7 To extract the pivot pin, slide the hammer along the bar until it contacts end stop
5-C
5
8 To remove the slide hammer kit, reverse steps
2
7
Page left intentionally blank
Chassis Assembly
Chassis Assembly
Description
Description
<GRAPHIC
<GRAPHIC
Fig 6.
The chassis consists of two articulated sections
A
B
The front chassis section
A
B
C
D
Steering is effected by steer ram
E
Front and Rear Chassis
Front and Rear Chassis
<GRAPHIC
<GRAPHIC
Fig 7.
To Separate
To Separate
1 Support the front chassis
1 Support the front chassis
A
2 Identify hydraulic hoses and disconnect where necessary.
3 Remove bolt C and drive out pin D
4 Remove nuts
E
F
5 Pull the two chassis sections apart.
To Join
To Join
1 Reverse the separation procedure
1 Reverse the separation procedure
K To Separate ( T B-6)
a
b
a Set the length of top link to 259 mm.
a Set the length of top link to 259 mm.
b Set the bottom ball joint to 100mm.
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Torque Settings
<TABLE ROW
Item
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
E
E
450 – 500
46 – 51
332 – 369
<TABLE ROW
F
F
450 – 500
46 – 51
332 – 369
Section C – Electrics
Section C
Section C
Electrics
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Manual – JCB 403
Service Manual – JCB 403
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Maintenance
Section 3 – Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
<GRAPHIC
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Notes:
<TABLE BODY
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
General Information
General Information
Battery
Battery
Maintenance
Maintenance
To ensure that the battery provides optimum performance the following steps should be observed:
1 Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion.
1 Make sure that the electrical connections are clean and tight. Smear petroleum jelly on connectors to prevent corrosion.
2 When applicable – never allow the electrolyte level to fall below the recommended level – 6 mm (1/4 in) above the plates. Use only distilled water for topping up.
3 Keep the battery at least three quarters charged, otherwise the plates may become sulphated (hardened) – this condition makes recharging the battery very difficult.
Extra precautions must be taken when bench charging maintenance free batteries, they are more prone to damage by overcharging than the standard type of battery:
– Never boost-charge a maintenance free battery.
– Never boost-charge a maintenance free battery.
– Never charge a maintenance free battery at a voltage in excess of 15.8 Volts.
– Never continue to charge a maintenance free battery after it begins to gas.
Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the battery away from sparks and flames.
Battery electrolyte contains sulphuric acid. It can burn you if it touches your skin or eyes. Wear goggles. Handle the battery c…
Set all switches in the cab to OFF before disconnecting and connecting the battery. When disconnecting the battery, take off the earth (-) lead first.
Re-charge the battery away from the machine, in a well ventilated area. Switch the charging circuit off before connecting or disconnecting the battery. When you have installed the battery in the machine, wait five minutes before connecting it up.
When reconnecting, fit the positive (+) lead first.
First Aid – Electrolyte
First Aid – Electrolyte
Do the following if electrolyte:
GETS INTO YOUR EYES
GETS INTO YOUR EYES
Immediately flush with water for 15 minutes, always get medical help.
IS SWALLOWED
IS SWALLOWED
Do not induce vomiting. Drink large quantities of water or milk. Then drink milk of magnesia, beaten egg or vegetable oil. Get medical help.
GETS ONTO YOUR SKIN
GETS ONTO YOUR SKIN
Flush with water, remove affected clothing. Cover burns with a sterile dressing then get medical help.
Testing
Testing
This test is to determine the electrical condition of the battery and to give an indication of the remaining useful `life’.
Before testing ensure that the battery is at least 75% charged (SG of 1.23 to 1.25 for ambient temperature up to 27˚C).
Ensure that the battery is completely disconnected from the vehicle.
Connect up the battery tester as follows:
1 Set the CHECK/LOAD switch
1 Set the CHECK/LOAD switch
1-A
1
2 Set rocker switch
1-B
1
3 Connect the red flying lead to the battery positive (+) terminal and the black flying lead to the battery negative (-) terminal.
4 Set the CHECK/LOAD switch
1-A
1
5 Set the CHECK/LOAD switch
1-A
1
Do not hold the switch in the LOAD position for more than 10 seconds.
6 K Table 1. Fault Diagnosis ( T C-2), if the foregoing tests are unsatisfactory.
6 K Table 1. Fault Diagnosis ( T C-2)
<GRAPHIC
<GRAPHIC
Fig 1. Battery Tester
Table 1. Fault Diagnosis
Table 1. Fault Diagnosis
<TABLE
<TABLE HEADING
<TABLE ROW
Battery Tester Readings
Remedy
<TABLE BODY
<TABLE ROW
1 CHECK: 0 – 12.6 Volts
1 CHECK: 0 – 12.6 Volts
1 CHECK: 0 – 12.6 Volts
LOAD: less than 6 Volts
Renew battery
<TABLE ROW
2 CHECK: 6 – 12.4 Volts
2 CHECK: 6 – 12.4 Volts
2 CHECK: 6 – 12.4 Volts
LOAD: less than 9 Volts and falls steadily but remains in yellow zone.
Recharge and re-test. If tests still unsatisfactory renew battery.
<TABLE ROW
3 CHECK: less than 10 Volts
3 CHECK: less than 10 Volts
3 CHECK: less than 10 Volts
LOAD: less than 3 Volts
Indicates battery has been over-discharged and unlikely to recover. Renew battery.
<TABLE ROW
4 CHECK: more than 11 Volts
4 CHECK: more than 11 Volts
4 CHECK: more than 11 Volts
LOAD: 6 – 10 Volts steady
Charge battery which will probably recover.
Specific Gravity Testing
Specific Gravity Testing
The specific gravity of the electrolyte gives an idea of the state of charge of the battery. Readings should be taken using a hy…
Readings should be as tabulated and should not vary between cells by more than 0.04. A greater variation indicates an internal fault on that particular cell.
If the electrolyte temperature is other than 15˚C (60˚F) a ‘correction factor’ must be applied to the reading obtained. Add 0.07 per 10˚C (18˚F) if the temperature is higher than 15˚C (60˚F) and subtract the same if the temperature is lower.
Table 2. Specific Gravity at 15˚C (60˚F)
Table 2. Specific Gravity at 15˚C (60˚F)
<TABLE
<TABLE HEADING
<TABLE ROW
Fully Charged
Half Discharged
Fully Discharged
<TABLE BODY
<TABLE ROW
Ambient temperature up to 27˚C (80˚F)
1.270 – 1.290
1.190 – 1.210
1.110 – 1.130
<TABLE ROW
Ambient temperature above 27˚C (80˚F)
1.240 – 1.260
1.170 – 1.190
1.090 – 1.110
Test Methods
Test Methods
Using a Multimeter
Using a Multimeter
In order to obtain maximum benefit from the fault finding information contained in Section C it is important that the technician…
These instructions are intended to cover the use of the recommended multimeters.
<GRAPHIC
<GRAPHIC
Fig 1. FLUKE 85
<GRAPHIC
<GRAPHIC
Fig 2. AVO 2003
<GRAPHIC
<GRAPHIC
Fig 3. A Typical Analogue Meter
1 Make sure that the test leads are plugged into the correct sockets. The black test lead should be plugged into the black socket (sometimes, this socket is also marked by a “
1 Make sure that the test leads are plugged into the correct sockets. The black test lead should be plugged into the black socket (sometimes, this socket is also marked by a “

E
COMMON
COM
+
V
2 When making measurements ensure that the test probes have a good clean contact with bare metal, free from grease, dirt, and corrosion as these can cause a false reading.
3 When measuring voltage: Make sure that the correct range is selected, that is set the selector to a value equal to or greater …
Measuring DC Voltage
Measuring DC Voltage
1 Select the correct range on the multimeter.
1 Select the correct range on the multimeter.
a On the FLUKE 85.
a On the FLUKE 85.
Turn the switch to position
1-B
1
b On the AV0 2003.
Move the right slider switch to position
2-A
2
c On an analogue meter.
Turn the dial to the appropriate DC Volts range.
2 Connect the black probe to the nearest available suitable earth point, usually this will be the starter motor earth, the battery negative, or the chassis. Connect the red probe to the wire or contact from which you are measuring the voltage.
Measuring Resistance
Measuring Resistance
1 Make sure there is no power to the part of the circuit you are about to measure.
1 Make sure there is no power to the part of the circuit you are about to measure.
2 Connect one probe at one end of the component or wire to be checked and the other probe at the other end. It does not matter which way round the two probes are placed.
3 Select the correct range on the multimeter.
a On the FLUKE 85.
a On the FLUKE 85.
i Turn the switch to position
i Turn the switch to position
1-C
1
F
1-G
1
REL
3
b On the AV0 2003.
i Move the right hand slider switch to position
i Move the right hand slider switch to position
2- B
2
c On an analogue meter.
i Move the dial to the appropriate Ohms (W) range.
i Move the dial to the appropriate Ohms (W) range.
Measuring Continuity
Measuring Continuity
1 Make sure there is no power to the part of the circuit you are checking for continuity.
1 Make sure there is no power to the part of the circuit you are checking for continuity.
2 Connect one probe to one end of the component or wire to be checked and the other probe to the other end. It does not matter which way round the two probes are placed.
3 Select the correct range on the multimeter.
a On the FLUKE 85.
a On the FLUKE 85.
Turn the switch to position
1-C
1
1-F
1
If there is continuity in the circuit, the beeper will sound. If there is no continuity (open circuit), the beeper will not sound.
b On the AV0 2003.
Move the right hand slider switch to position
2-B
2
2-C
2
If there is continuity (i.e. very low resistance) between two points the buzzer will sound.
c On an analogue meter.
Turn the dial to the lowest Ohms (W) range.
If there is continuity (i.e. very low resistance) between two points the needle will move across fully (or almost fully) to the right hand side of the scale.
Measuring Frequency
Measuring Frequency
The AVO 2003 and the analogue meter are not capable of measuring frequency, therefore a Fluke 85 digital multimeter must be used.
1 Insert the black plug into the COM socket on the meter and attach the probe to the nearest suitable earth point on the chassis, for example, the battery negative terminal.
1 Insert the black plug into the COM socket on the meter and attach the probe to the nearest suitable earth point on the chassis, for example, the battery negative terminal.
2 Insert the red probe into socket
1-J
1
3 Turn the selector switch to position
1-A
1
1-G
1
1-F
1
4 Press button
1-H
1
5 Touch or connect the red probe to the frequency source to be measured. Press and hold button if an average reading is required.
Testing a Diode or a Diode Wire
Testing a Diode or a Diode Wire
A diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end. The diode is sealed in heatshrink sleeving.
1 To test a Diode or a Diode Wire
1 To test a Diode or a Diode Wire
a On the FLUKE 85.
a On the FLUKE 85.
i Turn the switch to position
i Turn the switch to position
1-D
1
ii Press the
HOLD
iii Connect the black probe to the end of the diode with a band or to the male connector of the diode wire. Connect the red probe to the other end of the diode or diode wire. If the beeper does not sound the diode or diode wire is faulty.
iv Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. If the beeper sounds or the meter does not read
O.L.
v Press the HOLD button and check that the
H
b On the AV0 2003.
i Move the right hand slider to position
i Move the right hand slider to position
2-A
2
2-C
2
ii Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe should be connected to the other end of the diode or diode wire. If the Avometer does not buzz the diode is faulty.
iii Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe should be connected to the other end of the diode or diode wire. If the Avometer does not read “1” the diode is faulty.
c On an analogue meter.
i Select the Ohms 1000s (1k) range.
i Select the Ohms 1000s (1k) range.
Connect the black probe to the end of the diode marked with a band, or to the male connector of the diode wire, the red probe sh…
ii Select the Ohms 100s range.
Connect the red probe to the end of the diode marked with a band, or to the male connector of the diode wire, the black probe sh…
Schematic Circuits
Schematic Circuits
JCB 403 from Serial Number 1069500
JCB 403 from Serial Number 1069500
The schematic circuits are on four sheets which cover the following items:
K Fuses, Ignition Switch, ESOS, Horn ( T C-8)
K Fuses, Ignition Switch, ESOS, Horn ( T C-8)
K Instrumentation ( T C-10)
K Instrumentation ( T C-10)
K Transmission Controls, Park Brake, 12V Socket, Worklights ( T C-12)
K Transmission Controls, Park Brake, 12V Socket, Worklights ( T C-12)
K Roadlights ( T C-14)
K Roadlights ( T C-14)
K Earthing ( T C-16)
K Earthing ( T C-16)
Fuses, Ignition Switch, ESOS, Horn
Fuses, Ignition Switch, ESOS, Horn
Table 1.
Table 1.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components: K Fig 1. ( T C-9)
Main Components:
K Fig 1. ( T C-9)
<TABLE ROW
1
Battery
<TABLE ROW
2
Neutral Start Relay
<TABLE ROW
3
Neutral Diode
<TABLE ROW
4
Starter Motor
<TABLE ROW
5
Earth Strap
<TABLE ROW
6
Alternator
<TABLE ROW
7
Primary Fuse 1
<TABLE ROW
8
Ignition Switch
<TABLE ROW
9
Fuse A1
<TABLE ROW
10
Glow Plugs
<TABLE ROW
11
Fuse A2
<TABLE ROW
12
Emergency Shut-off System (ESOS)
<TABLE ROW
13
Fuse A8
<TABLE ROW
14
Horn Switch
<TABLE ROW
15
horn
Table 2.
Table 2.
<TABLE
<TABLE BODY
<TABLE ROW
Connections: K Fig 1. ( T C-9)
Connections:
K Fig 1. ( T C-9)
<TABLE ROW
A
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
B
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
C
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
CH
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
D
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
E
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
F
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
G
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
H
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
J
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
K
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
L
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
M
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
N
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
O
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
P
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
R
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
For next schematic
next
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
For component key
K Table 3. ( T C-10)
K Table 3. ( T C-10)
<TABLE ROW
For connecting schematics key
K Table 4. ( T C-10)
K Table 4. ( T C-10)
<GRAPHIC
<GRAPHIC
Fig 1. Fuses, Ignition Switch, ESOS, Horn
Instrumentation
Instrumentation
Table 3.
Table 3.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components: K Fig 2. ( T C-11)
Main Components:
K Fig 2. ( T C-11)
<TABLE ROW
1
Buzzer
<TABLE ROW
2
Instrument Panel (IP)
<TABLE ROW
3
Water Temperature Switch
<TABLE ROW
4
Engine Oil Pressure Switch
<TABLE ROW
5
Air Filter Blocked Switch
<TABLE ROW
6
Fuel Level Sender
<TABLE ROW
7
Fuse A3
Table 4.
Table 4.
<TABLE
<TABLE BODY
<TABLE ROW
Connections: K Fig 2. ( T C-11)
Connections:
K Fig 2. ( T C-11)
<TABLE ROW
B
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE ROW
BA
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
BB
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
BC
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
BD
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
BE
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
BF
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
BG
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
BH
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
BJ
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
BK
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
BL
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
BM
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
BN
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
BP
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
C
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE ROW
CJ
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
E
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE ROW
F
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE ROW
N
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
For next schematic
next
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
For component key
K Table 5. ( T C-12)
K Table 5. ( T C-12)
<TABLE ROW
For connecting schematics key
K Table 6. ( T C-12)
K Table 6. ( T C-12)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
For previous schematic
previous
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE ROW
For component key
K Table 1. ( T C-8)
K Table 1. ( T C-8)
<TABLE ROW
For connecting schematics key
K Table 2. ( T C-8)
K Table 2. ( T C-8)
<GRAPHIC
<GRAPHIC
Fig 2. Instrumentation
Transmission Controls, Park Brake, 12V Socket, Worklights
Transmission Controls, Park Brake, 12V Socket, Worklights
Table 5.
Table 5.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components: K Fig 3. ( T C-13)
Main Components:
K Fig 3. ( T C-13)
<TABLE ROW
1
Fuse A4
<TABLE ROW
2
Park Brake Switch
<TABLE ROW
3
Park Brake Solenoid
<TABLE ROW
4
Park Brake Buzzer Relay
<TABLE ROW
5
Fuse A5
<TABLE ROW
6
Joystick
<TABLE ROW
7
Forward Solenoid
<TABLE ROW
8
Neutral Relay
<TABLE ROW
9
Reverse Solenoid
<TABLE ROW
10
Reverse Alarm
<TABLE ROW
11
Fuse A7
<TABLE ROW
12
Worklight Switch
<TABLE ROW
13
Worklight Relay
<TABLE ROW
14
RH Front Worklight
<TABLE ROW
15
LH Front Worklight
<TABLE ROW
16
Rear Worklight
<TABLE ROW
17
Fuse A6
<TABLE ROW
18
12V Power Socket
<TABLE ROW
19
Beacon
Table 6.
Table 6.
<TABLE
<TABLE BODY
<TABLE ROW
Connections: K Fig 3. ( T C-13)
Connections:
K Fig 3. ( T C-13)
<TABLE ROW
A
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE ROW
BF
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
BK
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
BL
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
BM
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
BN
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
CA
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
CB
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
CC
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
CD
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
CE
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
CF
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
CG
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
CH
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE ROW
CJ
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
CK
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
CL
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
CM
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
CN
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
CO
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
CP
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
CR
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
CS
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
CT
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
G
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE ROW
H
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE ROW
J
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE ROW
K
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE ROW
M
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
For next schematic
next
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
For component key
K Table 7. ( T C-14)
K Table 7. ( T C-14)
<TABLE ROW
For connecting schematics key
K Table 8. ( T C-14)
K Table 8. ( T C-14)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
For previous schematic
previous
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
For component key
K Table 3. ( T C-10)
K Table 3. ( T C-10)
<TABLE ROW
For connecting schematics key
K Table 4. ( T C-10)
K Table 4. ( T C-10)
<GRAPHIC
<GRAPHIC
Fig 3. Transmission Controls, Park Brake, 12V Socket, Worklights
Roadlights
Roadlights
Table 7.
Table 7.
<TABLE
<TABLE BODY
<TABLE ROW
Main Components: K Fig 4. ( T C-15)
Main Components:
K Fig 4. ( T C-15)
<TABLE ROW
1
Ignition Relay 1
<TABLE ROW
2
Fuse B1
<TABLE ROW
3
Fuse B8
<TABLE ROW
4
Hazard Switch
<TABLE ROW
5
Flasher Unit
<TABLE ROW
6
Hazard Diode
<TABLE ROW
7
Indicator Switch
<TABLE ROW
8
LH Dip Beam
<TABLE ROW
9
LH Front Indicator Light
<TABLE ROW
10
RH Dip Beam
<TABLE ROW
11
RH Front Indicator Light
<TABLE ROW
12
RH Number Plate Light
<TABLE ROW
13
LH Number Plate Light
<TABLE ROW
14
Road-light Switch
<TABLE ROW
15
Fuse B7
<TABLE ROW
16
Fuse B6
<TABLE ROW
17
LH Tail Light
<TABLE ROW
18
LH Brake Light
<TABLE ROW
19
LH Rear Indicator Light
<TABLE ROW
20
LH Reverse Light
<TABLE ROW
21
LH Rear Fog Light
<TABLE ROW
22
Fuse B2
<TABLE ROW
23
RH Tail Light
<TABLE ROW
24
RH Brake Light
<TABLE ROW
25
RH Rear Indicator Light
<TABLE ROW
26
RH Reverse Light
<TABLE ROW
27
RH Rear Fog Light
<TABLE ROW
28
Rear Fog Light Switch
<TABLE ROW
29
Fuse B3
<TABLE ROW
30
RH Side Light
<TABLE ROW
31
LH Side Light
<TABLE ROW
32
Primary Fuse 2
Table 8.
Table 8.
<TABLE
<TABLE BODY
<TABLE ROW
Connections: K Fig 4. ( T C-15)
Connections:
K Fig 4. ( T C-15)
<TABLE ROW
BG
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
BH
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
BJ
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
BP
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
CB
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
CM
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
DA
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DB
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DC
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DD
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DE
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DF
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DG
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DH
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DJ
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DK
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DL
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DM
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DN
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DP
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DR
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DS
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DT
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DU
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DV
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
DW
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
L
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
For next schematic
next
K Fig 5. ( T C-17)
K Fig 5. ( T C-17)
<TABLE ROW
For component key
K Table 9. ( T C-16)
K Table 9. ( T C-16)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
For previous schematic
previous
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
For component key
K Table 5. ( T C-12)
K Table 5. ( T C-12)
<TABLE ROW
For connecting schematics key
K Table 6. ( T C-12)
K Table 6. ( T C-12)
<GRAPHIC
<GRAPHIC
Fig 4. Roadlights
Earthing
Earthing
Table 9.
Table 9.
<TABLE
<TABLE BODY
<TABLE ROW
Connections: See K Fig 5. ( T C-17)
Connections:
K Fig 5. ( T C-17)
<TABLE ROW
BA
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
BB
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
BC
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
BD
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
BE
K Fig 2. ( T C-11)
K Fig 2. ( T C-11)
<TABLE ROW
CA
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
CC
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
CD
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
CE
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
CF
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
CG
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
CK
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
CL
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
CN
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
CO
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
CP
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
CR
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
CS
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
CT
K Fig 3. ( T C-13)
K Fig 3. ( T C-13)
<TABLE ROW
D
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE ROW
DA
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DB
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DC
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DD
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DE
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DF
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DG
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DH
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DJ
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DK
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DL
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DM
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DN
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DP
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DR
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DS
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DV
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
DW
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
O
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE ROW
P
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE ROW
R
K Fig 1. ( T C-9)
K Fig 1. ( T C-9)
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
For previous schematic
previous
K Fig 4. ( T C-15)
K Fig 4. ( T C-15)
<TABLE ROW
For component key
K Table 7. ( T C-14)
K Table 7. ( T C-14)
<TABLE ROW
For connecting schematics key
K Table 8. ( T C-14)
K Table 8. ( T C-14)
<GRAPHIC
<GRAPHIC
Fig 5. Earthing
Harnesses
Harnesses
Wire and Harness Number Identification
Wire and Harness Number Identification
Introduction
Introduction
This section details the allocation of wire numbers and the identification of wires in the wiring harness.
<GRAPHIC
<GRAPHIC
Fig 1. Typical Wire and Harness Number
K Fig 1. ( T C-18). The illustration shows a typical connector and wires. Each wire has an individual identification number permanently marked on it, at regular intervals along it’s length.
K Fig 1. ( T C-18)
The number stamped on the wire identifies the following:
Table 1. Wire and Harness Number Identification
Table 1. Wire and Harness Number Identification
<TABLE
<TABLE HEADING
<TABLE ROW
Ident. No.
Description
<TABLE BODY
<TABLE ROW
#
#
The # indicates the start of the identification number. It is always printed to the left of the identification number.
#
<TABLE ROW
B
B
If applicable – The colour of the flying lead that the harness wire should mate with. For instance, if wire 819 from harness 719/37100 mated with a flying lead coloured black (colour code B) then the number printed on the wire would be B-819 9/371.
819
B
B
<TABLE ROW
819
819
The wire’s unique identification number. The wire functions and numbers allocated to them are consistent through out the JCB range of products. K Wire Numbers and Functions ( T C-19).
K Wire Numbers and Functions ( T C-19)
<TABLE ROW
9/371
9/371
If applicable – The part number of the harness that the wire originates from. If the harness part number is 719/37100, the number printed on the harness wires will be 9/371 (71 and 00 are common numbers and therefore deleted).
9/371
Wire Numbers and Functions
Wire Numbers and Functions
Wires 000-199
Wires 000-199
These numbers are reserved for ignition feeds, heater start circuits and start circuits. These can be further categorised by:
– Wires
– Wires
000 – 099
– Wires
100 – 199
Feeds via ignition relays are classed as ignition feeds.
Wires 200-399
Wires 200-399
These numbers are reserved for battery feeds, They can be further categorised by:
– Wires
– Wires
200 – 299
– Wires
300 – 399
Wires 400-599
Wires 400-599
These numbers are reserved for instruments, i.e. alternators to tachos, temperature switches to warning lights, etc. and signal wires used in electronic systems.
Wires 600-799
Wires 600-799
These numbers are used for earth wires. When the number is printed onto a wire
A
B
K Fig 2. ( T C-19)
<GRAPHIC
<GRAPHIC
Fig 2.
Where a load is switched negative, the wire number from the load to the switch shall be different to that of the wire from the switch to the earth.
Wires 800-999
Wires 800-999
These numbers are reserved for switched supplies to electrical loads, i.e. to lights, etc.
Wires In Splices
Wires In Splices
The main input wire is allocated with a wire number and a suitable description, i.e. Wire
640
640A
640B
K Fig 3. ( T C-19)
The letters I, O, Q and S are not used.
<GRAPHIC
<GRAPHIC
Fig 3.
General Points
General Points
1 Wires continue to have the same number even after passing through a connector block to another harness.
1 Wires continue to have the same number even after passing through a connector block to another harness.
2 If all the numbers in a category have been allocated, then the category is re-used with an additional prefix ‘1’, i.e. 1832.
Harnesses and Interconnection
Harnesses and Interconnection
Mainframe Harness
Mainframe Harness
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Harness No.
Harness No.
Issue
Issue
Remarks
Remarks
Drawing
Drawing
<TABLE ROW
332/R8561
2
K ( T C-23)
K ( T C-23)
<TABLE ROW
Main components connected to this harness:
<TABLE ROW
Interconnector
<TABLE ROW
Primary Fuse
<TABLE ROW
ESOS
<TABLE ROW
Fuel Sender
<TABLE ROW
Water Temperature Switch
<TABLE ROW
Oil Pressure Switch
<TABLE ROW
Air Filter Blocked Switch
<TABLE ROW
Park Brake Solenoid
<TABLE ROW
Forward Solenoid
<TABLE ROW
Reverse Solenoid
<TABLE ROW
Reverse Alarm
<TABLE ROW
Horn
<TABLE ROW
Power Outlet
<TABLE ROW
Work Light Connection
<TABLE ROW
Alternator
<TABLE ROW
Glow Plugs
<TABLE ROW
Start Solenoid
<TABLE ROW
Battery
<TABLE ROW
Joystick
<TABLE ROW
Beacon
<TABLE ROW
Cold Start Switch
<TABLE ROW
Cold Start
Panel Harness
Panel Harness
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Harness No.
Harness No.
Issue
Issue
Remarks
Remarks
Drawing
Drawing
<TABLE ROW
332-R2430
2
K ( T C-26)
K ( T C-26)
<TABLE ROW
Main components connected to this harness
Fuse Box
<TABLE ROW
Ignition Switch
<TABLE ROW
Neutral Start Relay
<TABLE ROW
Instrument Panel
<TABLE ROW
Horn Switch
<TABLE ROW
Park Brake Switch
<TABLE ROW
Neutral Relay
<TABLE ROW
Park Brake Relay
<TABLE ROW
Instrument Panel Buzzer
<TABLE ROW
Diode Pack
<TABLE ROW
Work Light Switch and Relay
<TABLE ROW
Road Light Connection
Drawings
Drawings
Drawings are reproduced from production electrical harness drawings. Each harness drawing includes tables showing wire connectio…
Mainframe Harness – CAD 332/R8561
Mainframe Harness – CAD 332/R8561
K Fig 4. ( T C-24)
K Fig 4. ( T C-24)
K Fig 5. ( T C-25)
K Fig 5. ( T C-25)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
NA
Interconnector
<TABLE ROW
NB
Primary Fuse
<TABLE ROW
NF
ESOS
<TABLE ROW
NH
Fuel Sender
<TABLE ROW
NJ
Water Temperature Switch
<TABLE ROW
NK
Oil Pressure Switch
<TABLE ROW
NL
Air Filter Blocked Switch
<TABLE ROW
NM
Park Brake Solenoid
<TABLE ROW
NN
Forward Solenoid
<TABLE ROW
NP
Reverse Solenoid
<TABLE ROW
NT
Reverse Alarm
<TABLE ROW
NW
Horn
<TABLE ROW
NZ
Power Outlet
<TABLE ROW
PA
Work Light Connection
<TABLE ROW
PB
Alternator D+ and Lamp
<TABLE ROW
PC
Alternator B+
<TABLE ROW
PD
Glow Plugs
<TABLE ROW
PE
Start Solenoid
<TABLE ROW
PF
Battery
<TABLE ROW
PG
Joystick
<TABLE ROW
PH
Earth
<TABLE ROW
PJ
Alternator W
<TABLE ROW
PR
Beacon
<TABLE ROW
PS
Cold Start Switch
<TABLE ROW
PT
Cold Start
<TABLE ROW
S2
Primary Fuse
<TABLE ROW
S3
Forward
<TABLE ROW
S4
Reverse
<TABLE ROW
S5
ESOS
<TABLE ROW
S6
Earth 1
<TABLE ROW
S7
Earth 2
<GRAPHIC
<GRAPHIC
Fig 4.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Mainframe Harness – CAD 332/R8561 ( T C-23)
K Mainframe Harness – CAD 332/R8561 ( T C-23)
<GRAPHIC
<GRAPHIC
Fig 5.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Mainframe Harness – CAD 332/R8561 ( T C-23)
K Mainframe Harness – CAD 332/R8561 ( T C-23)
Panel Harness – CAD 332-R2430
Panel Harness – CAD 332-R2430
K Fig 6. ( T C-27)
K Fig 6. ( T C-27)
K Fig 7. ( T C-28)
K Fig 7. ( T C-28)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key to Connectors:
<TABLE BODY
<TABLE ROW
NA
Fuse Box
<TABLE ROW
NC
Ignition Switch
<TABLE ROW
ND
Ignition Switch
<TABLE ROW
NE
Neutral Start Relay
<TABLE ROW
NG
Instrument Panel
<TABLE ROW
NR
Horn Switch
<TABLE ROW
NS
Park Brake Switch
<TABLE ROW
NU
Neutral Relay
<TABLE ROW
NV
Park Brake Relay
<TABLE ROW
NX
Instrument Panel Buzzer
<TABLE ROW
NY
Diode Pack
<TABLE ROW
PK
Work Light Switch
<TABLE ROW
PL
Interconnector
<TABLE ROW
PM
Work Light Relay
<TABLE ROW
PN
Road Light Connection
<TABLE ROW
S1
Earth
<TABLE ROW
S2
Battery
<TABLE ROW
S4
Reverse
<TABLE ROW
S8
Park Brake
<TABLE ROW
S9
Ignition
<GRAPHIC
<GRAPHIC
Fig 6.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Panel Harness – CAD 332-R2430 ( T C-26)
K Panel Harness – CAD 332-R2430 ( T C-26)
<GRAPHIC
<GRAPHIC
Fig 7.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Panel Harness – CAD 332-R2430 ( T C-26)
K Panel Harness – CAD 332-R2430 ( T C-26)
Wiring Harness Repair
Wiring Harness Repair
Introduction
Introduction
Instances do occur where it is necessary to incorporate auxiliary electrical components into existing electrical circuits and, a…
To ensure that either the inclusion of an auxiliary electrical component or a repair within a harness is completed to an accepta…
The sheath covering of the recommended splice is heat shrunk onto the original wire insulation. This results in a seal and corresponding joint to IP 67 specifications.
When installing Auxiliary Electrical Components always ensure that the additional load rating is suitable for that particular ci…
In addition to the warnings incorporated into this procedure, extreme care should be taken when handling the gas heating tool to…
When the heater is in use, the reflector and the air coming out are extremely hot. Keep away to avoid accidental burns. Do not t…
Repair Procedure
Repair Procedure
Table 2. Tools Required
Table 2. Tools Required
<TABLE
<TABLE HEADING
<TABLE ROW
Part No.
Description
Qty
<TABLE BODY
<TABLE ROW
892/00350
Butane Heater assembly
1
<TABLE ROW
892/00349
Crimp tool
1
<TABLE ROW
892/00351
Splice 0.5-1.5 mm (Red)
50
<TABLE ROW
892/00352
Splice 1.5-2.5 mm (Blue)
50
<TABLE ROW
892/00353
Splice 3.0-6.0 mm (Yellow)
50
1 Cut the wire and remove the protective insulation for a suitable distance dependent upon the size of wire and splice to be used. For the splices detailed in
1 Cut the wire and remove the protective insulation for a suitable distance dependent upon the size of wire and splice to be used. For the splices detailed in
K Table 2. ( T C-29)
<GRAPHIC
<GRAPHIC
Fig 8.
2 Using the correct sized splice, attach the new section of wire required or auxiliary flying lead to the existing harness and secure using the crimp tool.
K Fig 8. ( T C-29)
3 With the Butane heater assembly, seal the connection.
K Fig 9. ( T C-30)
a Remove the cap
a Remove the cap
10-A
10
10-B
10
<GRAPHIC
<GRAPHIC
Fig 9.
b Before assembling the gas cartridge to the reflector element
b Before assembling the gas cartridge to the reflector element
b Before assembling the gas cartridge to the reflector element
11-C
11
11-D
11
<GRAPHIC
<GRAPHIC
Fig 10.
c Position the tube hanging down from inside the reflector assembly into the hole at the top of the gas cartridge. Then press the gas cartridge up into the reflector assembly as far as possible until the two elements are clasped firmly together.
c Position the tube hanging down from inside the reflector assembly into the hole at the top of the gas cartridge. Then press the gas cartridge up into the reflector assembly as far as possible until the two elements are clasped firmly together.
c Position the tube hanging down from inside the reflector assembly into the hole at the top of the gas cartridge. Then press the gas cartridge up into the reflector assembly as far as possible until the two elements are clasped firmly together.
K Fig 11. ( T C-30)
<GRAPHIC
<GRAPHIC
Fig 11.
d Turn the small ring
d Turn the small ring
d Turn the small ring
12-E
12
12- F
12
<GRAPHIC
<GRAPHIC
Fig 12.
e Turn the red ring
e Turn the red ring
e Turn the red ring
13-D
13
Before turning the heater on, make sure that the cartridge is not hotter than the reflector element. This may occur if the cartr…
<GRAPHIC
<GRAPHIC
Fig 13.
f Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown.
f Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown.
f Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown.
Hold the heater vertically for 1 to 2 minutes until the catalytic reaction occurs. This is indicated when the blue flame fades and the ceramic element glows red. Then turn the small ring
14-E
14
14-F
14
The fact that the sound of liquid cannot be heard when the cartridge is shaken does not mean it is empty. No sound will be heard even when the cartridge is full.
<GRAPHIC
<GRAPHIC
Fig 14.
g The heater can be used in two modes:
g The heater can be used in two modes:
g The heater can be used in two modes:
i Side wings
i Side wings
15-G
15
<GRAPHIC
<GRAPHIC
Fig 15.
ii Side wings
16-G
16
<GRAPHIC
<GRAPHIC
Fig 16.
h To switch off the heater, turn the red ring
h To switch off the heater, turn the red ring
h To switch off the heater, turn the red ring
16-D
16
Page left intentionally blank
Section E – Hydraulics
Section E
Section E
Hydraulics
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Manual – JCB 403
Service Manual – JCB 403
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Maintenance
Section 3 – Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
<GRAPHIC
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Notes:
<TABLE BODY
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
Technical Data
Technical Data
Pressures
Pressures
Loader
Loader
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Main Relief Valve (MRV)
200 bar
204 kgf/cm2
2
2900 lbf/in2
2
<TABLE ROW
Auxiliary Relief Valves (ARV)
<TABLE ROW
Lift Ram Head Side
250 bar
254 kgf/cm2
2
3625 lbf/in2
2
<TABLE ROW
Shovel Ram Rod Side
200 bar
204 kgf/cm2
2
2900 lbf/in2
2
<TABLE ROW
Shovel Ram Head Side
150 bar
153 kgf/cm2
2
2175 lbf/in2
2
Steering
Steering
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Maximum system pressure
170 – 175 bar
173 – 178 kgf/cm2
2
2465 – 2540 lbf/in2
2
<TABLE ROW
Transmission
Transmission
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Charge pressure
<TABLE ROW
at idle
10 – 11 bar
10 – 11 kgf/cm2
2
145 – 160 lbf/in2
2
<TABLE ROW
at maximum speed
25 – 26 bar
25 – 26 kgf/cm2
2
360 – 380 lbf/in2
2
<TABLE ROW
Maximum system pressure
350 bar
357 kgf/cm2
2
5075 lbf/in2
2
Ram Dimensions
Ram Dimensions
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Ram Location
Bore
Rod Dia
Stroke
<TABLE ROW
(mm)
(in)
(mm)
(in)
(mm)
(in)
<TABLE BODY
<TABLE ROW
Lift
80
3.15
50
1.97
530
20.87
<TABLE ROW
Crowd
80
3.54
40
1.57
404
15.91
<TABLE ROW
Steering
45
1.77
22
0.87
315
12.41
General Information
General Information
Hydraulic Contamination
Hydraulic Contamination
Hydraulic Fluid Quality
Hydraulic Fluid Quality
Construction machinery uses a large volume of fluid in the hydraulic system for power transmission, equipment lubrication, rust …
Effects of Contamination
Effects of Contamination
Once inside the system, hydraulic circuit contaminants greatly effect the performance and life of hydraulic equipment. For examp…
1 Solid Particles – sand, fibres, metallic particles, welding scale, sealing materials and wear particles etc.
1 Solid Particles – sand, fibres, metallic particles, welding scale, sealing materials and wear particles etc.
1 Solid Particles
2 Liquid – usually water and incompatible oils and greases.
2 Liquid
3 Gases – Air, sulphur dioxide etc. which can create corrosive compounds if dissolved in the fluid.
3 Gases
These contaminants can appear during manufacture, assembly and operation.
Cleaning Operation
Cleaning Operation
The purpose of cleaning oil is to remove contaminants of all types and sludge by filtering hydraulic fluid through a cleaning unit.
K Fig 1. ( T E-3)
Procedure
Procedure
Connect the cleaning unit in place of the hydraulic filter.
K Fig 1. ( T E-3)
<GRAPHIC
<GRAPHIC
Fig 1. Cleaning Unit
Contaminant Standards
Contaminant Standards
Dirt that damages your system is in many cases too small to be seen with the eye. The particle size is measured in microns.
1 micron = 0.001 mm (0.0000394 in).
Listed below are a few typical comparisons:
– Red Blood Cell = 8 microns (0.008 mm, 0.000315 in)
– Red Blood Cell = 8 microns (0.008 mm, 0.000315 in)
– Human Hair = 70 microns (0.07 mm, 0.00275 in)
– Grain of Salt = 100 microns (0.1 mm, 0.00394 in)
Smallest particle visible to the naked eye is 40 microns (0.00157) approximately.
Standards will often be quoted to ISO (International Standards Organisation) for which literature can be obtained.
Filters
Filters
The filter assembly fitted to all product ranges is designed to filter all the contamination that is generated through use to the required level of cleanliness. The filter must be serviced to the requirements of the machine Service Schedules.
To ensure optimum performance and reliability it is important that the machines hydraulic system is serviced periodically in accordance with the manufacturers requirements.
Start-up Procedure
Start-up Procedure
The following start-up procedure should always be followed when starting up a new installation or when restarting an installation in which either a pump or motor has been removed from the system.
If a new or rebuilt pump is being fitted always refill the pump with filtered oil prior to start up. Use the correct fluid (see
Lubricants and Capacities, Section 3
Raise the machine so that all four wheels are clear of the ground. Position blocks under the front and rear axles. Ensure that the machine is stable.
The start-up procedure requires the machine to be disabled (wheels raised off the ground, work function disconnected, etc.) while the procedure is carried out.
Raise the machine so that all four wheels are clear of the ground. Position blocks under the front and rear axles. Ensure that the machine is stable.
Fill the hydraulic tank with the correct fluid (see
It is not possible to vent all residual pressure. Loosen the connection one full turn and allow the pressure to dissipate. Keep face and hands well clear of pressurised hydraulic oil and wear protective glasses.
Fill the hydraulic tank with the correct fluid (see
Fluid Under Pressure
Fine jets of fluid at high pressure can penetrate the skin. Keep face and hands well clear of fluid under pressure and wear prot…
Fill the hydraulic tank with the correct fluid (see
Lubricants and Capacities, Section 3
Check that the pump inlet lines are filled with fluid, by slackening the hose connections at the piston and gear pumps, then retighten the connections.
Top up the fluid in the hydraulic tank and continue to monitor the level throughout the start-up procedure.
Connect a pressure gauge as described for charge pressure test.
K Charge Pressure ( T E-22)
Remove the ESOS fuse to prevent the engine from starting. With the forward/reverse selector at neutral, turn the engine over for…
The charge pressure (as indicated on the gauge) should rise to the minimum specified in Technical Data
K Transmission ( T E-1)
Once charge pressure has been established, operate the drive system 10 times in each direction with the engine at idle then slow…
Jerky operation indicates the presence of air in the system.
Check the charge pressure at maximum engine speed which should be as specified in Technical Data.
K Transmission ( T E-1)
Stop the engine and remove the gauge. Check the system for leaks and top up the fluid as necessary.
Preparation for Towing or Winching
Preparation for Towing or Winching
It is only possible to tow or winch the machine very slowly for a short distance. If at all possible repair the disabled machine where it stands.
If the machine needs to be returned to the workshop for repair, it must be winched or lifted onto a trailer.
The machine is normally prevented from moving by hydraulic oil locked up in the transmission circuit. The following procedure must be carried out before attempting to move the machine.
1 Apply the park brake and block all four wheels.
Do not attempt to tow/winch the machine without first releasing the hydrostatic braking otherwise damage will occur to the hydraulic pumps.
1 Apply the park brake and block all four wheels.
1 Apply the park brake and block all four wheels.
2 Remove the floor plate to allow access to the pump.
<GRAPHIC
<GRAPHIC
Fig 2.
3 Unscrew bolt
A
4 Disconnect the two hoses from ports
B
C
<GRAPHIC
<GRAPHIC
C070230
Fig 3.
5 Connect the new tee-piece to a hydraulic hand pump with a pressure gauge and non-return valve.
6 Operate the hand pump to apply sufficient pressure to release the brakes. Maximum pressure to be applied is 30 bar (435 lbf/in
2
7 Connect the winch or towing vehicle to a suitable part of the machine before removing the wheel blocks and releasing the park brake.
If the machine is to be towed: Maximum towing speed is 2kph (1.2mph); Maximum towing distance is 1km (0.6 mile).
After Towing/Winching
After Towing/Winching
1 Apply the parking brake and block all four wheels.
1 Apply the parking brake and block all four wheels.
2 Release the pressure from the hand pump and reconnect the two hoses to ports
B
C
3 Tighten bolt
A
System Operation
System Operation
Introduction to Hydraulic Schematic Symbols
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
General (Basic and Functional Symbols)
Complex hydraulic components and circuits can be described to the engineer by using graphical symbols. The following pages illustrate and give a brief description for some of the more common symbols used.
There are many symbols in use and it would be impossible to include them all here. However it should be noted that most are only…
Once familiar with the symbols, the engineer can use hydraulic circuit diagrams as an aid to fault finding. It will be possible to see the complete hydraulic circuit and decipher the relationship between hydraulic components.
Table 1. General
Table 1. General
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Spring
<TABLE ROW
<GRAPHIC
<GRAPHIC
Flow restriction affected by viscosity
<TABLE ROW
<GRAPHIC
<GRAPHIC
Direction of flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Indication of rotation
<TABLE ROW
<GRAPHIC
<GRAPHIC
Indication of direction and paths of flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Variable control
Table 2. Rams
Table 2. Rams
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Single acting
<TABLE ROW
<GRAPHIC
<GRAPHIC
Double acting
<TABLE ROW
<GRAPHIC
<GRAPHIC
Double ended
<TABLE ROW
<GRAPHIC
<GRAPHIC
Double acting with damping at rod area end
Table 3. Pumps and Motors
Table 3. Pumps and Motors
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Variable capacity pump two directions of flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fixed capacity motor one direction of flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Fixed capacity motor two directions of flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Variable capacity motor one direction of flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Variable capacity motor two directions of flow
Table 4. Control Valves
Table 4. Control Valves
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Used to enclose several valves indicating they are supplied as one unit
<TABLE ROW
<GRAPHIC
<GRAPHIC
3-Position, 4-port spring centered pilot operated valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
3-position, 6-port spring centered pilot operated valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
3-Position, 4-port spring centered solenoid & pilot pressure operated valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
3-Position, 4-port spring centered detent hand operated valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
Non-return valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
Non-return valve with back pressure spring
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pilot operated non-return valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
One way restrictor
<TABLE ROW
<GRAPHIC
<GRAPHIC
High pressure selector (shuttle valve)
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Throttling orifice – normally closed
<TABLE ROW
<GRAPHIC
<GRAPHIC
Throttling orifice – normally open
<TABLE ROW
<GRAPHIC
<GRAPHIC
Relief valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
Variable restrictor
Table 5. Energy Transmissions and Conditioning
Table 5. Energy Transmissions and Conditioning
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Working line, return or feed
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pilot control
<TABLE ROW
<GRAPHIC
<GRAPHIC
Drain lines
<TABLE ROW
<GRAPHIC
<GRAPHIC
Flexible pipe
<TABLE ROW
<GRAPHIC
<GRAPHIC
Line junction
<TABLE ROW
<GRAPHIC
<GRAPHIC
Crossing lines
<TABLE ROW
<GRAPHIC
<GRAPHIC
Air bleed
<TABLE ROW
<GRAPHIC
<GRAPHIC
Line plugged, also pressure test point
<TABLE ROW
<GRAPHIC
<GRAPHIC
Line plugged with take off line
<TABLE ROW
<GRAPHIC
<GRAPHIC
Quick release couplings – connected
<TABLE ROW
<GRAPHIC
<GRAPHIC
Quick release couplings – disconnected
<TABLE ROW
<GRAPHIC
<GRAPHIC
Reservoir – return line above fluid level
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Reservoir – return line below fluid level
<TABLE ROW
<GRAPHIC
<GRAPHIC
Header tank
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pressure sealed tank
<TABLE ROW
<GRAPHIC
<GRAPHIC
Accumulator
<TABLE ROW
<GRAPHIC
<GRAPHIC
Filter or strainer
<TABLE ROW
<GRAPHIC
<GRAPHIC
Water trap
<TABLE ROW
<GRAPHIC
<GRAPHIC
Cooler – with no indication of coolant flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Cooler – indicating direction of coolant flow
<TABLE ROW
<GRAPHIC
<GRAPHIC
Heater
Table 6. Control Mechanisms
Table 6. Control Mechanisms
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Rotating shaft – one direction
<TABLE ROW
<GRAPHIC
<GRAPHIC
Rotating shaft – two directions
<TABLE ROW
<GRAPHIC
<GRAPHIC
Detent
<TABLE ROW
<GRAPHIC
<GRAPHIC
Locking device
<TABLE ROW
<GRAPHIC
<GRAPHIC
Over centre device
<TABLE ROW
<GRAPHIC
<GRAPHIC
Simple linkage
<TABLE ROW
<GRAPHIC
<GRAPHIC
General control
<TABLE ROW
<GRAPHIC
<GRAPHIC
Push button operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Lever operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pedal operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Stem operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Spring operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Roller operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Roller trip operated (one directional)
<TABLE
<TABLE BODY
<TABLE ROW
<GRAPHIC
<GRAPHIC
Solenoid one winding
<TABLE ROW
<GRAPHIC
<GRAPHIC
Solenoid two windings
<TABLE ROW
<GRAPHIC
<GRAPHIC
Electric motor operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Internal pressure pilot operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
External pressure pilot operated
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pressure operated spring release
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pilot operated by solenoid pilot valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pilot operated by a solenoid or seperate pilot valve
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pressure guage
<TABLE ROW
<GRAPHIC
<GRAPHIC
Pressure switch
Control Valves
Control Valves
Control valves are usually represented by one or more square boxes.
K Fig 4. ( T E-11) shows a control valve represented by three boxes. The number of boxes indicates the number of possible valve operating positions, (3 boxes – 3 positions etc).
K Fig 4. ( T E-11)
<GRAPHIC
<GRAPHIC
Fig 4.
K Fig 5. ( T E-11) – In circuit diagrams the pipework is usually shown connected to the box which represents the unoperated condition. (Hydraulic circuit diagrams are usually shown in the unoperated condition).
K Fig 5. ( T E-11)
<GRAPHIC
<GRAPHIC
Fig 5.
K Fig 7. ( T E-11) shows a valve described as a 3- position, 4-port control valve. Port describes the openings to and from the valve by which the hydraulic fluid enters or leaves. In the fig shown, Position
K Fig 7. ( T E-11)
2
<GRAPHIC
<GRAPHIC
Fig 6.
If the valve spool was moved to Position
1
P1
P2
P3
P4
K Fig 7. ( T E-11)
If the valve spool was moved to Position
3
P1
P4
P3
K Fig 7. ( T E-11)
<GRAPHIC
<GRAPHIC
Fig 7.
It must be noted that not all spools are of the same type. Their operating designs can be seen by following the path the flow arrows take in their respective operating squares.
Three typical JCB style spools are known as ‘D’ spools, ‘F’ spools and ‘N’ spools.
The ‘D’ spools generally control rams because when in the neutral position the outlet ports are blocked, preventing ram movement.
K Fig 7. ( T E-11)
K Fig 8. ( T E-11) – ‘F’ spools are often shown as four position spools with the three normal positions for neutral and service control; and the forth position, which has a detent, connects both sides of the ram together to allow the service to ‘float’.
K Fig 8. ( T E-11)
<GRAPHIC
<GRAPHIC
Fig 8.
K Fig 9. ( T E-11) – ‘N’ spools are sometimes used to control hydraulic motors, and it can be seen from the flow arrows, that in neutral position both service ports are connected to the exhaust oil port
K Fig 9. ( T E-11)
<GRAPHIC
<GRAPHIC
Fig 9.
Example of Schematic Circuit
Example of Schematic Circuit
<GRAPHIC
<GRAPHIC
Fig 10. Simple Schematic Circuit
Some of the symbols described on the preceding pages have been arranged into a simple schematic circuit.
K Fig 10. ( T E-12)
Hydraulic tank
10-A
10
10-B
10
10-C
10
10-D
10
Valve spool
10-E
10
If the lever operated spool is moved away from neutral position hydraulic fluid is directed to either head side or rod side of hydraulic ram
10-G
10
10-F
10
Example Circuit Key
Example Circuit Key
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
10-A
10-A
10
Hydraulic Tank
<TABLE ROW
10-B
10-B
10
Strainer
<TABLE ROW
10-C
10-C
10
Fixed Displacement Pump
<TABLE ROW
10-D
10-D
10
Relief Valve
<TABLE ROW
10-E
10-E
10
Spool
<TABLE ROW
10-F
10-F
10
One Way Valve
<TABLE ROW
10-G
10-G
10
Double Acting Hydraulic Ram
Schematic Circuits
Schematic Circuits
K Fig 11. ( T E-14)
K Fig 11. ( T E-14)
Table 7. Component Key
Table 7. Component Key
<TABLE
<TABLE BODY
<TABLE ROW
C
C
Cooler
<TABLE ROW
F1
F1
Return Filter
<TABLE ROW
F2
F2
Pump Filter
<TABLE ROW
P1
P1
Transmission Pump
<TABLE ROW
P2
P2
Charge Pump
<TABLE ROW
P3
P3
Loader and Steering Pump
<TABLE ROW
MA
MA
Front Left Hand Drive Motor
<TABLE ROW
MB
MB
Front Right Hand Drive Motor
<TABLE ROW
MC
MC
Rear Left Hand Drive Motor
<TABLE ROW
MD
MD
Rear Right Hand Drive Motor
<TABLE ROW
S
S
Suction Strainer
<TABLE ROW
T
T
Tank
<TABLE
<TABLE BODY
<TABLE ROW
1
1
Joystick
<TABLE ROW
2
2
Steer Valve
<TABLE ROW
3
3
Steer Ram
<TABLE ROW
4
4
Cable-operated Inching Pedal
<TABLE ROW
5
5
Park Brake Switch
<TABLE ROW
6
Loader Valve Block
<TABLE ROW
6a
6a
Main Relief Valve (MRV)
<TABLE ROW
6b
6b
Auxiliary Spool
<TABLE ROW
6c
6c
Lift Spool
<TABLE ROW
6d
6d
Crowd Spool
<TABLE ROW
6e
6e
Auxiliary Relief Valve (ARV) – Lift Ram Head Side
<TABLE ROW
6f
6f
Auxiliary Relief Valve (ARV) – Shovel Ram Rod Side
<TABLE ROW
6g
6g
Auxiliary Relief Valve (ARV) – Shovel Ram Head Side
<TABLE ROW
6h
6h
Load-hold Check Valve
<TABLE ROW
7
7
Shovel (Crowd) Ram
<TABLE ROW
8
8
Lift Ram
<TABLE ROW
9
9
Auxiliary Service (optional)
<TABLE ROW
10
Front Manifold
<TABLE ROW
11
11
Rear Manifold
<GRAPHIC
<GRAPHIC
Fig 11.
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
K Table 7. Component Key ( T E-13)
K Table 7. Component Key ( T E-13)
Descriptions
Descriptions
Pump Assembly
Pump Assembly
<GRAPHIC
<GRAPHIC
C039710
Fig 12.
The main parts of the pump assembly are the transmission piston pump
P1
P3
K Fig 12. ( T E-15)
There is also a charge pump
P3
K Fig 13. ( T E-16)
Oil is drawn from the tank via ports
S
S1
The loader and steering pump discharges oil through port
B1
The transmission pump feeds the motors via a loop circuit, through ports
A
B
K Fig 14. ( T E-16)
The output of the transmission pump is controlled by solenoid valve
V
The inching control cable connects to inching lever
L
<GRAPHIC
<GRAPHIC
C039720
Fig 13.
<GRAPHIC
<GRAPHIC
C039730
Fig 14.
Motor
Motor
The basic components of the transmission motor are the rotor and rollers which are located within a machined housing, this being…
Oil from the pump is fed into the appropriate enlarged cavity by means of the valve plate, causing the rotor to rotate. As it ro…
The drive from the rotor is transferred to the rear axle by means of a splined drive shaft.
Loop Flushing System
Loop Flushing System
<GRAPHIC
<GRAPHIC
Fig 15.
The loop flushing system allows oil from the closed loop to be fed into the motor casing during operation for cooling of the motor components and to flush out any contaminants.
When there is no pressure in the loop the shuttle spool is held in the central position by its springs. The illustration shows the high pressure in one side of the loop causing the shuttle spool to move to the left
K Fig 15. ( T E-17)
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Key
<TABLE BODY
<TABLE ROW
A
A
Pump high pressure
<TABLE ROW
B
B
Pump low pressure
<TABLE ROW
C
C
Rollers
<TABLE ROW
D
D
Rotor Housing
<TABLE ROW
E
E
Rotor
<TABLE ROW
F
F
Valve Plate
<TABLE ROW
Ma
Ma
Shuttle Spool
<TABLE ROW
Mb
Mb
Back Pressure Relief Valve
<TABLE ROW
T
T
Return to tank
Fault Finding
Fault Finding
Transmission Pump
Transmission Pump
Introduction
Introduction
Before you refer to the following Fault Tables make sure that the hydraulic oil is clean and filled to the correct level.
Make sure no dirt enters the pump.
Select the Fault Table according to the problem:
K Table 8. Transmission will not go into neutral ( T E-18)
K Table 8. Transmission will not go into neutral ( T E-18)
K Table 9. Low pump efficiency ( T E-19)
K Table 9. Low pump efficiency ( T E-19)
K Table 10. Transmission does not work in either forwards or reverse ( T E-20)
K Table 10. Transmission does not work in either forwards or reverse ( T E-20)
K Table 11. Transmission does not work in one direction only ( T E-21)
K Table 11. Transmission does not work in one direction only ( T E-21)
If the problem is still present after you have done the checks shown in the relevant table, contact JCB Service for advice. Do not dismantle the pump any more than is shown in this manual.
Fault Tables
Fault Tables
Table 8. Transmission will not go into neutral
Table 8. Transmission will not go into neutral
<TABLE
<TABLE HEADING
<TABLE ROW
CHECK
ACTION
<TABLE BODY
<TABLE ROW
1
Are the controls working correctly (including inching control)?
YES
Check 2.
<TABLE ROW
NO
Adjust or renew controls.
<TABLE ROW
2
Is the solenoid valve working correctly?
YES
Check 3.
<TABLE ROW
NO
Clean or renew solenoid.
<TABLE ROW
3
Is the pump neutral setting correct? K Neutral Setting ( T E-24)
K Neutral Setting ( T E-24)
YES
Suspect servo control not working correctly. See footnote below.
Dealers must not do servo control check – contact JCB Service for advice.
<TABLE ROW
NO
Adjust neutral setting. K Neutral Setting ( T E-24)
K Neutral Setting ( T E-24)
Table 9. Low pump efficiency
Table 9. Low pump efficiency
<TABLE
<TABLE HEADING
<TABLE ROW
CHECK
ACTION
<TABLE BODY
<TABLE ROW
1
Is the charge pressure correct? K Charge Pressure ( T E-22)
K Charge Pressure ( T E-22)
YES
Check 4.
<TABLE ROW
NO
Check 2.
<TABLE ROW
2
Is the suction filter restricted?
YES
Renew filter.
<TABLE ROW
NO
Check 3.
<TABLE ROW
3
Is the suction line restricted?
YES
Clean suction line and refit correctly with no tight bends.
<TABLE ROW
NO
Adjust charge pressure. K Charge Pressure ( T E-22)
K Charge Pressure ( T E-22)
<TABLE ROW
4
Is the maximum working pressure correct? K Maximum System Pressure ( T E-25)
K Maximum System Pressure ( T E-25)
YES
Check 6.
<TABLE ROW
NO
Check 5.
<TABLE ROW
5
Are the non-adjustable relief valves clean and in good condition? K Relief Valves ( T E-28)
K Relief Valves ( T E-28)
YES
Check 6.
<TABLE ROW
NO
Clean and/or renew the relief valves.
<TABLE ROW
6
Is the oil temperature correct?
YES
Check 8.
<TABLE ROW
NO
Check 7.
<TABLE ROW
7
Is the oil cooler clean?
YES
Check 8.
<TABLE ROW
NO
Clean the oil cooler.
<TABLE ROW
8
Disconnect inching control cable. K Inching Control ( T E-30) Does the pump efficiency Improve?
K Inching Control ( T E-30)
YES
Make sure inching cable is free and correctly adjusted.
<TABLE ROW
NO
Suspect servo control not working correctly. See footnote below
Dealers must not do servo control check – contact JCB Service for advice.
Table 10. Transmission does not work in either forwards or reverse
Table 10. Transmission does not work in either forwards or reverse
<TABLE
<TABLE HEADING
<TABLE ROW
CHECK
ACTION
<TABLE BODY
<TABLE ROW
1
Are the controls working correctly?
YES
Check 2.
<TABLE ROW
NO
Check and adjust controls.
<TABLE ROW
2
Is the solenoid valve working?
YES
Check 4.
<TABLE ROW
NO
Check 3.
<TABLE ROW
3
Is current reaching the solenoid valve?
YES
Clean or renew solenoid valve.
<TABLE ROW
NO
Check wiring and switch.
<TABLE ROW
4
Is the charge pressure correct? K Charge Pressure ( T E-22)
K Charge Pressure ( T E-22)
YES
Check 7.
<TABLE ROW
NO
Check 5.
<TABLE ROW
5
Is the suction filter restricted?
YES
Renew filter.
<TABLE ROW
NO
Check 6.
<TABLE ROW
6
Is the suction line restricted?
YES
Clean suction line and refit correctly with no tight bends.
<TABLE ROW
NO
Adjust charge pressure. K Charge Pressure ( T E-22)
K Charge Pressure ( T E-22)
<TABLE ROW
7
Are the non-adjustable relief valves clean and in good condition? K Relief Valves ( T E-28)
K Relief Valves ( T E-28)
YES
Check 8.
<TABLE ROW
NO
Clean and/or renew the relief valves.
<TABLE ROW
8
Is the pump drive broken?
YES
Repair the pump drive.
<TABLE ROW
NO
Suspect servo control not working correctly. See footnote below.
Dealers must not do servo control check – contact JCB Service for advice.
Table 11. Transmission does not work in one direction only
Table 11. Transmission does not work in one direction only
<TABLE
<TABLE HEADING
<TABLE ROW
CHECK
ACTION
<TABLE BODY
<TABLE ROW
1
Are the controls working correctly?
YES
Check 2.
<TABLE ROW
NO
Check and adjust controls.
<TABLE ROW
2
Is the solenoid valve working?
YES
Check 4.
<TABLE ROW
NO
Check 3.
<TABLE ROW
3
Is current reaching the solenoid valve?
YES
Clean or renew solenoid valve.
<TABLE ROW
NO
Check wiring and switch.
<TABLE ROW
4
Are the non-adjustable relief valves clean and in good condition? K Relief Valves ( T E-28)
K Relief Valves ( T E-28)
YES
Swap the relief valves then do Check 5.
<TABLE ROW
NO
Clean and/or renew the relief valves.
<TABLE ROW
4
Is the fault now moved to the opposite direction of drive?
YES
Clean and/or renew the relief valves.
<TABLE ROW
NO
Suspect servo control not working correctly. See footnote below.
Dealers must not do servo control check – contact JCB Service for advice.
Pressure Testing
Pressure Testing
Transmission Pump
Transmission Pump
General Precautions
General Precautions
Make sure that the hydraulic fluid is at correct working temperature (50 ˚C, 122 ˚F).
When working close to the machine with the engine running, protective clothing must be worn, ie. Safety glasses, ear protection, gloves etc.
Make sure that the hydraulic fluid is at correct working temperature (50 ˚C, 122 ˚F).
If a 4 wheel drive machine is to be raised and the engine/transmission run, make sure all four wheels are off the ground and supported by axle stands. If only one pair of wheels is raised, the machine could still drive through the other axle.
Make sure that the hydraulic fluid is at correct working temperature (50 ˚C, 122 ˚F).
Charge Pressure
Charge Pressure
K General Precautions ( T E-22)
K General Precautions ( T E-22)
<GRAPHIC
<GRAPHIC
Fig 16.
1 Stop engine. Insert a suitable tee-piece between hose and pump casing at
1 Stop engine. Insert a suitable tee-piece between hose and pump casing at
P2
2
K Fig 16. ( T E-22)
2 Run engine at idle and at maximum speed with transmission in neutral and check pressure at both speeds is as specified.
K Technical Data ( T E-1)
<GRAPHIC
<GRAPHIC
Fig 17.
3 If the pressure is not as specified, unscrew locknut
A
B
4 If you cannot get correct pressure, check the condition of the charge pressure valve.
K Charge Pressure Valve ( T E-23)
5 Continue procedure until pressure is correct then stop engine and remove pressure gauge.
Charge Pressure Valve
Charge Pressure Valve
<GRAPHIC
<GRAPHIC
Fig 18.
1 Unscrew valve
1 Unscrew valve
C
2 Thoroughly clean the valve parts and the valve seat inside the pump casing. Make sure there are no dents or scratches on the sealing faces of the valve or its seat inside the pump casing.
3 Refit the valve.
Neutral Setting
Neutral Setting
K General Precautions ( T E-22)
K General Precautions ( T E-22)
1 Raise all four wheels off the ground and support the machine with axle stands.
1 Raise all four wheels off the ground and support the machine with axle stands.
<GRAPHIC
<GRAPHIC
Fig 19.
2 Run engine at 1200 r.p.m. with transmission in neutral. If neutral setting is correct none of the driven road wheels will rotate.
3 If wheels rotate, slacken lock nut
A
B
4 Select drive in each direction then return to neutral. If neutral setting is correct none of the driven road wheels will rotate. Adjust screw
B
5 When neutral setting is correct, tighten lock nut
A
Maximum System Pressure
Maximum System Pressure
<GRAPHIC
<GRAPHIC
Fig 20.
K General Precautions ( T E-22)
K General Precautions ( T E-22)
1 Stop engine. Connect two 0 – 600 bar (0 – 9000 lb/in
1 Stop engine. Connect two 0 – 600 bar (0 – 9000 lb/in
2
M1
M2
M1
2 Disconnect the high pressure hoses from ports
A
B
A
B
If you need to test the pressure for one travel direction only, connect one gauge and blank one port.
K Table 12. ( T E-25)
3 Run engine at 1200 r.p.m. with transmission in neutral, then gradually select a slow forward speed and check pressure is as specified.
Do not hold the transmission in drive for more than 10 seconds or serious overheating will occur.
3 Run engine at 1200 r.p.m. with transmission in neutral, then gradually select a slow forward speed and check pressure is as specified.
K Technical Data ( T E-1)
4 Run engine at 1200 r.p.m. with transmission in neutral, then gradually select a slow reverse speed and check pressure is as specified.
K Technical Data ( T E-1)
5 If the pressure is not as specified, check or renew the relief valves then re-test.
K Relief Valves ( T E-28)
Table 12.
Table 12.
<TABLE
<TABLE HEADING
<TABLE ROW
Travel Direction
Test Point
High Pressure Port
<TABLE BODY
<TABLE ROW
Forward
M2
M2
B
B
<TABLE ROW
Reverse
M1
M1
A
A
Loader Main Relief Valve (M.R.V.)
Loader Main Relief Valve (M.R.V.)
Make sure that the hydraulic fluid is at correct working temperature (50 ˚C, 122 ˚F)
<GRAPHIC
<GRAPHIC
Fig 21.
Connect a 0 – 400 bar (0 – 6000 lb/in
2
2
A
With the engine running at maximum speed, lower the loader arms until the ram is fully closed and note the maximum gauge reading.
Keep clear of the loader arms.
The maximum system pressure should be as specified in Technical Data
Raised Equipment
Never walk or work under raised equipment unless it is supported by a mechanical device. Equipment which is supported only by a …
The maximum system pressure should be as specified in Technical Data
K Loader ( T E-1)
<GRAPHIC
<GRAPHIC
Fig 22.
If the pressure is incorrect, slacken lock nut
B
C
B
Remove the pressure gauge.
Steering Relief Valve (M.R.V.)
Steering Relief Valve (M.R.V.)
Make sure that the hydraulic fluid is at correct working temperature (50 ˚C, 122 ˚F)
<GRAPHIC
<GRAPHIC
Fig 23.
Connect a 0 – 400 bar (0 – 6000 lb/in
2
2
A
With the engine running at maximum speed, turn the steering on to full lock and note the maximum gauge reading.
The maximum system pressure should be as specified in Technical Data
Keep the articulation danger zone (chassis pivot area) clear of people when operating full steering lock.
The maximum system pressure should be as specified in Technical Data
K Steering ( T E-1)
Remove the pressure gauge.
Pumps
Pumps
Transmission (Piston) Pump
Transmission (Piston) Pump
Do not remove or dismantle the pump until you have done all the checks in the Fault Finding section.
K Fault Finding ( T E-18)
Relief Valves
Relief Valves
<GRAPHIC
<GRAPHIC
Fig 24.
The two relief valves are located in the pump housing, the one controlling reverse is at
V
Removal and Replacement
Removal and Replacement
Clean the outside of the pump before unscrewing the valve. Make sure no dirt enters the pump.
<GRAPHIC
<GRAPHIC
<GRAPHIC
Fig 25.
1 Unscrew valve cap
1
2 Extract spring
2
3
3 Thoroughly clean the valve parts and the valve seat inside the pump casing. Make sure there are no dents or scratches on the sealing faces of the valve or its seat inside the pump casing.
4 Renew the `O’ rings. Fit the plunger, springs and valve cap. Make sure that spring
2
3
5 Tighten valve cap
1
Solenoid Valve
Solenoid Valve
Removal and Replacement
Removal and Replacement
Clean the outside of the pump before unscrewing the valve. Make sure no dirt enters the pump.
<GRAPHIC
<GRAPHIC
Fig 26.
1 Remove and label wiring connectors
1 Remove and label wiring connectors
X
Y
2 Label the ends of the solenoid valve
C
D
3 Remove the four screws
E
K Fig 27. ( T E-29)
<GRAPHIC
<GRAPHIC
Fig 27.
Take care not to lose the restrictors that are fitted in ports
A
B
4 Remove the `O’ rings from the face of the solenoid valve. If necessary, shake the valve to remove the restrictors. Make sure that the restrictors are not blocked.
5 Thoroughly clean the valve parts and the valve sealing face on the pump casing. Make sure there are no dents or scratches on the sealing faces of the valve or its sealing face on the pump casing.
6 Renew the `O’ rings.
7 Remove the bung from the pump casing (see step 3). Fit the solenoid valve. Make sure it faces the correct way round. Tighten the screws evenly to 5 Nm (3.6 lbf ft).
8 Connect the wiring. Make sure it is connected the right way round.
Inching Control
Inching Control
<GRAPHIC
<GRAPHIC
Fig 28.
Adjustment
Adjustment
Adjust cable
A
C
B
C
Cable
A
Motors
Motors
Removal and Replacement
Removal and Replacement
Removal
Removal
Raise the machine and remove the road wheel.
Jacking
A machine can roll off jacks and crush you unless the wheels have been blocked. Always block the wheels at the opposite end of t…
Raise the machine and remove the road wheel.
The illustrations show a front motor. The rear motors are similar.
Label the hoses to make sure they are fitted in their correct positions.
<GRAPHIC
<GRAPHIC
Fig 29.
Disconnect and plug the main feed hoses
A
B
Disconnect and plug the drain hose
C
<GRAPHIC
<GRAPHIC
Fig 30.
Support the motor and remove cap screws
D
Withdraw the motor from the chassis.
Replacement
Replacement
Replacement is the reversal of the removal procedure.
Apply JCB High Strength Threadlocker to cap screws
D
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Torque Settings
<TABLE ROW
Item
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
D
D
139
14
103
<TABLE ROW
Wheel Nuts
120
12
89
Dismantling and Assembly
Dismantling and Assembly
<GRAPHIC
<GRAPHIC
Fig 31.
The numerical sequence shown is a guide to dismantling. For assembly the sequence should be reversed.
Dismantling
Dismantling
Cleanliness is extremely important when repairing a hydraulic motor.
Work in a clean area. Before disconnecting the hoses, clean the port area of the motor thoroughly. Use a wire brush to remove foreign material and debris from around the exterior joints of the motor.
Check the shaft, remove all nicks, burrs or sharp edges that might damage the bearing housing seals during assembly.
Before starting the dismantling procedures, drain the oil from inside the motor.
K Fig 31. ( T E-32)
K Fig 31. ( T E-32)
1 Place the motor in a vice with the output shaft down. Clamp across the mounting flange of the motor not the housing. Excessive…
1 Place the motor in a vice with the output shaft down. Clamp across the mounting flange of the motor not the housing. Excessive…
2 Remove four bolts
1
3 Lift valve housing
2
20
21
22
25
26
4 Carefully remove `O’ ring
3
5 Remove shuttle valve retaining plug
4
5
6 Extract dash pot
6
7
8
9
10
11
12
7 If necessary to replace `O’ ring
13
14
8 Remove retaining plug
15
16
17
18
19
9 Remove two pins
20
21
22
10 Remove inner
23
24
11 Remove valve
25
26
12 Remove ‘O’ ring
27
13 Remove valve drive
28
14 Remove Geroler
29
15 Remove splined drive
30
16 Remove ‘O’ ring
31
32
17 Remove wear plate
32
18 Remove shaft face seal
33
19 Remove ‘O’ ring
36
35
20 It may be necessary to use a press to remove the shaft and bearing assembly
34
21 Use a small screwdriver to remove shaft seal
37
38
39
Individual parts of the shaft and bearing assembly are not sold separately. Replace as a unit.
Assembly
Assembly
Check all mating surfaces. Replace any parts that have scratches or burrs that could cause leakage.
Clean all metal parts in clean solvent. Blow dry with air. Do not wipe dry with cloth or paper towel because lint or other matter can get in the hydraulic system and cause damage.
Do not use a coarse grit or try to file or grind these parts.
Check the chamfered area of the shaft for burrs, nicks or sharp edges that can damage the seals when reassembling the bearing housing.
Lubricate all seals (prior to installation) with petroleum jelly. Use new seals when assembling.
K Fig 32. ( T E-34)
K Fig 32. ( T E-34)
1 Use a press to install exclusion seal
1 Use a press to install exclusion seal
39
35
2 Place back-up washer
38
37
3 Clamp housing in a vice.
4 Wrap tape over the end of the shaft to prevent cutting the seals. Apply petroleum jelly to inside diameter of dust and shaft s…
5 Apply petroleum jelly to `O’ ring
36
K Fig 31. ( T E-32)
<GRAPHIC
<GRAPHIC
Fig 32.
6 Alignment studs can be very helpful in reassembly of the motor. Make up two studs as follows
a Use 9.5 mm diameter steel rod of the length shown
a Use 9.5 mm diameter steel rod of the length shown
K Fig 33. ( T E-34)
b Cut a thread at one end as shown.
c Grind a flat on each side as at
A
7 Install the two studs diagonally opposed in the bearing housing.
8 Install shaft face seal
33
32
K Fig 32. ( T E-34)
9 Install wear plate
32
K Fig 32. ( T E-34)
10 Apply a light film of petroleum jelly to `O’ ring
31
11 Install splined drive
30
K Fig 31. ( T E-32)
<GRAPHIC
<GRAPHIC
Fig 33.
12 Align the notch on the outside of Geroler
29
32
13 Install valve drive
28
The next stage of assembly involves the timing of the motor. Timing determines the direction of rotation of the output shaft.
14 Timing is done in three steps:
a Locate the largest open pocket in the Geroler
a Locate the largest open pocket in the Geroler
29
A
K Fig 34. ( T E-34)
Apply a light film of petroleum jelly to `O’ ring
27
K Fig 31. ( T E-32)
26
Align the notch on the outside of valve plate
26
29
K Fig 34. ( T E-34)
<GRAPHIC
<GRAPHIC
Fig 34.
b Locate the slot opening in the valve plate which is in line with the largest open pocket of the Geroler as shown at
B
K Fig 34. ( T E-34)
c Locate any one of the six ports of valve
25
C
Install the valve by rotating it clockwise until the spline teeth engage (1/2 spline tooth max.) as shown at
D
15 K Fig 31. ( T E-32)
15 K Fig 31. ( T E-32)
Place shims
18
16
17
19
15
16 Install new `O’ ring
13
14
17 Install dashpot
12
11
10
9
8
7
6
18 Install new `O’ ring
5
4
19 Install two springs
21
20
2
20 Apply a light film of petroleum jelly to `O’ ring
3
21 Apply petroleum jelly to inner
23
24
22
<GRAPHIC
<GRAPHIC
Fig 35.
Install face seals in the positions shown or the motor will not operate properly
K Fig 35. ( T E-35)
22 Align pin notches in balance ring at
E
20
2
K Fig 31. ( T E-32)
23 Insert a finger through the port of the valve housing and apply pressure to the side of the balance ring. Hold ring in position until valve housing
2
26
After installing the valve housing on the valve plate, check for proper placement. Push down on the valve housing. There should be a slight spring action.
24 Install tie bolts
1
Loader Control Valve
Loader Control Valve
Dismantling and Assembly
Dismantling and Assembly
<GRAPHIC
<GRAPHIC
C039270
Fig 36.
The numerical sequence is a guide to removing a typical spool.
Remove the spool from the control side as shown.
Always renew the seals
15
16
17
If required, unscrew main relief valve (MRV)
A
D
B
Torque Settings
Torque Settings
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Torque Settings
<TABLE ROW
Item
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
3
3
9.8
1
7
<TABLE ROW
A
A
42
4.3
31
<TABLE ROW
B
B
24
2.4
18
<TABLE ROW
C
C
24
2.4
18
Rams
Rams
Typical Loader Ram
Typical Loader Ram
<GRAPHIC
<GRAPHIC
Dismantling and Assembly
Dismantling and Assembly
The numerical sequence shown on the illustration is intended as a guide to dismantling.
For assembly the sequence should be reversed.
When Dismantling
When Dismantling
Discard all seals and ‘O’ rings.
To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a wire brush to clean components.
When Assembling
When Assembling
Thoroughly clean the threads of piston head
6
7
1
K JCB Ram Sealing Procedure ( T E-40)
Fit and torque-tighten the piston head.
K Table 14. Torque Settings ( T E-39)
Fit the locking dowel
5
New rod and piston head
New rod and piston head
If both are required, the following procedure should be followed:
1 Drill through the piston head into the piston rod, shown.
1 Drill through the piston head into the piston rod, shown.
K Fig 37. ( T E-38)
K Table 13. Drilling Details For Piston Head Retention (all dimensions in mm) ( T E-39)
<GRAPHIC
<GRAPHIC
Fig 37.
2 Remove all swarf and contamination. Insert dowel
5
New piston head fitted to a pre-drilled piston rod
New piston head fitted to a pre-drilled piston rod
1 Redrill and dowel
1 Redrill and dowel
BOTH
K New rod and piston head ( T E-38)
New piston rod fitted to a pre-drilled piston head
New piston rod fitted to a pre-drilled piston head
Use the pre-drilled hole in the piston head. Care must be taken not to elongate the existing hole in the piston head.
1 Use a drill of the same diameter as the pre-drilled hole in the piston head to make a ‘centre mark’ in the piston rod.
1 Use a drill of the same diameter as the pre-drilled hole in the piston head to make a ‘centre mark’ in the piston rod.
DO NOT
2 Use an undersized diameter drill as a guide and drill into the piston rod to the required depth making sure that the drill has centred correctly on the ‘centre mark’ made in step 1.
K Table 13. Drilling Details For Piston Head Retention (all dimensions in mm) ( T E-39)
3 Use the correct size diameter drill to suit the dowel and drill to the required depth.
K Table 13. Drilling Details For Piston Head Retention (all dimensions in mm) ( T E-39)
4 Remove all swarf and contamination. Insert the dowel
5
Table 13. Drilling Details For Piston Head Retention (all dimensions in mm)
Table 13. Drilling Details For Piston Head Retention (all dimensions in mm)
<TABLE
<TABLE BODY
<TABLE ROW
Ram
Ram Size
Dowel Drill Ø X
X
Dowel Drill Depth Y
Y
<TABLE ROW
Crowd
80 x 40
6
22-23
<TABLE ROW
Lift
80 x 50
6
22-23
Taking care to retain the end cap
1
If hydraulic oil contacts uncured Threadlocker, a weakening of the bond will result. Cure times vary according to the ambient temperature. Allow approximately 1 hour at 20 ˚C between assembly and filling the ram with oil.
When fitting cylinder and piston eye bushes
12
Table 14. Torque Settings
Table 14. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
Lift ram
Lift ram
<TABLE ROW
1
678
69
500
<TABLE ROW
6
405
41
300
<TABLE ROW
Crowd ram
Crowd ram
<TABLE ROW
1
678
69
500
<TABLE ROW
6
405
41
300
Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working.
JCB Ram Sealing Procedure
JCB Ram Sealing Procedure
1 Fit new rod seals.
1 Fit new rod seals.
Use seal fitting tool
38-A
38
38-B
38
<GRAPHIC
<GRAPHIC
Fig 38. Seal Fitting Tool
The pins are screwed into threaded holes in the tool body, the spacing of the holes is designed to suit small or large diameter rod seals.
a Open the tool and insert the new rod seal
a Open the tool and insert the new rod seal
39-A
39
<GRAPHIC
<GRAPHIC
Fig 39.
Later ram end caps and piston heads are metric threads. The seals are also different, make sure the correct seals are fitted. On metric threaded rams make sure the seals are fitted the correct way round, as shown at
40-A
40
40-B
40
<GRAPHIC
<GRAPHIC
Fig 40.
b Close the tool.
K Fig 41. ( T E-40)
<GRAPHIC
<GRAPHIC
Fig 41.
c Before fitting the rod seals check the seal grooves are free of contamination and sharp edges.
d Locate the seal in the end cap groove.
K Fig 42. ( T E-40)
<GRAPHIC
<GRAPHIC
Fig 42.
e Fit rod wiper seal
40-A
40
Some rod wipers, i.e. power track rod, may use a metal encased seal which is pressed into the housing. Care must be taken to ensure the seal is square before it is pressed in.
f Sleeve
43-A
43
Service Tools
<GRAPHIC
<GRAPHIC
Fig 43.
2 Fit new head piston seals.
a Use a blunt instrument
a Use a blunt instrument
44-A
44
44-B
44
<GRAPHIC
<GRAPHIC
Fig 44.
b Fit outer seal
44-C
44
44-B
44
c Ensure the O-ring is fitted into the internal seal groove on the piston head. Screw the piston head onto the thread of the piston rod, refer to the relevant section for torque figure and completion of ram assembly.
d Fit the piston head retaining dowel, refer to the relevant section for torque figure and completion of ram assembly.
e Fit wear rings
45-A
45
45-B
45
45-C
45
<GRAPHIC
<GRAPHIC
Fig 45.
3 Fit the piston rod and head assembly into the cylinder.
a Insert the piston/rod assembly into the cylinder. Align the rod and head assembly until parallel with the cylinder then push the assembly into the cylinder.
a Insert the piston/rod assembly into the cylinder. Align the rod and head assembly until parallel with the cylinder then push the assembly into the cylinder.
b Fit the end cap, refer to the relevant section for torque figure and completion of ram assembly.
Steering Ram
Steering Ram
Dismantling and Assembly
Dismantling and Assembly
The numerical sequence shown on the illustration is intended as a guide to dismantling.
For assembly the sequence should be reversed.
When Dismantling
When Dismantling
Discard all seals and ‘O’ rings.
To avoid burning, wear protective gloves when handling hot components. To protect your eyes, wear goggles when using a wire brush to clean components.
When Assembling
When Assembling
Thoroughly clean the threads of piston head, piston rod , end cap and cylinder with a wire brush. Use new seals and ‘O’ rings throughout.
K JCB Ram Sealing Procedure ( T E-40)
Ensure that lubricants used during assembly do not come into contact with the locking fluids.
Tighten the piston head to the specified torque setting.
K Table 15. Torque Settings ( T E-43)
Apply JCB Threadlocker and Sealer to the grub screw thread before fitting.
Taking care to retain the end cap at the further end of the piston rod from the cylinder, coat the last three threads of the cyl…
K Table 15. Torque Settings ( T E-43)
If hydraulic oil contacts uncured Threadlocker, a weakening of the bond will result. Cure times vary according to the ambient temperature. Allow approximately 1 hour at 20 ˚C between assembly and filling the ram with oil.
Cold weather operation. When operating in conditions which are consistently below freezing, it is recommended that the rams are operated slowly to their full extent before commencing normal working.
Table 15. Torque Settings
Table 15. Torque Settings
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Nm
kgf m
lbf ft
<TABLE BODY
<TABLE ROW
Piston head
200
20
148
<TABLE ROW
End cap
350
36
250
Page left intentionally blank
Section K – Engine
Section K
Section K
Engine
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Service Manual – JCB 403
Service Manual – JCB 403
<TABLE ROW
Section 1 – General Information
Section 1 – General Information
<TABLE ROW
Section 2 – Care and Safety
Section 2 – Care and Safety
<TABLE ROW
Section 3 – Maintenance
Section 3 – Maintenance
<TABLE ROW
Section A – Attachments
Section A – Attachments
<TABLE ROW
Section B – Body and Framework
Section B – Body and Framework
<TABLE ROW
Section C – Electrics
Section C – Electrics
<TABLE ROW
Section E – Hydraulics
Section E – Hydraulics
<TABLE ROW
Section K – Engine
Section K – Engine
<GRAPHIC
<GRAPHIC
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Notes:
<TABLE BODY
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
<TABLE ROW
Technical Data
Technical Data
Engine Type D2009 LO3
Engine Type D2009 LO3
<TABLE
<TABLE
<TABLE BODY
<TABLE ROW
Number of Cylinders
3
<TABLE ROW
Cylinder Arrangement
In Line
<TABLE ROW
Bore
90 mm (3.543 in)
<TABLE ROW
Stroke
90 mm (3.543 in)
<TABLE ROW
Total Displacement
1718 cm3 (1048 in3)
3
3
<TABLE ROW
Compression ratio
19:6
<TABLE ROW
Working Cycle
4-Stroke Diesel Engine
<TABLE ROW
Combustion System
Naturally Aspirated Engine with Direct Injection
<TABLE ROW
Direction of Rotation
Counter-clockwise when looking at the Flywheel
<TABLE ROW
Lubrication
Force Feed
<TABLE ROW
Maximum Oil Temperature (measured at the engine sump)
130 ˚C (266 ˚F)
<TABLE ROW
Minimum Oil Pressure at 3000 rpm1):
at 3000 rpm1)
2 bar (30 lbf/in2)
2
<TABLE ROW
Engine Firing Order
1 – 2 – 3
<TABLE ROW
V-belt Tension
<TABLE ROW
Weight (with starter and generator)
1) Minimum oil pressure values apply to warm engines, with a oil temperature of 110 ˚C and without engine oil heating systems.
1)
Torque Settings
Torque Settings
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Item
Size
Nm
lbf ft
<TABLE BODY
<TABLE ROW
Cylinder head cover
27
20
<TABLE ROW
Rocker arm setting screw
27 +/- 2
20 +/- 1.5
<TABLE ROW
Intake elbow
M8 x 12.5
27
20
<TABLE ROW
Air intake pipe
27
20
<TABLE ROW
Exhaust manifold
27
20
<TABLE ROW
Oil drain plug (sheet metal sump)
M14 x 1.5
32
24
<TABLE ROW
Injection valve housing
28
21
<TABLE ROW
Oil filter cartridge
27
20
<TABLE ROW
Starter
41
30
Fault Finding
Fault Finding
Basic Engine Fault Diagnostics
Basic Engine Fault Diagnostics
Introduction
Introduction
The purpose of this section is to help you trace faults to a faulty unit. Once you have located the fault, refer to the appropri…
To help identify electrical problem mentioned in the fault finding procedures, refer to the electrical schematics in Section C –
Electrics
IMPORTANT:
IMPORTANT:
1 Before you begin fault finding, read the Safety Information at the beginning of this manual.
1 Before you begin fault finding, read the Safety Information at the beginning of this manual.
2 Make any relevant electrical checks before moving on to the engine components.
3 Make simple checks before stripping a major component.
4 Replace any seals such as ‘O’ rings before re- assembling components.
Fault Charts
Fault Charts
<TABLE
<TABLE
<TABLE HEADING
<TABLE ROW
Fault(s):
<TABLE BODY
<TABLE ROW
K Table 1. Engine does not start or is difficult to start. ( T K-3)
K Table 1. Engine does not start or is difficult to start. ( T K-3)
<TABLE ROW
K Table 2. Engine starts but runs irregularly or stalls ( T K-4)
K Table 2. Engine starts but runs irregularly or stalls ( T K-4)
<TABLE ROW
K Table 3. Engine becomes excessively hot. Temperature high warning system activated ( T K-4)
K Table 3. Engine becomes excessively hot. Temperature high warning system activated ( T K-4)
<TABLE ROW
K Table 4. Engine appears down on power – poor performance ( T K-4)
K Table 4. Engine appears down on power – poor performance ( T K-4)
<TABLE ROW
K Table 5. Engine does not run on all cylinders ( T K-4)
K Table 5. Engine does not run on all cylinders ( T K-4)
<TABLE ROW
K Table 6. Engine oil pressure excessively low ( T K-4)
K Table 6. Engine oil pressure excessively low ( T K-4)
<TABLE ROW
K Table 7. Engine oil consumption excessive ( T K-5)
K Table 7. Engine oil consumption excessive ( T K-5)
<TABLE ROW
K Table 8. Engine emissions – Blue smoke ( T K-5)
K Table 8. Engine emissions – Blue smoke ( T K-5)
<TABLE ROW
K Table 9. Engine emissions – White smoke ( T K-5)
K Table 9. Engine emissions – White smoke ( T K-5)
<TABLE ROW
K Table 10. Engine emissions – Black smoke ( T K-5)
K Table 10. Engine emissions – Black smoke ( T K-5)
Table 1. Engine does not start or is difficult to start.
Table 1. Engine does not start or is difficult to start.
<TABLE
<TABLE BODY
<TABLE ROW
Possible Cause
Possible Cause
Action
Action
<TABLE ROW
Engine below starting limit temperature
Pre-heat engine correctly
<TABLE ROW
Incorrect engine oil viscosity or SAE class
Drain and refill with the correct grade of oil
<TABLE ROW
Poor quality or contaminated fuel
Drain and refill with correct grade of clean fuel
<TABLE ROW
Battery discharged or defective.
Charge and test battery
<TABLE ROW
Electrical cable connections to starter electrical system loose or oxidised
Check and rectify connections or cables as required
<TABLE ROW
Starter Switch, solenoid or relay defective
Replace faulty component
<TABLE ROW
Starter defective or pinion does not engage
Check starter motor. Repair, replace as required
<TABLE ROW
Injector Faulty
Test and replace as required
Table 2. Engine starts but runs irregularly or stalls
Table 2. Engine starts but runs irregularly or stalls
<TABLE
<TABLE BODY
<TABLE ROW
Possible Cause
Possible Cause
Action
Action
<TABLE ROW
Poor quality or contaminated fuel
Drain and refill with correct grade of clean fuel
<TABLE ROW
Injection pipe, fuel line damaged or leaking
Rectify damaged leaking pipe
<TABLE ROW
Injector Faulty
Test and replace as required
Table 3. Engine becomes excessively hot. Temperature high warning system activated
Table 3. Engine becomes excessively hot. Temperature high warning system activated
<TABLE
<TABLE BODY
<TABLE ROW
Possible Cause
Possible Cause
Action
Action
<TABLE ROW
Engine oil level too low
Top-up to the correct level with the correct grade of oil
<TABLE ROW
Engine oil level too high
Drain to the correct level
<TABLE ROW
Air cleaner element clogged
Clean replace elements as required
<TABLE ROW
Air cleaner service switch defective
Check and replace as required
<TABLE ROW
Radiator clogged
Check, clean radiator
<TABLE ROW
Cooling fan defective, poorly adjusted V-belt
Check fan, adjust V-belt as required
<TABLE ROW
Resistance in cooling system too great, through-flow of air insufficient
Clean cooling system
<TABLE ROW
Injector Faulty
Test and replace as required
Table 4. Engine appears down on power – poor performance
Table 4. Engine appears down on power – poor performance
<TABLE
<TABLE BODY
<TABLE ROW
Possible Cause
Possible Cause
Action
Action
<TABLE ROW
Engine oil level too high
Drain to the correct level
<TABLE ROW
Poor quality or contaminated fuel
Drain and refill with correct grade of clean fuel
<TABLE ROW
Air cleaner element clogged
Clean, replace elements as required
<TABLE ROW
Air cleaner service switch defective
Check and replace as required
<TABLE ROW
Air intake hose restricted
Check and repair as required
<TABLE ROW
Injection pipe, fuel line damaged or leaking
Rectify damaged leaking pipe
<TABLE ROW
Injector Faulty
Test and replace as required
Table 5. Engine does not run on all cylinders
Table 5. Engine does not run on all cylinders
<TABLE
<TABLE BODY
<TABLE ROW
Possible Cause
Possible Cause
Action
Action
<TABLE ROW
Injection pipe, fuel line damaged or leaking
Rectify damaged leaking pipe
<TABLE ROW
Injector Faulty
Test and replace as required
Table 6. Engine oil pressure excessively low
Table 6. Engine oil pressure excessively low
<TABLE
<TABLE BODY
<TABLE ROW
Possible Cause
Possible Cause
Action
Action
<TABLE ROW
Engine oil level too low
Top-up to the correct level with the correct grade of oil
<TABLE ROW
Incorrect engine oil viscosity or SAE class
Drain and refill with the correct grade of oil
<TABLE ROW
Excessive inclination of engine
Return machine to a level plain
Table 7. Engine oil consumption excessive
Table 7. Engine oil consumption excessive
<TABLE
<TABLE BODY
<TABLE ROW
Possible Cause
Possible Cause
Action
Action
<TABLE ROW
Engine oil level too high
Drain to the correct level
<TABLE ROW
Excessive inclination of engine
Return machine to a level plain
Table 8. Engine emissions – Blue smoke
Table 8. Engine emissions – Blue smoke
<TABLE
<TABLE BODY
<TABLE ROW
Possible Cause
Possible Cause
Action
Action
<TABLE ROW
Engine oil level too high
Drain to the correct level
<TABLE ROW
Excessive inclination of engine
Return machine to a level plain
Table 9. Engine emissions – White smoke
Table 9. Engine emissions – White smoke
<TABLE
<TABLE BODY
<TABLE ROW
Possible Cause
Possible Cause
Action
Action
<TABLE ROW
Engine below starting limit temperature
Pre-heat engine correctly
<TABLE ROW
Poor quality or contaminated fuel
Drain and refill with correct grade of clean fuel
<TABLE ROW
Incorrect valve clearances
Check and adjust valve clearances
<TABLE ROW
Injector Faulty
Test and replace as required
Table 10. Engine emissions – Black smoke
Table 10. Engine emissions – Black smoke
<TABLE
<TABLE BODY
<TABLE ROW
Possible Cause
Possible Cause
Action
Action
<TABLE ROW
Air cleaner element clogged
Clean replace elements as required
<TABLE ROW
Air cleaner service switch defective
Check and replace as required
<TABLE ROW
Air intake hose restricted
Check and repair as required
<TABLE ROW
Incorrect valve clearances
Check and adjust valve clearances
<TABLE ROW
Injector Faulty
Test and replace as required
Page left intentionally blank

 

Download Ebook

JCB 403 Wheel Loading Shovel Repair Service Manual.pdf

Source : Sitelux.com

Leave a Reply

Your email address will not be published. Required fields are marked *