JCB Side Engine Loadalls Service Manual – 9803/3730-10

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JCB Side Engine Loadalls Service Manual – 9803/3730-10
(S/N: 1186000 Onwards)

This service manual PDF download for the JCB Side Engine Loadalls 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 531-70 (JCB 444 Engine) – from S/N: 1186000 Onwards
– JCB 533-105 (JCB 444 Engine) – from S/N: 1186000 Onwards
– JCB 535-95 (JCB 444 Engine) – from S/N: 1186000 Onwards
– JCB 535-125 (JCB 444 Engine) – from S/N: 1186000 Onwards
– JCB 535-140 (JCB 444 Engine) – from S/N: 1186000 Onwards
– JCB 536-60 (JCB 444 Engine) – from S/N: 1186000 Onwards
– JCB 540-140 (JCB 444 Engine) – from S/N: 1186000 Onwards
– JCB 540-170 (JCB 444 Engine) – from S/N: 1186000 Onwards
– JCB 541-70 (JCB 444 Engine) – from S/N: 1186000 Onwards
– JCB 550-140 (JCB 444 Engine) – from S/N: 1186000 Onwards
– JCB 550-170 (JCB 444 Engine) – from S/N: 1186000 Onwards

This manual contains topics that relate to JCB side engine Loadall machines with JCB Dieselmax engines and analogue cab instrumentation.
Serial Numbers 1422000 to 1441999.

TABLE OF CONTENTS :

Section 1 – General Information
Section 2 – Care and Safety
Section 3 – Routine 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 L – Flowshare

MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
Publication No. : 9803/3730-10
Total Pages : 1405

This complete JCB Telescopic Handler | Loadall | Telescopic Loader 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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9803-3730

Section 1 – General Information
General Information
Introduction
About this Publication
Applicable Machines
Schematic Codes
Colour Codes
Machine Identification
Machine Identification Plate
Typical Vehicle Identification Number (VIN)
Component Identification Plates
Typical Engine Identification Number
Transmission Identification Numbers
ROPS/FOPS and OECD Certification Plates
Fuel
Acceptable and Unacceptable Fuels
Additives
Service Requirements for use of B20 Biodiesel
Warranty
Fuel Types
Usage and Effects of Fuels
Sulphur Content
Effects of Fuel Contaminates
Torque Settings
Zinc Plated Fasteners and Dacromet Fasteners
Introduction
Bolts and Screws
Hydraulic Connections
‘O’ Ring Face Seal System
‘Torque Stop’ Hose System
Service Tools
Numerical List
Tool Detail Reference
Service Aids
Sealing and Retaining Compounds

Section 2 – Care and Safety
Care and Safety
Safety Notices
Introduction
Important Information
The Operator Manual
Safety Warnings
Safety Check List
Safety – Yours and Others
Common Rail (SE Engine) Specific
General Safety
Operating Safety
Maintenance Safety
Safety Decals
General Procedures
Introduction
Related Topics
Parking the Machine and Making it Safe
Boom Safety Strut
Installing
Removing
Venting Hydraulic Pressure
Connecting/Disconnecting Hydraulic Hoses
Introduction
Connecting the Hoses
Disconnecting the Hoses
Quick Release Couplings
Connecting and Disconnecting
Hydraulic Contamination
Hydraulic Fluid Quality
Effects of Contamination
Cleaning Operation
Contaminant Standards
Filters
Battery Disconnection/Connection
Disconnection
Connection
Removing and Replacing Components
Battery Charging System Precautions
Hydraulic Rams
Installation
Caution During Use
Maintenance, Inspection Points

Section 3 – Routine Maintenance
Introduction
Health and Safety
Lubricants
Battery
Service Schedules – Machines with SA, SB and SC Engines
Related Topics
Introduction
Fuel System
How to Use the Service Schedules
Calendar Equivalents
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Service Schedules – Machines with SE Engines
Related Topics
Introduction
Calendar Equivalents
How to Use the Service Schedules
Fuel System
Pre-start Cold Checks, Service Points and Fluid Levels
Functional Test and Final Inspection
Fluids, Lubricants and Capacities
Related Topics
Specifications
Coolant Mixtures
Cleaning the Machine
Related Topics
Introduction
Detergents
Pressure Washing and Steam Cleaning
Preparing the Machine for Cleaning
Cleaning the Machine
Inspection
Checking for Damage
Seat Belts
Checking the Seat Belt Condition and Security
ROPS/FOPS (and OECD) Structure
Checking the ROPS/FOPS (and OECD) Structure
Greasing
Related Topics
Greasing
Preparing the Machine for Greasing
Every 50 Hours
Every 500 Hours
Every 1000 Hours
Oiling
Park Brake Cable
Control Levers
Heater and Air Conditioning
Related Topics
Changing the Air Intake Filter
Brakes
Related Topics
Checking the Foot Brake Fluid Level
Electrical System
Related Topics
Battery
Battery Disconnection/Connection
Checking the Electrolyte Level
Battery Isolator
Jump Starting the Engine
Fuses and Relays
Fuses
Link Box Fuses
Relays
Engine Air Filter
Related Topics
Cleaning the Air Filter Dust Valve
Changing the Elements
Engine
Related Topics
Checking the Oil Level
Changing the Oil and Filter
Cooling System
Checking the Coolant Level
Changing the Coolant
Front End Accessory Drive Belt
Introduction
Inspecting the Drive Belt
Changing the Drive Belt
Fuel System
Related Topics
Fuel
Filling the Tank
Water Separator and Engine Fuel Filter
Introduction
Draining the Water Separator and Engine Fuel Filter
Changing the Engine Fuel Filter Element
Cleaning Water Separator Pump (if fitted)
Bleeding the System
Hydraulic System
Related Topics
Oil and Filters
Checking the Hydraulic Fluid Level
Changing the Filter Element
Changing the Pilot Filter Element (If Fitted)
Hose Burst Protection Valves
Transmission
Related Topics
Gearbox
Checking the Oil Level
Changing the Oil and Filter
Front and Rear Axle
Checking the Axle Oil Level
Changing the Axle Oil
Oil Immersed Brakes
Checking the Front Axle Breather
Tyres and Wheels
Tyre Inflation
Checking the Wheel Nut Torques
Wheel Nut Torque Indicators (if fitted)
Wheel Alignment
Introduction
Manual Steer Mode Selector
Electronic Steer Mode Selector
Wear Pads
Related Topics
Wear Pads
Boom Wear Pad Clearance
Windscreen Washer
Related Topics
Checking the Level
Access Panels
Related Topics
Battery Cover
Opening and Closing
Engine Cover
Opening and Closing
Undershield
Removal and Replacement
Fire Extinguisher (if fitted)
Checking the Fire Extinguisher

Section A – Attachments
Attachments
Service Procedures
Quick Release Couplings
Connecting and Disconnecting

Section B – Body and Framework
Technical Data
Air Conditioning (Option)
Basic Operation
Boom – Telescopic Operation
3 Stage Boom
Air Conditioning (Option)
Safety Procedures
R134a Refrigerant
PAG Type Refrigerant Oil
System Operation
System Control
Load Moment Indicator (LMI)
Electrical Connections
Air Conditioning (Option)
Type 1: Cooling Pack Mounted Condenser
Type 2: Cab Roof Mounted Condenser
Load Moment Indicator (LMI)
Machines with Analog Display
Machines with Digital Display
Fault Finding
Air Conditioning (Option)
General Fault Indications
System Diagnosis using Test Gauges
Load Moment Indicator (LMI)
Fault Codes
General Fault Finding
Diagnostic Tests
Service Procedures
Rivet Nuts
Fitting Procedure
Slide Hammer Kit
Fitting Procedure
Air Conditioning (Option)
Service Checks
Leak Testing
Tightening Leaking Hoses
Refrigerant Charging and Discharging
Binary Pressure Switch Testing
Compressor Drive Belt – Adjustment
Condenser Matrix Cleaning
Cab
ROPS, FOPS Structure – Checks
Direct Glazing
Load Moment Indicator (LMI)
Calibration Procedure
Calibration Charts
Boom
Wear Pad Renewal
Load Moment Indicator (LMI)
Removal and Replacement
Axle Transducer
Air Conditioning (Option)
Removal and Replacement
Air Conditioning Unit (HVAC)
Freeze Thermostat
Binary Pressure Switch
Roof Mounted Condenser Unit
Cooling Pack Mounted Condenser Unit
Boom
Fork Carriage Removal and Replacement
2 Stage Booms
3 and 4 Stage Booms
Inclinometer Indicator
Removal and Replacement
Boom Rear Cover (HiViz Machines)
Removal and Replacement
Removal and Replacement
2 Stage Boom (531, 541 Machines)
2 Stage Boom (526, 536 Machines)
3 and 4 Stage Booms
Dismantling and Assembly
2 Stage Boom
3 Stage Boom
4 Stage Boom
Boom Shimming
Typical Method
Measurements
Pivot Shims
Cab
Internal Components
Roller Blind
Roof Liner
Instrument Panels
External Components
Door Handle Removal and Replacement
Door Removal and Replacement
Roof Guard
Wiper Motor Front
Wiper Motor Rear
Wiper Motor Roof
Removal and Replacement
Cab Heater Valve
Removal and Replacement
Removal
Replacement
Fuel Tank
Removal and Replacement
Removal
Replacement
Fuel Level Sender
Engine Cover
Removal and Replacement
Mudguards
Removal and Replacement
Mudguard Assembly

Section C – Electrics
Technical Data
General Electrical Data
Fuses and Relays
Fuses
Link Box Fuses
Relays
Schematic Circuits
SA,SB and SC Engines – With Analog Display Panel
Machines up to 10.5m Lift Height – 4 Speed Transmission
SA,SB and SC Engines – With Analog Display Panel
Machines Up To 10.5m Lift Height – 6 Speed Transmission
SA,SB and SC Engines – With Analog Display Panel
Machines Over 10.5m Lift Height
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
Testing
Specific Gravity Testing
Alternator
General Description
Service Precautions
Charging Circuit Test
Alternator Charging Test
Starter Motor
Starting Circuit Test
Wire and Harness Number Identification
Introduction
Wire Numbers and Functions
Wiring Harness Repair
Introduction
Repair Procedure
Battery
Removal and Replacement
Removal
Alternator
Removal, Inspection and Replacement
Dismantle and Assemble
Renewing the Voltage Regulator and Brushes
Renewing the Drive Pulley
Starter Motor
Removal, Inspection and Replacement
Dismantle and Assemble
Renewing the Brush Gear
Renewing the Starter Solenoid
Earth Points
Location
Harness Data
Drawings and Interconnection
Harnesses – All Variants upto 10.5m Lift Height, SA, SB, SC Engines
Harnesses – All Variants over 10.5m Lift Height, SA, SB, SC Engines
Drawings

Section D – Controls
Controls
Column Switches
Removal and Replacement
Steering Column
Removal and Replacement
Control Cables
Engine Throttle Cable (SA, SB, SC Engines)
Removal
Replacement
Parkbrake Cable
PS750 Gearbox
PS760 Gearbox
Throttle Pedal
Removal and Replacement
Throttle Pedal Assembly
Throttle Switch
Removal and Replacement
Throttle Pedal and Throttle Position Sensor (TPS)
Operation
Removal and Replacement
Throttle Pedal Assembly
Throttle Position Sensor (TPS)

Section E – Hydraulics
Hydraulics
Technical Data
Hydraulic System Types
Hydraulic Pump
Double Pump
Triple Pump
Control Valve Block
Parallel Service Valve Block
Parallel Service Valve Block (Servo)
Cooling Fan Motor
Machines with SA,SB and SC Engines
Smooth Ride System (SRS)
Accumulator
Basic Operation
Component Location and Neutral Circuit Description
Introduction to Hydraulic Schematic Symbols
General (Basic and Functional Symbols)
Control Valves
Example of Schematic Circuit
Schematic Circuits
Machines with Dual Lever Controls
Machines with Single Lever Controls
Machines with Servo Controls
Circuit Descriptions
Pump Operation
Parallel Service Valve Block
4 Spool Control Valve
6 Spool Control Valve with Unloader Section
2 Spool Remote Control Valve (if fitted)
Main Relief Valve (MRV) Operation
Auxiliary Relief Valve (ARV) Operation
Parallel Lift
Boom Raise Cycle
Boom Lower Cycle
Boom Regenerative Valve (if fitted)
Boom Extend Cycle
Boom Retract Cycle
Smooth Ride System (SRS), Parallel Hydraulic System
Service Spool Microswitches
Hydraulic Schematic
Electrical Schematic
Electrical Operation
Wires and Connectors
Boom and Stabiliser Interlock System 540-170 Machines
Introduction
Basic Operation
Interlock Characteristics
Fault Finding
Parallel Service Valve Block
Boom Extension Faults
Parallel Lift
Smooth Ride System (SRS)
Service Procedures
`Positional Type’ Hydraulic Adaptors
Fitting Procedure
Flow and Pressure Tests
Checking Pump Flow
Parallel Service Valve Block
Smooth Ride System (SRS) Accumulators
Charging and Discharging
Control Valve Block
Removal and Replacement
Parallel Service Valve Block
2 Spool Remote Control Valve (if fitted)
Dismantle and Assemble
Parallel Service Valve Block
2 Spool Remote Control Valve (if fitted)
Main Pump
Removal and Replacement
Dismantle, Inspection and Assemble
Double Pump
Triple Pump
Steering Priority Valve
Removal and Replacement
Dismantle, Inspection and Assemble
Pilot Pressure Reducing Valve
Dismantle and Assemble
Solenoid Diverter Valve (if fitted)
Removal and Replacement
Servo Control Lever (if fitted)
Removal and Replacement
Hydraulic Control Lever
Fan Motor (including reversible fans)
Removal and Replacement
Dismantle, Inspection and Assemble
Hydraulic Rams
Precautions During Use
Installation
Caution During Use
Maintenance, Inspection Points
Removal and Replacement
Lift Ram
Single Displacement Ram (Excluding 526-56 Machines)
Single Displacement Ram (526-56 Machines)
Twin Displacement Rams
Extension Ram
Tilt Ram
Stabiliser Ram (if fitted)
Sway Ram (if fitted)
Dismantle and Assemble
Typical Ram
Extension Ram Make-Up Valve (if fitted)
JCB Ram Sealing Procedure
Piston Head Retention
4 – Stage Boom Outer Ram
Assembly
Bleed Procedures
3-Stage Boom Extension Ram Circuit
4-Stage Boom Extension Ram Circuit
Tilt Ram Circuit
Sway Ram Circuit
Smooth Ride System (SRS)
Accumulators
Removal and Replacement

Section F – Transmission
Transmission
Technical Data
Tyre Sizes and Pressures
Front Axles
Unit Identification
Rear Axles
Unit Identification
Powershift Gearboxes
PS750 4-Speed
PS764 4-Speed
PS766 6-Speed
Engine Stall Speed Combinations
Basic Operation
General Description
Transmission Assembly
PS750 Transmission
PS760 Transmission
Front Axles – Steer Drive Type SD70, SD80
Component Identification
Rear Axles – Steer Drive Type SD55, SD80
Component Identification
PS750 Powershift Gearbox
Component Identification
Principle of Operation
Hydraulic and Electrical Operation
Drivepaths
PS764 and PS766 Powershift Gearboxes
Component Identification
Principle of Operation
Hydraulic and Electrical Operation
Operation Characteristics – PS766, 6 Speed Gearbox
Drivepaths – 4 Speed
Drivepaths – 6 Speed
Torque Converter
Component Identification
Principle of Operation
Lock-Up Torque Converter
Component Identification
Principle of Operation
Systems Description
PS750 Powershift Gearbox
Forward and Reverser Clutch Operation
2 and 4 Wheel Drive Clutch (4WD Spring ON) Operation
2 and 4 Wheel Drive Clutch (4WD Pressure ON) Operation
PS764 and PS766 Powershift Gearboxes
Forward and Reverser Clutch Operation
Mainshaft, Layshaft and 6-Speed Clutch Operation
2 and 4 Wheel Drive Clutch Operation
Electrical Connections
Powershift Gearbox (PS 750 4 Speed)
Introduction
Quick Reference
Wires and Connectors
Powershift Gearbox (PS 760 4 Speed)
Introduction
Quick Reference
Wires and Connectors
Powershift Gearbox (PS766 ECU 2.2 6 Speed)
Introduction
ECU Electrical Connections
Quick Reference
Wires and Connectors
Lock Up Torque Converter
Introduction
Quick Reference
Service Procedures
Rear Axles SD55 and SD80
Renewing the Pinion Oil Seal
Wheel Removal and Replacement
Wheel Studs
Front Axles SD70 and SD80
Renewing the Pinion Oil Seal
Wheel Removal and Replacement
Wheel Studs
Testing for Brake Piston Seal Leakage
PS750 Powershift Gearbox
Flushing the Transmission Oil
Torque Converter Stall Test
Pressure and Flow Tests
Solenoid Identification
PS764 and PS766 Powershift Gearboxes
Flushing the Transmission Oil
Torque Converter Stall Test
Pressure and Flow Tests
Solenoid Control Valve Cartridge – Solenoid Coil
Solenoid Control Valve Cartridge
Oil Pressure Switch
Oil Temperature Switch – Non Lock Up Torque Converter Variants
Oil Temperature Switch – Lock Up Torque Converter Variants
PS766 Powershift Gearbox
Speed Sensors
Electronic Control Unit
ShiftMaster Diagnostics 2.3 – User Guide
Testing the Lock Up Torque Converter
Speedometer (if fitted)
Calibration Procedure
Fault Finding
Powershift Gearbox
Introduction
Fault Finding Tables
Propshafts
Removal and Replacement
Front Axles SD70 and SD80
Removal and Replacement
SD70 Fixed Axle
SD70 Sway Axle
SD80 Fixed Axle
SD80 Pivot Sway Axle
SD80 Trunnion Sway Axle
Dismantle and Assemble
Rear Axles SD55 and SD80
Removal and Replacement
SD55 Axle
SD80 Pivot Axle
SD80 Trunnion Axle
Dismantle and Assemble
Gearbox
Removal and Replacement
Dismantle, Inspection and Assembly
Torque Converter
Removal and Replacement
Bevel Gearbox
Removal and Replacement
Dismantle, Inspection and Assembly
Oil Cooler, Liquid to Liquid
Removal, Testing and Replacement
Oil Cooler, Air Blast Type
Removal and Replacement

Section G – Brakes
Brakes
Technical Data
Service Brakes
Machines with SD55, SD70 Axles
Machines with SD80 Axles
Park Brake
Type 1: External Calliper
Type 2: Gearbox Integral
Basic Operation
General Description
Fault Finding
Brake System
Service Procedures
Service Brakes
Brake Light Switch – Adjustment
Bleeding
Brake Piston Seal Leakage
Brake Vacuum Test (if applicable)
Axle Breather (Braked Axles) – Inspection
Park Brake (Type 1: External Calliper)
Testing
Adjustment
Switch Adjustment
Renewing the Brake Pads
Park Brake (Type 2: Gearbox Integral)
Testing
Adjustment
Switch Adjustment
Master Cylinder
Removal and Replacement
Fluid Reservoir
Removal and Replacement
Servo Unit (if applicable)
Removal and Replacement
Machines with SD55, SD70 Axles
Machines with SD80 Axles
Servo Exhauster Unit
Removal and Replacement
Service Brakes
Dismantling and Assembly
All Machines
Machines with Hub Brakes
Park Brake
Type 1: External Calliper
Torque Figures
Calliper – Removal and Replacement
Calliper – Dismantle, Inspection and Assemble
Type 2: Gearbox Integral
Dismantle, Inspection and Assemble
Park Brake Cable
Removal and Replacement
Park Brake Switch
Removal and Replacement

Section H – Steering
Steering
Technical Data
Hydraulic Steer Unit
Gearpump Machines
Priority Valve
Gearpump Machines
Basic System Operation
General Description
Hydraulic Operation
Electrical Operation
Circuit Schematics
Hydraulic System
Machines upto 10.5m Lift Height (power track rods)
Machines over 10.5m Lift Height (steer rams)
Electrical System
Steer Modes
Circuit Descriptions
Machines with Steer Rams
2-Wheel Steer Selected
4-Wheel Steer Selected
Crab Steer Selected
Machines with Power Track Rods
2-Wheel Steer Selected
4-Wheel Steer Selected
Crab Steer Selected
Priority Valve Operation
Neutral
Turning
Electrical Connections
Steer Mode Controls
Machines Up to 10.5 Metre Lift Height with Analog Display
Machines Over 10.5 Metre Lift Height with Analog Display
Fault Finding
Steering System
Fault Finding Tables
Diagnostic `Blink’ Codes
Service Procedures
Re-phasing the Road Wheels
Machines with Solenoid Operated Steer Mode Valve
Machines with Manual Steer Mode Valve (Option)
Bleeding the System
Machines with Solenoid Operated Steer Mode Valve
Machines with Manual Steer Mode Valve (Option)
Proximity Switch – Setting
Machines with SD55, SD70 Axles
Machines with SD80 Axles
Steer Mode Valve – Checking Solenoid Operation
Anti-Cavitation Valve (if fitted)
Bypassing Procedure
Checking for Internal Hydraulic Leakage
Checking Energiser Seals
LSP Gearpump Machines
Hydraulic Pressure Tests
Steer Priority Valve – Cleaning
Priority Valve
Removal and Replacement
Gearpump Machines
Power Track Rod
Removal and Replacement
Link Arms
Removal and Replacement
Rams
Dismantle and Assemble
Steer Rams
Removal and Replacement
Dismantle and Assemble
Steer Mode Valve
Machines Upto 10.5m Lift Height
Removal and Replacement
Dismantle and Assemble
Machines Over 10.5m Lift Height
Removal and Replacement
Dismantle and Assemble
Hydraulic Steer Unit
Removal and Replacement

Section K – Engine
Engine
Technical Data
JCB Dieselmax
Engine Specifications
Circuit Descriptions
Cold Start Heater – SA, SB, SC Engines
Diagnostic `Blink’ Codes
Wires and Connectors
Cooling Pack
Removal and Replacement
Machines with Non-Intercooled Engines
Machines with Intercooled Engines
Dismantle and Assemble
Coolant Expansion Tank
Removal and Replacement
Removal
Replacement
Coolant Level Sensor
Vacuum Switch
Removal and Replacement
Silencer
Removal and Replacement
Removal
Replacement
Removal and Replacement
Machines with SA,SB,SC Engines
Introduction
Removal
Replacement
Separating the Engine and Bevel Box
Dismantling
Assembly

Section L – Flowshare
Flowshare
Introduction
Scope
Machine Types
Service Tools
Numerical List
Technical Data
Hydraulic System Types
Gearpump
Variflow Pump
Control Valve Block (LSP Gearpump)
Control Valve Block (LSP Variflow)
Basic Operation
LSP Gearpump
Component Location and Identification
Oil Pump
Servo Pilot Valve
Manual Control
Proportional Control
Load Sensing
Inloader Operation
Pressure Compensation (Flowshare)
Control Lever
Hydraulic Circuit Operation
LSP Variflow
Component Location and Identification
Oil Pump
Servo Pilot Valve
Manual Control
Proportional Control
Load Sensing
Pressure Compensation (Flowshare)
Control Lever
Hydraulic Circuit Operation
Gearpump Operation
Inloader Valve
Variflow Pump
Servo Pilot Valve
Thumbwheel Controls Basic Operation
PWM Controller Electronic Control Unit (ECU)
ECU Inputs
ECU Outputs
Pulse Width Modulation (PWM)
Schematic Circuits
Hydraulic Schematics
LSP Gearpump
LSP Variflow
Circuit Descriptions
Hydraulic Services
Pressure Compensator Valves Operation
No Service Selected (All Spools in Neutral)
Operating a Service
Operating an Individual Service
Operating Multiple Services
Inloader Valve Operation
Pump P2 Directed to Tank
Pump P2 in Circuit (Inloader Operation)
Inloader Operation Override
Graph of System Pressures
Pilot Valve Proportional Solenoid Operation
Boom Extend and Retract – Example
Smooth Ride System – LSP Gearpump, LSP Variflow
Service Spool Microswitches
Hydraulic Schematic
Electrical Schematic
Electrical Operation
Wires and Connectors
Variflow Pump Operation
Fault Finding
Gearpump Machines
Hydraulic Services System
Diagnostic `Blink’ Codes
Boom Extension Faults
Parallel Lift
Smooth Ride System (SRS)
LSP Variflow
Hydraulic Services System
Diagnostic `Blink’ Codes
Boom Extension Faults
Parallel Lift
Smooth Ride System (SRS)
Service Procedures
`Positional Type’ Hydraulic Adaptors
Fitting Procedure
Measuring Spool Displacement (Manual Spools)
LSP Gearpump – Flow and Pressure Tests
Checking Pump Flow
Checking the Servo Pilot Pressure
Testing Load Sense Relief Valve (LSRV)
Testing Auxiliary Relief Valve (ARV’s)
Testing Pilot Operated Relief Valve
LSP Variflow – Flow and Pressure Tests
Checking Pump Flow
Main System Pressures
System Pressures
Checking the Servo Pilot Pressure
Main Pump
Gearpump
Removal and Replacement
Dismantle and Assemble
Variflow
Removal and Replacement
Dismantle and Assemble
Control Valve Block
LSP Gearpump, LSP Variflow
Handling
Removal
Replacement
Dismantle and Assemble
Inloader Valve
Removal and Replacement
Servo Pilot Valve
Removal and Replacement

 

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