jcb 535-125 Hi Viz User Manual Download

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Copyright © 2004 JCB SERVICE. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any other means,

electronic, mechanical, photocopying or otherwise, without prior permission from JCB SERVICE.

World Class

Customer Support

9803/3750-05

Publication No.

Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

Service Manual

Side Engine Loadalls

Section 1 - General Information

Section 2 - Care and Safety

Section 3 - Routine Maintenance

Section B - Body and Framework

Section C - Electrics

Section E - Hydraulics

Section F - Transmission

Section G - Brakes

Section H - Steering

Section K - Engine

Section M - Electronic Data Systems

ProCarManuals.com

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Summary of Contents for 535-125 Hi Viz

Page 1: ...Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Service Manual Side Engine Loadalls...

Page 2: ...Section 0 Service Manual 0 0 0 0 9803 3750 05 Notes ProCarManuals com...

Page 3: ...Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section 1 General Information Service Manual Side...

Page 4: ...Section 1 General Information 1 0 1 0 9803 3750 05 Notes ProCarManuals com...

Page 5: ...Plates 1 3 5 Torque Settings Introduction 1 4 1 Zinc Plated Fasteners and Dacromet Fasteners 1 4 2 Hydraulic Connections 1 4 6 Positional Type Hydraulic Adaptors 1 4 10 Service Tools Introduction 1 5...

Page 6: ...Page No Contents Section 1 General Information 1 ii 1 ii ProCarManuals com...

Page 7: ...y to different variants of the same model is given in the applications tables and in the Topics throughout the manual where applicable Use the applications tables to see which topics relate to which m...

Page 8: ...ef Title Variant 540 170 5AF 550 140 5AG 540 140 5AL 550 170 5AM 535 125 HiViz 5AN 535 140 HiViz 5AP 1 2 Use All Machines 1 3 Machine Identification All Machines 1 4 Torque Settings All Machines 1 5 S...

Page 9: ...1 3 9803 3750 05 1 14 01 Section 2 Care and Safety Machine models Topic Ref Title Variant 540 170 5AF 550 140 5AG 540 140 5AL 550 170 5AM 535 125 HiViz 5AN 535 140 HiViz 5AP 2 1 Safety Notices All Mac...

Page 10: ...icants and Capacities All Machines 3 5 Cleaning the Machines All Machines 3 6 Inspection All Machines 3 7 Seat Belts All Machines 3 8 ROPS FOPS and OECD Structure All Machines 3 9 Greasing All Machine...

Page 11: ...B3 Cab Air Conditioning SYSTEM z z z z z z B4 Load Moment Indicator LMI SYSTEM z z z z z z B6 Cab z z z z z z B7 Air Conditioning Condensor Cooling Pack Mounted z z z z z z B8 Air Conditioning Condens...

Page 12: ...els Topic Ref Title Variant 540 170 5AF 550 140 5AG 540 140 5AL 550 170 5AM 535 125 HiViz 5AN 535 140 HiViz 5AP C1 Fuses and Relays z z z z z z C2 Schematics z z z z z z C3 Electrical Harness SYSTEM z...

Page 13: ...ection To January 2009 z z To January 2009 z z E6 Parallel Control Valve 5 Section From January 2009 From January 2009 E7 Parallel Control Valve 2 Section z z E8 Servo Control Valves z z E9 Servo Sole...

Page 14: ...s SD80 Pivot sway z z z z SD80 Trunnion sway z z F5 PS750 Gearbox SYSTEM z z z z z z F6 PS750 Mk IV Gearbox SYSTEM z z z z z z F7 PS764 Gearbox SYSTEM z z z z F8 PS750 Gearbox z z z z z z F9 PS750 Mk...

Page 15: ...YSTEM S1 z z G2 Twin Axle Service Brakes SYSTEM S2 z z z z G3 External Park Brake SYSTEM PS750 gearbox z z z z z z G4 Internal Park Brake SYSTEM PS760 gearbox z z z z G5 Park Brake Calliper PS750 gear...

Page 16: ...5AM 535 125 HiViz 5AN 535 140 HiViz 5AP H1 Steering SYSTEM z z z z z z H2 Manual Steer Mode SYSTEM z z z z z z H3 Auto Steer Mode SYSTEM z z z z z z H4 Hydraulic Steering Unit z z z z z z H5 Priority...

Page 17: ...ld Start Heater SYSTEM Mechani cal F I Engines z z z z z z K4 Starter Motor z z z z z z K5 Cooling Pack Non Intercooled z z z K6 Cooling Pack Intercooled Mechanical F I Engines z z z z z z K7 Cooling...

Page 18: ...170 5AF 550 140 5AG 540 140 5AL 550 170 5AM 535 125 HiViz 5AN 535 140 HiViz 5AP M1 CANbus SYSTEM z z z z z z M2 Loadall Monitoring SYSTEM z z z z z z M3 Fault Code SYSTEM z z z z z z M4 Servicemaster...

Page 19: ...mation about the structure of the manual and how to use the manual K Scope T 1 2 2 K Personnel T 1 2 2 K Applications T 1 2 2 K Newest Data T 1 2 2 K Format T 1 2 3 K Left and Right Sides T 1 2 4 K Hy...

Page 20: ...nd general techniques associated with the maintenance and repair of hydraulic earthmoving equipment Finally please remember above all else SAFETY MUST COME FIRST Applications This manual contains data...

Page 21: ...et of data about a machine SYSTEM or Device Some topics are only applicable to some machine models Use the Applications Tables in this section to see which topic is applicable to which machine model E...

Page 22: ...n 1 2 General Information Use Left and Right Sides 1 2 4 1 2 4 9803 3750 05 1 01 00 Left and Right Sides Left Hand and Right Hand are as viewed from the rear of the machine facing forwards ProCarManua...

Page 23: ...ion of a service Depending on application this may be anything between neutral circuit pressure and LSRV operating pressure Pink Pressure Pressure that is above neutral circuit pressure but lower than...

Page 24: ...tem is used in this manual Each main category of devices is given a code type Each device is given one code and the code is used throughout the manual The same code is given to both the device and its...

Page 25: ...d on the machine devices there are identification data plates K Related Topics T 1 3 2 K Machine Identification Plate T 1 3 3 K Typical Product Identification Number PIN T 1 3 3 K Component Identifica...

Page 26: ...information related to this topic Refer to the applicable topics to complete your procedures Where applicable the text in this section contains cross references to this page to help you find the corre...

Page 27: ...number being quoted when replacement parts are ordered The machine and engine serial numbers can help identify exactly the type of equipment you have 420811 Fig 1 Typical Product Identification Number...

Page 28: ...box Model 1 Digit 5 Randomly generated check letter 1 Digit 6 Machine Serial Number 8 Digits Each machine has a unique serial number Standard Builds 5AF 540 170 5AM 550 170 5AG 550 140 5AN 535 125 HiV...

Page 29: ...cludes the engine identification number 2E A typical engine identification number is explained as follows 1 Engine Type SD turbocharged SE electronic common rail fuel injection turbocharged and interc...

Page 30: ...3750 05 1 02 01 Transmission Identification Numbers The transmission components have a serial number stamped on a data plate A as shown A710840 C1 Fig 3 Front Axle A710830 C1 Fig 4 Rear Axle 263370 C...

Page 31: ...ines built to ROPS FOPS standards have an identification label A fitted to the inside of the cab Machines built to ROPS FOPS and OECD standards have identification label B fitted to the inside of the...

Page 32: ...Section 1 3 General Information Machine Identification Component Identification Plates 1 3 8 1 3 8 9803 3750 05 1 02 01 Page left intentionally blank ProCarManuals com...

Page 33: ...us 3 Torque figures are given for fasteners with different surface treatments Make sure you use the correct torque figures Where torques are given in topics within the other sections always use these...

Page 34: ...ted bolt Note All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification Note Dacromet bolts due to their high corrosion resistance are used in...

Page 35: ...7 0 18 0 130 5 3 4 19 0 1 1 8 343 0 35 0 253 0 309 0 31 5 227 9 7 8 22 2 1 15 16 547 0 55 8 403 4 492 0 50 2 362 9 1 25 4 1 1 2 814 0 83 0 600 4 732 0 74 6 539 9 1 1 8 31 7 1 7 8 1181 0 120 4 871 1 10...

Page 36: ...20 20 30 562 0 57 3 414 5 506 0 51 6 373 2 M24 24 36 971 0 99 0 716 9 874 0 89 1 644 6 M30 30 46 1930 0 196 8 1423 5 1737 0 177 1 1281 1 M36 36 55 3374 0 344 0 2488 5 3036 0 309 6 2239 2 Bolt Size Hex...

Page 37: ...t Size Nm kgf m lbf ft ISO Metric Thread mm M3 3 1 2 0 1 0 9 M4 4 3 0 0 3 2 0 M5 5 6 0 0 6 4 5 M6 6 10 0 1 0 7 5 M8 8 24 0 2 5 18 0 M10 10 48 0 4 9 35 5 M12 12 82 0 8 4 60 5 Bolt Size Nm kgf m lbf ft...

Page 38: ...e Hexagon A F Nm kgf m lbf ft in mm 1 4 19 0 18 0 1 8 13 0 3 8 22 0 31 0 3 2 23 0 1 2 27 0 49 0 5 0 36 0 5 8 30 0 60 0 6 1 44 0 3 4 32 0 81 0 8 2 60 0 1 38 0 129 0 13 1 95 0 1 1 4 50 0 206 0 21 0 152...

Page 39: ...ill vary depending upon the torque applied Table 10 BSP Hose Torque Settings BSP Hose Size Hexagon A F Nm kgf m lbf ft in mm 1 8 14 0 14 0 16 00 1 4 1 6 10 3 11 8 1 4 19 0 24 0 27 0 2 4 2 7 17 7 19 9...

Page 40: ...onent Connections with Bonded Washers Table 11 BSP Adaptors with Bonded Washers Torque Settings BSP Size Nm kgf m lbf ft in 1 8 20 0 2 1 15 0 1 4 34 0 3 4 25 0 3 8 75 0 7 6 55 0 1 2 102 0 10 3 75 0 5...

Page 41: ...being damages as a result of over tightening Torque Stop Hoses have an additional shoulder 3 D which acts as a physical stop Note Minimum dimension 3 E fixed by shoulder 3 D Table 12 BSP Torque Stop H...

Page 42: ...adaptor Note that the washer should not move freely if the washer is slack do not use the adaptor 3 Check the O ring 4 A is fitted and that it is free from damage or nicks Before fitting the adaptor s...

Page 43: ...e from JCB Service or in some instances can be manufactured locally from the specifications given in this section Note Tools other than those listed will be required It is expected that such general t...

Page 44: ...reference for content K Fig 1 T 1 5 5 320 20050 Engine Lifting Bracket Kit K Fig 63 T 1 5 22 332 E7911 Exhaust fitting clamp K Fig 61 T 1 5 21 4104 1310 Hand Cleaner K Fig 15 T 1 5 8 460 15708 Flow Te...

Page 45: ...8 Ram Protection Sleeve for 40 mm Rod Diameter K Fig 53 T 1 5 20 892 01019 Ram Protection Sleeve for 50 mm Rod Diameter K Fig 53 T 1 5 20 892 01020 Ram Protection Sleeve for 50 mm Rod Diameter K Fig 5...

Page 46: ...K Fig 55 T 1 5 20 992 09900 Hexagon Spanner 115 mm A F K Fig 55 T 1 5 20 992 10000 Hexagon Spanner 125 mm A F K Fig 55 T 1 5 20 992 12300 12V Mobile Oven K Fig 11 T 1 5 7 992 12400 24V Static Oven 2...

Page 47: ...01105A M10 x 26 mm Rivet Nut 2 Installation Tool available from Bollhoff Fastenings Ltd www bollhof com Fig 2 993 68100 Slide Hammer Kit 1 993 68101 Slide Hammer 7 993 68107 Bar M20 x M20 X 800 mm 2 9...

Page 48: ...prior to installation Fig 5 892 00845 Cartridge Gun Hand operated Essential for the application of sealants polyurethane materials etc Fig 6 892 00846 Glass Extractor Handles Used with braided cutting...

Page 49: ...Unit quantity 500 off Fig 11 992 12300 Mobile Oven 12V 1 cartridge capacity Required to pre heat adhesive prior to use It is fitted with a male plug 703 23201 which fits into a female socket 715 04300...

Page 50: ...moval of polyurethane adhesives 454g 1 lb tub Fig 16 992 01100 Glazing Tool used to insert aperture seal expansion strip Fig 17 892 00844 Long Knife Used to give extended reach for normally inaccessib...

Page 51: ...General Information Service Tools Tool Detail Reference 1 5 9 1 5 9 9803 3750 05 1 06 00 Fig 21 892 00905 LMI Test Box For testing load moment indicator system Fig 22 993 85700 Battery Tester ProCarM...

Page 52: ...ay Pin Housing 5B 7214 0004 4 Way Pin Retainer 5C 7214 0003 4 Way Socket Retainer 5D 7214 0001 4 Way Socket Connector 6A 7216 0002 6 Way Pin Housing 6B 7216 0004 6 Way Pin Retainer 6C 7216 0003 6 Way...

Page 53: ...Service Tools Tool Detail Reference 1 5 11 1 5 11 9803 3750 05 1 06 00 Fig 25 892 00349 Crimp Tool Fig 26 Splice 892 00351 Splice 0 5 1 5 mm Red 892 00352 Splice 1 5 2 5 mm Blue 892 00353 Splice 3 0...

Page 54: ...P 892 00271 Adapter 3 4 in F x 5 8 in M BSP 892 00272 Adapter 5 8 in F x 3 4 in M BSP 816 20008 Adapter 3 4 in F x 1 2 in M BSP 892 00275 Adapter 1 2 in F x 3 4 in M BSP 892 00276 Adapter 3 4 in F x 3...

Page 55: ...uge Fig 30 998 11051 JCB ServiceMaster Digital Hydraulic Datalogger Pressure Test Kit 998 11052 Hand Held 4 Channel ServiceMaster Unit 998 11053 SensoWin Software Kit and PC Cable 998 11054 Equiment C...

Page 56: ...x 3 8 in 1606 0015 1 in x 1 1 4 in Fig 33 Pressure Test Adapters 892 00255 1 4 in BSP x Test Point 892 00256 3 8 in BSP x Test Point 892 00257 1 2 in BSP x Test Point 892 00258 5 8 in BSP x Test Point...

Page 57: ...ig 36 Female Blanking Caps 892 00055A 1 4 in BSP 892 00056A 3 8 in BSP 892 00057 1 2 in BSP 892 00058A 5 8 in BSP 892 00059A 3 4 in BSP 892 00060 1 in BSP Fig 37 Male Cone Blanking Caps 816 90045 1 4...

Page 58: ...Micro bore Hose 1 4 in BSP x 3 metres 892 00274 Adapter 1 4 in M BSP x 3 8 in M BSP Taper 892 00262 1 4 in M BSP x 1 4 in F BSP x Test Point 892 00706 Test Probe 892 00278 Gauge 0 40 bar 0 600 lbf in...

Page 59: ...460 15707 Banjo bolt 2 2401 0222 O ring 3 2403 0110 O ring 4 2403 0108 O ring 5 1604 0004 Adaptor 2 off 6 1406 0018 Sealing washer 2 off A313250 C1 1 3 4 2 6 5 Fig 47 892 00301 Flow Test Adaptor Note...

Page 60: ...nfoss Orbitrol Unit 892 00181 Replacement Plastic Boss Fig 51 Ram Piston Nut Removal Fitting Spanner 993 99512 Spanner 55 mm A F 993 99513 Spanner 60 mm A F 993 99514 Spanner 65 mm A F 993 99515 Spann...

Page 61: ...Nut Removal Fitting Rig 993 99525 Rig Assembly not including spanners and ram 993 99522 Anchor Side Plate supplied loose unwelded 993 99523 Anchor Cross Member supplied loose unwelded 993 99524 Ram E...

Page 62: ...01022 For 60 mm Rod Diameter slew ram 892 01023 For 65 mm Rod Diameter 892 01024 For 70 mm Rod Diameter 892 01025 For 75 mm Rod Diameter 892 01026 For 80 mm Rod Diameter 892 00167 For 90 mm Rod Diame...

Page 63: ...5 1 06 00 Fig 57 992 04000 Torque Multiplier Fig 58 892 00822 Splined Bolt Socket Fig 59 892 00812 Drive Coupling Spanner Fig 60 892 00893 Torque Converter Alignment Tool For use with 11 torque conver...

Page 64: ...22 1 5 22 9803 3750 05 1 06 00 Fig 63 320 20050 Lifting Bracket Kit Fig 64 892 01174 Data Link Adaptor Kit A USB PC Cable 718 20235 B Serial PC Cable 718 20236 C USB DLA 728 26500 D Machine Cable 718...

Page 65: ...tions T 1 5 23 to determine the size of rivet nut to be used for particular applications If for any reason a new rivet nut requires fitting then the correct installation procedure must be followed K F...

Page 66: ...Wind the body of the installation tool down the threaded mandrel until it touches the head of the rivet nut 67 B Fig 67 4 Insert the rivet nut assembled to the tool into the hole drilled in step 1 5 H...

Page 67: ...ins Fitting Procedure 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 69 A as shown...

Page 68: ...Section 1 5 General Information Service Tools Slide Hammer Kit 1 5 26 1 5 26 9803 3750 05 1 06 00 Page left intentionally blank ProCarManuals com...

Page 69: ...ice Consumables Introduction Consumables such as sealing and retaining compounds are necessary to complete some procedures Before you start work make sure that the consumables show in the tables are a...

Page 70: ...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 4101 0552 200 ml JCB T...

Page 71: ...ing engine related faults find out what types and sources of fuel are used by the operator K Related Topics T 1 7 2 K Acceptable and Unacceptable Fuels T 1 7 3 K Additives T 1 7 4 K Service Requiremen...

Page 72: ...omplete your procedures Where applicable the text in this section contains cross references to this page to help you find the correct information Some machines have different systems and devices Make...

Page 73: ...Additives T 1 7 4 MIL T38219 XF63 NATO F63 French EN590 RME5 with 5 maximum AVTURFSII NATO F34 JP8 MIL T83133 DERD 2463 DEF STAN 91 87 SE SD SF Engines Engines operated with these fuels will have a re...

Page 74: ...nce related issues Make sure the fuel is stored correctly care must be taken to make sure no water enters the machine fuel tank or the storage tank Water will encourage micro bacterial growth Make sur...

Page 75: ...or equivalent This fuel has totally replaced automotive road use diesel in the European Union since October 1996 and has sulphur limited to a maximum of 0 05 by weight 3 Ultra Low Sulphur Diesel Refo...

Page 76: ...ls FAME VOME These fuels have been derived from a wide range of vegetable oils and animal fats resulting in better stability viscosity and cetane number than those produced from unmodified vegetable o...

Page 77: ...requirements K Service Requirements for use of B20 Biodiesel T 1 7 4 If the recommended actions are not taken there may be the following consequences low temperature filter clogging injectors lacquer...

Page 78: ...poor storage or careless handling and will almost inevitably condense in fuel tanks The smallest amounts of water can result in effects that are just as disastrous to the fuel injection pump as dirt c...

Page 79: ...l speed test is a very useful way to quickly and easily determining if the engine transmission or hydraulic system is faulty Do the stall speed tests to help diagnose which system is at fault Refer to...

Page 80: ...opics to complete your procedures Where applicable the text in this section contains cross references to this page to help you find the correct information Some machines have different systems and dev...

Page 81: ...hat have done a minimum of 250 working hours therefore they should not be used for pre delivery inspection PDI checks All figures are recorded with the transmission oil at 60 C 140 F and the hydraulic...

Page 82: ...Section 1 8 General Information Stall Speed Combinations Specifications 1 8 4 1 8 4 9803 3750 05 1 15 01 Page left intentionally blank ProCarManuals com...

Page 83: ...lication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section 2 Care and Safety Service Manua...

Page 84: ...Section 2 Care and Safety 2 0 2 0 9803 3750 05 Notes ProCarManuals com...

Page 85: ...Related Topics 2 2 2 Parking the Machine and Making it Safe 2 2 3 Boom Safety Strut 2 2 4 Venting Hydraulic Pressure 2 2 7 Connecting Disconnecting Hydraulic Hoses 2 2 8 Quick Release Couplings 2 2 9...

Page 86: ...If proper precautions are not taken it is highly probable that the operator or others could be killed or seriously injured INT 1 2 1 MWARNING Denotes a hazard exists If proper precautions are not take...

Page 87: ...damaged or becomes unreadable Safety Warnings In this publication and on the machine there are safety notices Each notice starts with a signal word The signal word meanings are given below MDANGER Den...

Page 88: ...fe If you are unsure of anything about the machine or the job ask someone who knows Do not assume anything Remember BE CAREFUL BE ALERT BE SAFE Common Rail SE Engine Specific In addition to the genera...

Page 89: ...f safety procedures and practices relating to a common rail SE engine SAFETY IS YOUR RESPONSIBILITY Do make sure the engine and surrounding area has been thoroughly cleaned prior to completing any mai...

Page 90: ...coholic drinks or take drugs before or while operating the machine or attachments Be aware of medicines which can cause drowsiness INT 1 3 9_2 MWARNING Feeling Unwell Do not attempt to operate the mac...

Page 91: ...t use the machine if there is lightning in your area 5 1 1 2 MWARNING Machine Modifications This machine is manufactured in compliance with legislative and other requirements It should not be altered...

Page 92: ...0_2 MWARNING You could be killed or seriously injured if you operate a machine with a damaged or missing ROPS FOPS If the Roll Over Protection Structure ROPS Falling Objects Protection Structure FOPS...

Page 93: ...cal regulations which affect you and your machine INT 1 3 3 MWARNING Practice You or others can be killed or seriously injured if you do unfamiliar operations without first practising them Practise aw...

Page 94: ...rranty 2 4 5 2_1 MWARNING 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 se...

Page 95: ...ng turns 5 1 5 4 MWARNING Entering Leaving Entering or leaving the cab or canopy must only be made where steps and handrails are provided Always face the machine when entering and leaving Make sure th...

Page 96: ...RNING 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 protective glasses and gloves Hold a piece of card...

Page 97: ...nded cleaning agents and solvents INT 3 2 11 MWARNING When using cleaning agents solvents or other chemicals you must adhere to the manufacturer s instructions and safety precautions GEN 1 9 MCAUTION...

Page 98: ...5_3 MWARNING 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 GEN 1 12 MWARNING To avoid...

Page 99: ...ARNING Accumulators The accumulators contain hydraulic fluid and gas at high pressure Prior to any work being carried out on systems incorporating accumulators the system pressure must be exhausted by...

Page 100: ...3 1 7_1 MCAUTION 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...

Page 101: ...sure you wear them when reading the safety labels Do not over stretch or place yourself in dangerous positions to read the safety labels If you do not understand the hazard shown on the safety label t...

Page 102: ...cedures K Parking the Machine and Making it Safe T 2 2 3 K Boom Safety Strut T 2 2 4 K Installing T 2 2 4 K Removing T 2 2 6 K Venting Hydraulic Pressure T 2 2 7 K Connecting Disconnecting Hydraulic H...

Page 103: ...formation related to this topic Refer to the applicable topics to complete your procedures Where applicable the text in this section contains cross references to this page to help you find the correct...

Page 104: ...t the hydraulic pressure K Venting Hydraulic Pressure T 2 2 7 6 Remove the starter key 7 Let the machine cool sufficiently before you do work on or near to the engine or hydraulic system 8 If procedur...

Page 105: ...key MCAUTION You will have to climb onto the machine to fit or remove the strut Take care especially if the machine is wet Remove mud and oil before climbing onto the machine Do not use the exhaust a...

Page 106: ...Section 2 2 Care and Safety General Procedures Boom Safety Strut 2 2 5 2 2 5 9803 3750 05 2 02 01 807540 1 Fig 2 T012120 2 Fig 3 ProCarManuals com...

Page 107: ...the boom to remove the weight from the strut 2 Stop the engine Make sure the park brake is engaged and the transmission is in neutral Remove the starter key MCAUTION You will have to climb onto the m...

Page 108: ...procedure 1 Park the machine and make it safe K Parking the Machine and Making it Safe T 2 2 3 2 If necessary install the boom safety strut K Boom Safety Strut T 2 2 4 Stop the engine 3 Carefully remo...

Page 109: ...e can penetrate the skin Keep face and hands well clear of fluid under pressure and wear protective glasses and gloves Hold a piece of cardboard close to suspected leaks and then inspect the cardboard...

Page 110: ...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...

Page 111: ...ke sure that ball 4 C in the female coupling is located in one of its slots 4 Fit the male coupling into the female coupling To ensure that the coupling is not accidentally released rotate sleeve 4 E...

Page 112: ...nce lower discharges Wear particles generated will circulate with the hydraulic fluid to cause further deterioration in the performance of this and other equipment Contaminants also enter principal sl...

Page 113: ...m 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 obtai...

Page 114: ...Disconnection 1 Get access to the battery See K Related Topics T 2 2 2 2 Remove the leads Disconnect the earth terminal first Connection 1 Check the battery a If the terminal is dirty clean the post 7...

Page 115: ...Renewal of oil seals gaskets etc and any component showing obvious signs of wear or damage is expected as a matter of course It is expected that components will be cleaned and lubricated where approp...

Page 116: ...will result in damage to the regulator or rectifying diodes 3 Main output cables are live even when the engine is not running Take care not to earth connectors in the moulded plug if it is removed fro...

Page 117: ...using is suitable or not c The number one cause of ram oil leakage is rod damage Be careful not to damage the rod 2 Warm up sufficiently before beginning work a In cold conditions the rod seals may be...

Page 118: ...s still installed on the machine can be dangerous as unexpected movements of the machine can occur Remove the ram from the machine and then dismantle b If reassembled with dirty hands foreign matter c...

Page 119: ...Section 2 2 Care and Safety General Procedures Hydraulic Rams 2 2 18 2 2 18 9803 3750 05 2 02 01 Page left intentionally blank ProCarManuals com...

Page 120: ...cation No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section 3 Routine Maintenance Service Man...

Page 121: ...Section 3 Routine Maintenance 3 0 3 0 9803 3750 05 Notes ProCarManuals com...

Page 122: ...oduction 3 5 2 Preparing the Machine for Cleaning 3 5 3 Cleaning the Machine 3 5 4 Inspection Checking for Damage 3 6 1 Seat Belts Checking the Seat Belt Condition and Security 3 7 1 ROPS FOPS and OEC...

Page 123: ...0 Hydraulic System Related Topics 3 16 1 Oil and Filters 3 16 2 Hose Burst Protection Valves 3 16 6 Transmission Related Topics 3 17 1 Gearbox 3 17 2 Front and Rear Axle 3 17 4 Tyres and Wheels Tyre I...

Page 124: ...icants filters and contaminated materials must be disposed of in accordance with local regulations Use authorised waste disposal sites INT 3 2 14 All waste products should be disposed of in accordance...

Page 125: ...ith water for 15 minutes If irritation persists get medical attention Swallowing If oil is swallowed do not induce vomiting Get medical advice Skin In the case of excessive skin contact wash with soap...

Page 126: ...it the positive lead first 5 3 4 12 MCAUTION Do not disconnect the battery while the engine is running otherwise the electrical circuits may be damaged INT 3 1 14 MWARNING Electrical Circuits Understa...

Page 127: ...t medical help 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 Flush with water...

Page 128: ...r to the applicable topics to complete your procedures Where applicable the text in this section contains cross references to this page to help you find the correct information Some machines have diff...

Page 129: ...gular check on the hourmeter readings to correctly gauge service intervals Do not use a machine which is due for a service Make sure any defects found during the regular maintenance checks are rectifi...

Page 130: ...Check Water Separator and Engine Fuel Filter Drain Water Separator Fuel Filter 6 Change Engine Fuel Filter 6 Change Front End Accessory Drive FEAD Belt Condition Check Front End Accessory Drive FEAD...

Page 131: ...ity Front Hub Bearings Check Wheel Nut Security Check Tyre Pressures Condition Check Wheel Alignment Check Transmission Strainer Clean Drive Shafts and Universal Joints 10 Security and Grease Axle Piv...

Page 132: ...heck REGISTRATION CERTIFICATION SWL Stickers UK and Flip Chart Renew as Required 1 First 100 Hours Service only to be completed by your JCB Distributor 2 If operating under arduous conditions do an en...

Page 133: ...any bedding in wear This is particularly important if new brake plates have been fitted 10 The axles and driveshafts are factory greased with a high performance grease if during service a standard gre...

Page 134: ...RING Steering Operation Phasing Check 2WD 4WD Selection if fitted Check Transmission Operation Check Forward Reverse Gear Selection Operation Check Torque Converter Main Line Pressure 2 Check Neutral...

Page 135: ...l Equipment Operation warning lights beacon alarms horn wipers etc Check Load Moment Indicator 2 Check Calibrate Stabilizer Indicators Check BODYWORK AND CAB Inclinometer if fitted 2 Check Glazing for...

Page 136: ...complete your procedures Where applicable the text in this section contains cross references to this page to help you find the correct information Some machines have different systems and devices Mak...

Page 137: ...ely Calendar Equivalents Note Services should be carried out at either the hourly interval or calendar interval whichever occurs first How to Use the Service Schedules In the example shown A shows all...

Page 138: ...for contamination and Drain Water Separator Fuel Filter 6 Change Engine Fuel Filter 6 Change Front End Accessory Drive FEAD Belt Condition Check Front End Accessory Drive FEAD Belt Change Powertrain...

Page 139: ...Drive Shafts and Universal Joints 10 Security and Grease Axle Pivots and Linkages 10 Grease HYDRAULICS Oil Level Check Oil 7 Sample Change Oil Filter 11 Change Suction Strainer Clean Pilot Filter if...

Page 140: ...filter every 250 hours Refer to Fuel System for more information 5 More frequently if operating in dusty working environments 6 If the engine is difficult to start or the engine has poor performance...

Page 141: ...on Operation Check Forward Reverse Gear Selection Operation Check Torque Converter Main Line Pressure 2 Check Neutral Start Operation Check Clutch Disconnect Dump Button Check HYDRAULICS MRV Pressure...

Page 142: ...arms horn wipers etc Check Load Moment Indicator 2 Check Stabiliser Indicators Check BODYWORK AND CAB Inclinometer if fitted 2 Check Glazing for Correct Fit Leaks Check Seat Seat Belts Check Air Condi...

Page 143: ...Section 3 3 Routine Maintenance Service Schedules Machines with SE Engines Introduction 3 3 8 3 3 8 9803 3750 05 3 21 00 Page left intentionally blank ProCarManuals com...

Page 144: ...applicable topics to complete your procedures Where applicable the text in this section contains cross references to this page to help you find the correct information Some machines have different sys...

Page 145: ...CH 4 SJ 4001 2700 MIN 12 5 2 75 MAX 15 3 3 Engine Coolant All Engines 22 4 4 JCB High Performance Antifreeze and Inhibitor Water K Coolant Mixtures T 3 4 4 ASTM D6210 4006 1100 Transmission JCB Extrem...

Page 146: ...more appropriate for heavy duty applications such as sustained high loads and operation at elevated temperatures 3 Friction modified oils must not be used e g Dexron ATF type 4 Must be suitable for u...

Page 147: ...er authority 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 Perform...

Page 148: ...edures Where applicable the text in this section contains cross references to this page to help you find the correct information Some machines have different systems and devices Make sure you refer to...

Page 149: ...the paint finish may occur Always adhere to local regulations regarding the disposal of debris created from machine cleaning Pressure Washing and Steam Cleaning MCAUTION Never use water or steam to c...

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