JCB 926, 930, 940 Rough Terrain Fork Lift Service Manual – 9803/5100-16

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JCB 926, 930, 940 Rough Terrain Fork Lift Service Manual – 9803/5100-16
926 (S/N: 602000 Onwards) – 930 (S/N: 607700 Onwards) – 940 (S/N: 660300 Onwards)

This service manual PDF download for the 926, 930, 940 JCB Rough Terrain Fork Lift 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 Rough Terrain Fork Lift

JCB 926 (S/N: 602000 Onwards)
JCB 930 (S/N: 607700 Onwards)
JCB 940 (S/N: 660300 Onwards)

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 F – Transmission
Section G – Brakes
Section H – Steering
Section K – Engine

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/5100-16
Total Pages : 530

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 !!!!

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9803-5100
Rough Terrain Fork Lift

Section 1
General Information
Introduction
About This Manual
Machine Model and Serial Number
Using the Service Manual
Section Numbering
Units of Measurement
Left Side, Right Side
Cross References
Identifying Your Machine
Machine Identification Plate
Typical Vehicle Identification Number (VIN)
Component Identification Plates
Typical Engine Identification Number
Transmission Identification Numbers
FOPS Certification Plate
Standard Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Condition 1
Condition 2
Verbus Ripp Bolts
Hydraulic Connections
‘O’ Ring Face Seal System
Adaptors Screwed into Valve Blocks
Hoses Screwed into Adaptors
Adaptors into Component Connections with Bonded Washers
‘Torque Stop’ Hose System
Service Tools
Numerical List
Tool Detail Reference
Section B – Frame and Bodywork
Section C – Electrics
Section E – Hydraulics
Section F – Transmission
Section H – Steering
Section K – Engine
Service Consumables
Sealing and Retaining Compounds
Terms and Definitions
Schematic Codes
Hydraulic Schematic Colour Codes

Section 2
Safety Notices
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety – Yours and Others
General Safety
Operating Safety
Maintenance Safety
Safety Decals
Introduction
Safety Decal Definitions

Section 3
Maintenance
Health and Safety
Lubricants
Introduction
Hygiene
Storage
Waste Disposal
Handling
New Oil
Used Oil
First Aid – Oil
Eyes
Swallowing
Skin
Spillage
Fires
Battery
First Aid – Electrolyte
GETS INTO YOUR EYES
IS SWALLOWED
GETS ONTO YOUR SKIN
Warning Symbols
Service Schedules
How to Use the Service Schedules
Machines with A and R Series Engines
Pre-start Cold Checks
Functional Test and Final Inspection
Machines with JCB Dieselmax Engine
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
New Engines
Lubrication Charts
Coolant Mixtures
Cleaning the Machine
Introduction
Detergents
Pressure Washing and Steam Cleaning
Preparing the Machine for Cleaning
Cleaning the Machine
Checking for Damage
Seat Belt (if fitted)
Checking the Seat Belt Condition and Security
FOPS Structure
Mast Support Chains
Fitting the Mast Support Chains
Removing the Mast Support Chains
Greasing
Daily
Rear Axle Pivot Pin
Rear Axle (Early 2WD Machines)
Rear Axle (4WD and Later 2WD Machines)
Rear Driveshafts (4 Wheel Drive Machines)
Front Driveshaft
Mast Tilt Rams and Pivots
500 Hours
Mast Chains
Oiling
Park Brake Cable
Control Levers
Cylinder Bores and Rods
2/4 Wheel Drive Lever (If fitted)
Access Panels
Engine Cover
Opening and Closing
Engine Side Panels
Brakes
Park Brake Adjustment
Checking the Foot Brake Fluid Level
Machines with A and R Series Engines
Machines with JCB Dieselmax Engine
Electrical System
Battery
Battery Disconnection/Connection
Disconnection
Connection
Checking the Electrolyte Level
Battery Isolator (if fitted)
Jump Starting the Engine
Fuses and Relays
Engine Air Filter
Cleaning the Pre-Cleaner (if fitted)
Cleaning the Air Filter Dust Valve
Changing the Elements
Machines with A and R Series Engines
Machines with JCB Dieselmax Engine
Engine (A and R Series Engines)
Check the Oil Level
Change Oil and Filter
Checking the Coolant Level
Changing the Coolant
Adjusting the Fan Belt
Engine (JCB Dieselmax Engine)
Checking the Oil Level
Changing the Oil and Filter
Checking the Coolant Level
Changing the Coolant
Front End Accessory Drive Belt
Inspecting the Drive Belt
Changing the Drive Belt
Fuel System (General Information)
Types of Fuel
Recommended Fuel Specification
Acceptable Fuel Specification
Sulphur Content
Aviation Kerosene Fuels
Low Temperature Fuels
Fatty Acid Methyl Ester Fuels as a Replacement for diesel Fuels
Petrol
Filling the Tank
Fuel System (A and R Series Engines)
Fuel Filter
Draining the Fuel Filter
AA Build Engines
AR Build Engines
R Series Engines
Changing the Filter Element
AA Build Engines
AR Build Engines
R Series Engines
Fuel Sediment Bowl
Draining the Sediment Bowl
Cleaning the Sediment Bowl
Fuel Lift Pump
Early Machines
Cleaning the Lift Pump Gauze
Later Machines
Cleaning the Strainer
Bleeding the System
Machines with Type AA or AB Engines
Machines with Type AK, AM or AR engines
Machines with Type RE engines
Fuel System (JCB Dieselmax Engine)
Draining the Water Separator and Engine Fuel Filter
Changing the Water Separator Filter
Changing the Engine Fuel Filter Element
Bleeding the System
Hydraulic System
Checking the Hydraulic Fluid Level
Renew Filter Element
Draining and Refilling the Hydraulic Tank
Cleaning the Suction Strainer
Transmission
Checking the Transmission Oil Level
Changing the Transmission Oil and Filter
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torques
Axles
Front and Rear Axle
Checking the Axle Oil Level
Changing the Axle Oil
Oil Immersed Brakes
Checking the Hub Oil Levels
Changing the Hub Oil
Windscreen Washer
Checking the Level

Section A
Attachments
Service Procedures
Quick Release Couplings
Connecting and Disconnecting
Quick Release Couplings – Do’s and Don’ts
Connecting Quick Release Couplings
Disconnecting Quick Release Couplings
Swivel Coupling
Dismantling and Assembly
When Dismantling
When Assembling
Hose Reel
Dismantling and Assembly
Dismantling
Assembly

Section B
Section B
Service Procedures
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Fitting Procedure
Glazing
Direct Glazing
Removing the Broken Glass and Old Sealant
Preparing the Cab Frame Aperture
Preparing the New Glass
Installing the New Glass
Chains
Servicing
Lubrication
Adjustment
Wear Limits
Removal, Inspection and Replacement
Removal
Inspection
Lubrication
Replacement
North American Machines (fitted with Olofsson Masts)
Carriage
Removal and Replacement
Removal
Replacement
Adjustment
Side Shift Carriages
Wear Pads
Inspection
Removal and Replacement
Early Machines
Removal
Replacement
Later Machines
Wear Pad Inspection and Replacement
Hose Guard
Removal and Replacement
Removal
Replacement
Masts
Typical Mast
Servicing
Checking Mast and Carriage Roller Bearings and Pulleys
Checking Carriage Side Thrust Roller Bearings
Checking Carriage Roller Bearings
Checking Mast Roller Bearings
Checking Chain Pulleys
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Dismantling
When Assembling
Rollers
Pulleys
Chain Adjustment
Early Side Shift Masts (North America Only)
Removal and Replacement
Dismantling and Assembly
Dismantling
When Assembling
Rollers
Ram and Mast Pivot Pins
Pulleys
Chain Adjustment
Later Side Shift Masts (North America Only)
Removal and Replacement
Removal
Replacement
Olofsson Masts (North America Only)
Servicing
Checking Mast, Carriage Roller Bearings and Pulleys
Checking Carriage Side Thrust Roller Bearings
Checking Carriage Roller Bearings
Checking Mast Roller Bearings
Checking Chain Pulleys
Removal and Replacement
Dismantling and Assembly
Mast Dismantling
When Assembling
Rollers
Pulleys
Chain Adjustment
Hydraulic Tank
Removal and Replacement
Removal
Replacement

Section C
Electrics
Technical Data
General Electrical Data
IP67 Electrics
Fuses and Relays
Fuses
926 (from SN 602000 to 602073), 930 (from SN 607700 to 607717)
926 (from SN 602074 to 605999), 930 (from SN 607718 to 609999), 940 (up to SN 660299)
All Models (from SN 660300 to 822998)
All Models (from SN 822999 to 823755)
All Models (from SN 823756 to 825399)
All Models (from SN 825400)
Link Box Fuses
All Models (from SN 822999 to 823755)
All Models (from SN 823756 to 825399)
All Models (from SN 825400)
Relays
All Models (up to SN 660299)
All Models (from SN 660300)
Air Conditioning (if fitted)
Basic System Operation
General Description
Circuit Schematics
Quick Reference Chart
Wire Identification
Machines without IP67 Electrics
926 (From SN 602074 to 602901), 930 (From SN 607718 to 608655)
Machines with IP67 Electrics
926 (From SN 602902 to 605999), 930 (From SN 608656 to 609999), 940 (Up to SN 660299)
All Machines (from SN 660300 to 822998)
All Models (from SN 822999 to 823755)
All Models (from SN 823756 to 825399)
All Models (from SN 825400)
Machines with Transmission Dump Pedal
Machines with Transmission Dump Switch
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
First Aid – Electrolyte
GETS INTO YOUR EYES
IS SWALLOWED
GETS ONTO YOUR SKIN
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Check 1
Check 2
Alternator Charging Test
Starter Motor
Starting Circuit Test
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wires 000-199
Wires 200-399
Wires 400-599
Wires 600-799
Wires 800-999
Wires In Splices
General Points
Wiring Harness Repair
Introduction
Repair Procedure
Alternator
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Lucas Type
When Dismantling
When Assembling
Alternator (JCB Dieselmax Engine)
Removal, Inspection and Replacement
Removal
Inspection
Replacement
Dismantle and Assembly
Starter Motor
Removal and Replacement
Dismantling, Inspection and Assembly
Dismantling
Inspection
Assembly
Starter Motor (JCB Dieselmax Engine)
Removal, Inspection and Replacement
Removal
Inspection
Replacement
Dismantle and Assembly
Harness Data
Drawings and Interconnection
Introduction
Mainframe Harness
All Models (from SN 660300 to 822062)
All Models (from SN 822063 to 822444)
All Models (from SN 822445 to 822898)
All Models (from SN 822899 to 823755)
All Models (from SN 823756 to 825399)
All Models (from SN 825400)
Machines with Transmission Dump Pedal
Machines with Transmission Dump Switch
Cab Panel Harness
All Models (from SN 6642290 to 822062)
All Models (from SN 822063 to 822898)
All Models (from SN 822899 to 823755)
All Models (from SN 823756 to 825399)
All Models (from SN 825400)
Machines with Transmission Dump Pedal
Machines with Transmission Dump Switch

Section E
Section E
Hydraulics
Technical Data
All Models
Basic System Operation
General Description
Component Basic Operation
Hydraulic Pump
Basic Operation
Neutral Circuit
Lift Operation
MRV Operation (Screw Adjustable)
ARV Operation
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Example Circuit Key
Circuit Schematics
Machines up to SN 828755
Component Key
Machines from SN 828756
Component Key
Circuit Description
Neutral and Steering Circuit
926 up to SN 602749, 930 up to 608299
926 from SN 602750, 930 from 608300
Lift and Tilt Circuits
Lift Operation and Free Lift Mast
926 from SN 602874, 930 from SN 608590 and all machines incorporating TI 9/007
Service Procedures
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Procedure
Contaminant Standards
Filters
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hoses
Disconnecting the Hoses
Lubrication Check
Lift Ram (Top End)
Hydraulic Pump
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
When Dismantling
Inspection
When Assembling
Hydraulic Pump (JCB 444 Engine)
Removal and Replacement
Removal
Replacement
Dismantling and Assembly
Loader Valves
Removal and Replacement
Typical Machine Installation
Removal
Replacement
Machines with Cab Mounted Valves
Removal
Replacement
Dismantling and Assembly
Tie Rods
Introduction
Assembly
Valve Block Sections
Relief Valves and Inter-section Sealing
When Dismantling
When Assembling
Spools
When Dismantling
When Assembling
Testing and Adjustment
Pressure Testing
Main Relief Valve (MRV)
Auxiliary Relief Valve (ARV) Removed
Carriage Lift Auxiliary Relief Valve (ARV)
Procedure 1
Procedure 2
Procedure 3
Attachment ARV’s
Deration Relief Valve
Servicing
Cleaning and Re-sealing
Testing and Adjustment
Deration Diverter Valve
Removal and Replacement
Later Machines
Removal
Replacement
Dismantling and Assembly
Early Machines
Later Machines
Dismantling
Inspection
Assembling
Hydraulic Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Lift Rams
Early Models
Removal
Replacement
Later Models
Removal
Replacement
Tilt Rams
Removal
Replacement
Tilt Rams (Free-lift Mast)
Inner
Removal
Replacement
Tilt Rams (Olofsson Masts)
Outer
Removal
Replacement
Inner
Removal
Replacement
Side Shift Ram (USA Machines only)
Removal
Replacement
Dismantling and Assembly
Lift Ram
When Assembling
Lift Ram (Free-lift Mast)
Outer
Dismantling and Assembly
When Assembling
Inner
When Assembling
Lift Ram (Olofsson Masts)
Tools Required
Dismantling
Assembly
Tilt Ram (Early Models)
Dismantling
When Assembling
Tilt Ram (Typical Ram with Dowelled Piston Head)
Dismantling
When Assembling
Side Shift Ram (USA Machines only)
When Dismantling
When Assembling
JCB Ram Sealing Procedure
Piston Head Retention
Existing piston head and rod
New piston head and rod
Existing piston head and new rod
New piston head and existing rod
Drilling Dimensions
Adjustment
Tilt Ram
Rod Adjustment (Mast Kick Adjustment)

Section F
Transmission
Technical Data
Synchro Shuttle Gearbox
Unit Identification
Front Axle
Unit Identification
Rear Axle – 2WD Machines
Unit Identification
Rear Axle – 4WD Machines
Unit Identification
Tyre Pressures
Basic Operation
General Description
Transmission
Axle
Moving a Disabled Machine
Preparation for Towing
Synchro Shuttle Gearbox
Component Identification
Principle Of Operation
Hydraulic and Electrical Operation
Front and Rear Axle
Cutaway of Front Axle
Cutaway of Rear Axle – 4WD Machines
Cutaway of Rear Axle – 2WD Machines
Systems Description
Synchro Shuttle Gearbox
Synchromesh (Blocking Pin Type)
Synchromesh Operation
Clutch Operation
Service Procedures
Front and Rear Axles
Renewing the Pinion Oil Seal
Fault Finding
Gearbox Fault Finding
Transmission Oil Cooling
Fault Finding
Synchro Shuttle Gearbox
Dismantling, Inspection and Assembly
Front and Rear Axles
Front Axle Hub and Driveshaft
Dismantling and Assembly
Front Axle Drivehead
Dismantling and Assembly
Front Axle Brakes
Dismantling and Assembly
Rear Axle – 2WD Machines
Dismantling and Assembly
Rear Drive Head – 4WD Machines
Dismantling and Assembly
Rear Axle Hub and Driveshaft
Mechanical 4 Wheel Drive Unit
Dismantling and Assembly
Dismantling
Assembly
Torque Converter
Removal and Replacement

Section G
Section G
Brakes
Technical Data
All Models
Basic System Operation
General Description
Dual Brake Pedal Machines
Single Brake Pedal Machines
Single Brake Pedal and Dual Brake Pedal Machines fitted with Compensating Master Cylinders
Service Procedures
Brake Pedal Adjustment
Service Brakes
Bleeding
Single Pedal Configuration
Dual Pedal Configuration
Right Hand Master Cylinder
Left Hand Master Cylinder
Bridge Pipe
Brake Vacuum Tests (940 Only)
Test 1
Test 2
Test 3
Test 4
Test 5
Test 6
Test 7
Test 8
Test 9
Parking Brake
Applicability
Introduction
Type 1 Installation
Type 2 Installation
Type 3 Installation
Type 1 Installation
Renewing the Brake Pads
Dismantling and Assembly
Dismantling
Assembly
Testing and Adjustment
Testing
Adjustment
Type 2 Installation
Renewing the Brake Pads
Dismantling and Assembly
When Dismantling
When Assembling
Testing and Adjustment
Check Adjustment
Check and Adjust the Pad Position
Taking up the Cable Slack
Type 3 Installation
Brake Caliper
Removal and Replacement
Removal
Inspection
Replacement
Renewing the Brake Pads
Torque Figures
Dismantle, Inspection And Assemble
Component Identification
Dismantle
Inspection
Assemble
Testing and Adjustment
Testing
Adjustment
Lever Adjustment
Cable Adjustment
Servo Exhauster Unit (940 Only)
Removal and Replacement

Section H
Steering
Technical Data
926 (up to SN 602749), 930 (up to SN 608299)
926 (SN 602750 – 602797), 930 (SN 608300 – 608418)
926 (SN 602798 on), 930 (SN 608419 on)
Basic System Operation
General Description
926 (up to SN 602749), 930 (up to SN 608299)
926 (from SN 602750), 930 (from SN 608300)
Circuit Description
Power Steering
926 (up to SN 602750), 930 (up to 608300)
926 (SN 602750 on), 930 (SN 608300 on)
Flow Regulating Valve
Steering Pump
Dismantling and Assembly
When Dismantling
Inspection
When Assembling
Hydraulic Steering Unit
Dismantling and Assembly
Applicability
Early Machines
Later Machines
Priority Valve
Introduction
Dismantling and Assembly
When Dismantling
When Assembling

Section K
Engine
Technical Data
Machines with A Series Engines
Specification
Unit Identification
Machines with R Series Engines
Specification
Unit Identification
Machines with JCB Dieselmax Engines
Specification
Unit Identification
Typical Engine Identification Number
Basic System Operation
General Description
Service Procedures
Checking the Low and High Idle Speeds
Start and Warm-up the Engine
Check the Low Idle Speed
Check the High Idle Speed

 

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JCB 926, 930, 940 Rough Terrain Fork Lift Service Manual – 9803/5100-16.pdf

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