jcb 135 HD, Service Manual

Page: 28 / 51

01 - Machine
06 - About this Manual
06 - Using the Manual
01 - 22 9813/4450-2 01 - 22
06 - Using the Manual
Introduction
Information in this manual conforms to a standard
JCB service manual format. The format uses section
headings taken from a PIL (Parts Identification
List). These headings are assigned numerical
identification references.
Table 1.
Example Section Main Assembly / Head-
ing
Component / Sub-head-
ing
PIL reference 33 03 03
Heading Electrical System Battery Isolator Switch
Information within each PIL reference is included
under a set of standard headings such as
Introduction, Health and Safety, Technical Data and
Operation for example. Where additional relevant
information is contained within another PIL reference
a cross reference is provided.
The main systems information is contained in the
manual as follows.
Table 2.
System PIL Reference Heading
Hydraulic System 30-00-50 Schematic Circuit
Electrical System 33-03-03 Battery - Isolator Switch
33-09-00 Power Distribution (including fuses
and relays)
33-00-50 Schematic Circuit
Electronic Diagnostic 33-57 Electronic Diagnostic (including
Servicemaster)
Machine Variants
Where information is different depending on machine
variant, the applicable information sets are included
within the same PIL reference. Headings are
included to identify which information is for which
variant. Make sure you use the correct information.
Diagnostics
Information in this manual can help you diagnose
machine faults.
Before attempting to diagnose possible faults check
the following.
• Ensure that the operator understands the
machine controls, functions and use. Refer to
the applicable Operator Manual.
• Check that the maintenance record complies
with the applicable schedule for the operating
environment. Refer to PIL 78-24.
• Check that the fluids in use comply with the
standards specified. Refer to PIL 75-00.
• Ensure that the machine electronic set-up is
applicable. Use the applicable Servicemaster
vehicle set-up tool. Refer to PIL 33-57-03.
• Use the applicable Servicemaster diagnostics
tools. Refer to PIL 33-57-03.
Torque Tightening
When you replace components, always tighten the
applicable fixings to the correct torque value. Use the
torque tightening values contained in the individual
procedures (Remove and Install, Disassemble and
Assemble etc.). If no torque values are specified,
use the standard torque tightening values. Refer
to Fasteners and Fixings, Screws, Bolts, Nuts,
Technical Data (PIL 72-00). For the torque setting to
be effective, do the following before you install the
fixings.
• Make sure that all the applicable component
assemblies are correct.
• Make sure that the applicable fixings are to the
correct specification. If necessary discard the
original fixings and replace them with new ones.
The relevant procedures indicate when this is
necessary.
• Make sure that the applicable fixings and
threaded holes are free from contamination.
This includes dirt, debris, old sealants and
compounds, fluids and lubricants.