JCB Groundhog 4×4 Utility Vehicle Service Manual – 9803/9820-2

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JCB Groundhog 4×4 Utility Vehicle Service Manual – 9803/9820-2
(S/N: 1444000 – 1446999)

This service manual PDF download for the Groundhog 4×4 JCB Utility Vehicle 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 Groundhog 4×4
S/N: 1444000 – 1446999

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 D – Controls
Section E – Hydraulics
Section F – Transmission
Section G – Brakes
Section H – Steering
Section K – Engine
Section S – Suspension

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/9820-2
Total Pages : 310

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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9803-9820
Groundhog 4×4

Section 1
Introduction
About this Publication
Machine Identification
Identifying Your Machine
Machine Identification Plates
Engine Identification Number Location
Consumables
Sealing and Retaining Compounds
Service Tools
Numerical List
Fastener Torque Chart
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Special Torques

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

Section 3
Maintenance
Routine Maintenance
Service Requirements
Introduction
Owner/Operator Support
Service/Maintenance Agreements
Initial Service and Inspection (100 Hours)
Obtaining Replacement Parts
Health and Safety
Lubricants
Introduction
Hygiene
Storage
Waste Disposal
Handling
New Oil
Used Oil
First Aid – Oil
Eyes
Swallowing
Skin
Spillage
Fires
Battery
Warning Symbols
First Aid – Electrolyte
Gets into your eyes
Is swallowed
Gets onto your skin
Service Schedules
Introduction
How to Use the Service Schedules
Calendar Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Tests and Final Inspection
Fluids, Lubricants and Capacities
Types of Fuel
Recommended Fuel Specification
Cetane Number
Viscosity
Density
Sulphur Content
Distillation
Aviation Kerosene Fuels
Low Temperature Fuels
Fatty Acid Methyl Ester Fuels as a Replacement for Diesel Fuels
Coolant Mixtures
Prepare the Machine for Maintenance
Introduction
Make the Machine Safe
Cleaning the Machine
Introduction
Detergents
Pressure Washing and Steam Cleaning
Prepare the Machine for Cleaning
Cleaning the Machine
Checking for Damage
Check the Machine Body and Structure
Check the Tyres
Check the Seat and Seat Belt
Checking the ROPS
Greasing
Introduction
Prepare the Machine for Greasing
Greasing the Machine
Access Panels
Front Access Panel
Fuse and Battery Cover
Brakes
Park Brake
Introduction
Testing the Park Brake
Adjusting the Park Brake
At the Cab Lever
At the Calliper
Foot Brake
Brake Pad Inspection
Brake Fluid Check
Electrics
Battery
Battery Disconnection/Connection
Disconnection
Connection
Checking the Electrolyte Level
Battery Isolation
Jump Start the Engine
Fuses
Engine
Oil and Filter
Checking the Oil Level
Changing the Oil and Filter
Changing the Air Filter Element
Cooling System
Check the Coolant Level
Changing the Coolant
Checking the Hoses and Clamps
Alternator Drive Belt
Check and Adjust
Fuel System
Introduction
Change the Fuel Filter
Bleed the Fuel System
Hydraulics
Hydraulic Oil Level
Checking the Loadbay Tipper Mechanism Oil Level
Changing the Loadbay Tipper Mechanism Oil
Transmission
Gearbox
Checking the Gearbox Oil Level
Adding Oil to the Gearbox
Changing the Oil
Differentials
Introduction
Checking the Differential Oil Level
Adding Oil to the Differential
Checking the Driveshaft CV Joint Gaitors
Checking the CVT Belt
Tyres and Wheels
Tyre Inflation
Introduction
Procedure
Checking the Wheel Nut Torques
Replace a Wheel
Windscreen Washer

Section A
Attachments
Attachments
Lighting Pack

Section B
Body and Framework
General Description
Overview

Section C
Electrics
Technical Data
General Electrical Data
Electrical System
Relays
Replacing Relays
Service Tools
Numerical List
Tool Detail Reference
Fault Finding
Lighting System
Instrumentation
Cold Start System
Starting System
Charging System
Circuits
Schematic Diagrams
Fuses, Ignition Switch and Horn
ESOS and Instrumentation
Main Beam, Diff. Lock, Fan, 12V Socket, Work Lights, Hydraulic Tip
Road Lights
Screen Wash/Wipe
Earths
Harness Data
Drawings and Interconnections
Harnesses
Service Procedures
Using a Multimeter
Measuring DC Voltage
Measuring Resistance
Measuring Continuity
Measuring Frequency
Testing a Diode or a Diode Wire
Battery
Maintenance
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging System Test
Testing Regulated Output
Testing Stator Winding Continuity
Testing Stator Winding Short to Ground
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
Speedometer Calibration
Fault Finding

Section D
Controls
Adjustments
Differential lock
Adjustment at lever
Four wheel drive selector
Adjustment at lever
Adjustment at gearbox
Forward/Reverse selector
Adjustment at gearbox
Adjustment at lever
Throttle
Park brake
Service brake pedal

Section E
Hydraulics
Hydraulic Tipping System
General Description
Hydraulic Power Pack
Dismantling
Assembly

Section F
Transmission
Technical Data
General Information
Variable Speed Drive System
Gearbox
Differential
Wheels and Tyres
Service Tools
Numerical List
Basic Operation
General Description
Differentials
Fault Finding
Gearbox and Transmission
Differential
CVT
Drive Belt and Pulleys
Belt Removal
Belt Refitting
Pulley Alignment
Gearbox
General Information
Component Identification
Dismantling
Assembly
Propshafts
Front propshaft
Removal
Refitting
Rear propshaft
Removal
Refitting
Differentials
Front differential
Removal
Refitting
Rear differential
Removal
Refitting
Driveshafts and Hubs
Front Driveshaft
Removal
Refitting
Rear Driveshaft
Removal
Refitting
Rear Hub
Removal

Section G
Brakes
Technical Data
Groundhog 4×4
Basic Operation
Brake Circuit
Fault Finding
Brake System
Service Procedures
Front Brake
Front brake pad removal and replacement
Front brake caliper removal
Front brake caliper refitting
Front brake caliper piston/seal removal
Front brake caliper piston/seal refitting
Rear Brake
Rear brake pad removal and replacement
Rear brake caliper removal
Rear brake caliper refitting
Rear brake caliper piston/seal removal
Rear brake caliper piston/seal refitting
Parking Brake Adjustment
Service brake pedal
Bleeding Procedure

Section H
ManualSubHeading – Steering
Heading – Technical Data
Heading – General Information
Heading – Basic Operation
Heading – General Description
Heading – Service Procedures
Heading – Steering Rack
Heading – Removal
Heading – Refitting
Heading – Swivel Hubs
Heading – Removal
Heading – Refitting
Heading – Wheel Alignment

Section K
Engine
Technical Data
Specification
Fault Finding
Groundhog 4×4
Coolant
Engine
Cooling System
Groundhog 4×4
General information
Removing the engine cooling radiator
Refitting the engine cooling radiator
Removing the radiator cooling fan
Refitting the radiator cooling fan
Engine
Groundhog 4×4
Removing the Engine
Refitting the Engine
Engine cradle bushes

Section S
Suspension
Technical Data
Groundhog 4×4
Service Tools
Numerical List
Front Suspension
Groundhog 4×4
Suspension strut
Removal
Refitting
Suspension wishbone
Removal
Refitting
Suspension bushes
Rear Suspension
Groundhog 4×4
Suspension strut
Removal
Refitting
Trailing arm
Removal
Refitting
Suspension bushes

 

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JCB Groundhog 4×4 Utility Vehicle Service Manual – 9803/9820-2.pdf

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