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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

9803-9390-2

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

Groundhog 6x4

Section 1 - General Information

Section 2 - Care and Safety

Section 3 - Routine Maintenance

Section A - Optional Equipment

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

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3
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Summary of Contents for Groundhog 6x4

Page 1: ...0 2 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 Groundhog 6x4 Sec...

Page 2: ...ENT DOWNLOAD FROM www repair manuals com MEMBERSHIP ACCOUNT HOLDERS CAN DOWNLOAD ALL MANUALS WITHOUT ANY ADDITIONAL COST THE LARGEST PDF MANUALS COMPLEX FOR HEAVY MECHANICAL TECHNICIANS EXPLORE AVAILA...

Page 3: ...0 2 Publication No 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 Se...

Page 4: ...Section 1 General Information 1 0 1 0 9803 9390 2 Notes...

Page 5: ...duction About this Publication 1 1 Machine Identification Identifying Your Machine 1 3 Torque Settings Zinc Plated Fasteners and Dacromet Fasteners 1 5 Hydraulic Connections 1 9 Service Tools Numerica...

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

Page 7: ...n sections the first three are numbered and contain information as follows 1 General Information includes torque settings and service tools 2 Care Safety includes warnings and cautions pertinent to as...

Page 8: ...Section 1 General Information Introduction About this Publication 1 2 1 2 9803 9390 2 Page left intentionally blank...

Page 9: ...the new serial number in place of the old one Fig 1 Typical Vehicle Identification Number VIN 1 World Manufacturer Identification 2 Machine Model 3 Year of Manufacture 4 2004 5 2005 6 2006 7 2007 4 Ma...

Page 10: ...Section 1 General Information Machine Identification Identifying Your Machine 1 4 1 4 9803 9390 2 Page left intentionally blank...

Page 11: ...llow plated 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...

Page 12: ...77 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 1...

Page 13: ...M20 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 H...

Page 14: ...lt 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 15: ...ze 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 16: ...D will 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...

Page 17: ...mponent 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...

Page 18: ...ng being damages as a result of over tightening Torque Stop Hoses have an additional shoulder 4 D which acts as a physical stop Note Minimum dimension 4 E fixed by shoulder 4 D Table 12 BSP Torque Sto...

Page 19: ...d here For full details of all tools including the content of kits and sets see the relevant section in this manual Note Tools other than those listed will be required It is expected that such general...

Page 20: ...Section 1 General Information Service Tools Numerical List 1 14 1 14 9803 9390 2 Page left intentionally blank...

Page 21: ...gh 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 Thre...

Page 22: ...Section 1 General Information Consumables Sealing and Retaining Compounds 1 16 1 16 9803 9390 2 Page left intentionally blank...

Page 23: ...390 2 Publication 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 Sect...

Page 24: ...Section 2 Care and Safety 2 0 2 0 9803 9390 2 Notes...

Page 25: ...Contents Section 2 Care and Safety 2 i 2 i Safety Notices Introduction 2 1 Safety Checklist 2 2 Safety Yours and Others 2 2 General Safety 2 2 Operating Safety 2 3 Maintenance Safety 2 6 Safety Decal...

Page 26: ...Page No Contents Section 2 Care and Safety 2 ii 2 ii...

Page 27: ...ion and on the machine there are safety notices Each notice starts with a signal word The signal word meanings are given below MDANGER Denotes an extreme hazard exists If proper precautions are not ta...

Page 28: ...rstand anything ask your employer or JCB dealer to explain it Keep the Operator Manual clean and in good condition Do not operate the machine without an Operator Manual in the cab or if there is anyth...

Page 29: ...lidate any of these requirements For advice consult your JCB Distributor INT 1 3 10_2 Operating Safety MWARNING Machine Condition A defective machine can injure you or others Do not operate a machine...

Page 30: ...NT 2 2 3 MWARNING Parking An incorrectly parked machine can move without an operator Follow the instructions in the Operator Manual to park the machine correctly INT 2 2 4_2 MWARNING Banks and Trenche...

Page 31: ...an Do not operate the machine if you cannot see clearly 5 1 4 7 MWARNING Electrical Power Cables You could be electrocuted or badly burned if you get the machine or its attachments too close to electr...

Page 32: ...r areas examples of danger areas are the rotating blades and belt on the engine the attachments and linkages and anywhere beneath or behind the machine People can be killed or injured if these precaut...

Page 33: ...uid at system pressure can injure you Before connecting or removing any hydraulic hose residual hydraulic pressure trapped in the service hose line must be vented Make sure the hose service line has b...

Page 34: ...ts 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 O rings Seals and Gaskets Badly...

Page 35: ...h calcium hydroxide solution for 15 60 minutes Get medical attention immediately INT 3 3 5_2 MWARNING Protect your eyes when grinding metal Wear safety glasses or goggles Remove or protect any combust...

Page 36: ...s and crush you unless the wheels have been chocked Always chock the wheels at the opposite end of the machine that is to be jacked Do not work underneath a machine supported only by jacks Always supp...

Page 37: ...ure replacement parts include warning decals where necessary Keep all decals clean and readable Replace lost or damaged decals Each decal has a part number printed on it use this number to order a new...

Page 38: ...Section 2 Care and Safety Safety Notices Safety Decals 2 12 2 12 9803 9390 2 Page left intentionally blank...

Page 39: ...0 2 Publication 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 Se...

Page 40: ...Section 3 Routine Maintenance 3 0 3 0 9803 9390 2 Notes...

Page 41: ...e Oil Level 3 17 Changing the Oil and Filter 3 17 Engine Cooling System 3 19 Checking the Coolant Level 3 19 Checking Radiator Hoses and Clamps 3 20 Draining Flushing and Refilling the Coolant 3 21 Cl...

Page 42: ...Page No Contents Section 3 Routine Maintenance 3 ii 3 ii...

Page 43: ...drains sewers or the ground Clean up all spilt fluids and or lubricants Used fluids and or lubricants filters and contaminated materials must be disposed of in accordance with local regulations Use au...

Page 44: ...ce vomiting Get medical advice Skin In the case of excessive skin contact wash with soap and water Spillage Absorb on sand or a locally approved brand of absorbent granules Scrape up and remove to a c...

Page 45: ...ff before connecting or disconnecting the battery When you have installed the battery in the machine wait five minutes before connecting it up When reconnecting fit the positive lead first First Aid E...

Page 46: ...othes skin mouth and eyes Wear safety glasses INT 3 2 1_3 MCAUTION Damaged or spent batteries and any residue from fires or spillage should be put in a closed acid proof receptacle and must be dispose...

Page 47: ...e 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 rectified immediately Ta...

Page 48: ...saxle Mounting Bolt Tightness Check CVT Oil Change CVT Oil Level Check ELECTRICS Battery Electrolyte Level Check Battery Charge Condition Check Battery Terminals for Condition and Tightness Check Wiri...

Page 49: ...eed Check and Adjust Exhaust System Security Fouling Check Exhaust Smoke excesssive Check Throttle System and Control cable Check BRAKES Park Brake Operation Check Brake Linkage Check and Adjust ELECT...

Page 50: ...r further information advice on water hardness contact your local water authority The correct concentration of antifreeze protects the engine against frost damage in winter and provides year round pro...

Page 51: ...that the antifreeze complies with International Specification ASTM D6210 Always read and understand the manufacturer s instructions Ensure that a corrosion inhibitor is included Serious damage to the...

Page 52: ...ower washing can cause damage to seals and bearings Do not direct high power water jets at oil seals universal joints or electrical components Inspect steelwork for damage Note damaged paintwork for f...

Page 53: ...nufacturer may be dangerous and will invalidate the ROPS certification 13 1 1 27_1 Access to the ROPS mounting bolts is obtained by raising the load bay 1 Check that mounting bolts 1 A and 1 B are pre...

Page 54: ...ed if the fabric is worn or if the machine has been in an accident Fit a new seat belt every three years 2 3 1 7_1 1 Inspect the seat belts for signs of fraying and stretching Check that the stitching...

Page 55: ...machine must always be greased after pressure washing or steam cleaning Greasing should be done with a grease gun Normally two strokes of the gun should be enough Stop greasing when fresh grease appea...

Page 56: ...stop the engine If the vehicle has a manually operated load bay remove the starter key 2 Raise the load bay If your vehicle has an electric tipper ensure that the starter key is removed 3 Apply lubri...

Page 57: ...he equipment a Use only an air supply system which includes a pressure regulator Set the regulator no higher than 1 38 bar 20 psi above the recommended tyre pressure For recommended tyres and pressure...

Page 58: ...oved 3 Undo the two retaining clips 6 A holding the cover and remove the element Do not tap or knock the element as you remove it 4 Clean the inside of the canister 6 B and dust valve 6 C 5 Prior to f...

Page 59: ...contaminants held in suspension will then be drained with the oil Note To gain access to the filter you will first need to make the machine safe and raise the load bay K Checking the Oil Level T 3 17...

Page 60: ...ew filter with oil Screw in the new filter hand tight only 3 Fill the System Fill the engine to the upper mark on the dipstick with new oil through the filler K Checking the Oil Level T 3 17 For recom...

Page 61: ...ly check that the level of the coolant in the expansion bottle is between the two pipes 10 A and 10 B If the level is low then continue with steps 4 to 6 MWARNING Antifreeze can be harmful Obey the ma...

Page 62: ...ngine Cooling System 3 20 3 20 9803 9390 2 Checking Radiator Hoses and Clamps Periodically inspect the condition of the hoses 11 Aand check that the clamps and connections 11 B are secure and free fro...

Page 63: ...remove this using a suction device or by removing the radiator 5 Refit the bottom hose 12 1 6 Prepare a suitable mixture of water and sodium carbonate or a commercially available alternative 7 Fill th...

Page 64: ...lectric tipper ensure that the starter key is removed 3 For further access you can remove the air inlet grille if necessary as shown MWARNING Make sure the engine cannot be started Disconnect the batt...

Page 65: ...turn the engine by pulling the fan or fan belt This could cause injury or premature component failure 0094 3 Inspect the belt for damage and wear Renew the belt if necessary Note If applicable fit the...

Page 66: ...r this fuel may reduce the life of the fuel injection equipment The use of this fuel may also affect the engine performance GEN 9 3 ASTM D975 91 Class 1 1DA JP7 MIL T38219 XF63 NATO F63 Sulphur Conten...

Page 67: ...follow these precautions INT 3 2 2_1 Petrol MWARNING Petrol Do not use petrol in this machine Do not mix petrol with the diesel fuel in storage tanks the petrol will rise to the top and form flammabl...

Page 68: ...ap 15 A 4 Support the bowl 15 B and unscrew bolt 15 C Remove the bolt 15 C remove and discard washer15 D and O ring 15 E 5 Remove filter element 15 F bowl 15 B and base 15 G as a unit 6 Discard O ring...

Page 69: ...c which could get caught in rotating parts When the engine is turning keep clear of rotating parts 2 3 3 10 1 Raise the load bay 2 To bleed air from the filter slacken bleed screw 16 A Operate fuel pr...

Page 70: ...bay 3 Remove dipstick 17 1 wipe it clean then screw it fully back into the transaxle case Remove the dipstick again and check the level which should be within the hatched area Top up if required throu...

Page 71: ...s removed Hot oil and engine components can burn you Keep to one side when you remove the plug 13 3 1 15 3 Place a container that can hold at least 4 5 litres 0 99 UK gal beneath drain plug 18 1 Remov...

Page 72: ...ting equipment to raise the machine far enough to block the wheels clear of the ground Raise the load bay Do the following for both chains 1 Rotate the rear wheels towards each other to bring all the...

Page 73: ...sen the four fasteners 20 A On each side of the machine turn adjuster 20 B to take up the slack in the chain Adjust until the tension on both sides are equal and within limits Evenly tighten fasteners...

Page 74: ...rate climate applications should not need topping up However in certain conditions such as prolonged operation at tropical temperatures or if the alternator overcharges the electrolyte level should be...

Page 75: ...Section 3 Maintenance Routine Maintenance Fuses 3 33 3 33 9803 9390 2 Fuses See Fuses and Relays Section C...

Page 76: ...battery starter problems contaminated or loose wiring connection Improper viscosity of engine oil Inspect and replace as necessary Possible seizure in engine Repair 1 1 Indicates jobs which should be...

Page 77: ...t Cause Remedy Defective fuel injection pump Adjust or replace if necessary 1 1 Indicates jobs which should be done by a specialist Refer to Engine Service Manual Improper spray from fuel injection no...

Page 78: ...eshooting 3 36 3 36 9803 9390 2 Table 11 Abnormal noise fuel or mechanical Table 12 Engine oil filter Cause Remedy Bad fuel Replace Damage inside silencer Replace Cause Remedy Engine oil dirty Replace...

Page 79: ...ective thermostat Replace Defective water pump Replace Dirty radiator clogged Clean Defective monitor Replace Message Cause Remedy LOW OIL PRESSURE Low engine oil Refill Oil leakage at connections Rep...

Page 80: ...Section 3 Maintenance Routine Maintenance Troubleshooting 3 38 3 38 9803 9390 2 Page left intentionally blank...

Page 81: ...0 2 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section A Optional Equipment Sec...

Page 82: ...Section 1 General Information 1 0 1 0 9803 9390 2 Notes...

Page 83: ...Page No Contents Section A Optional Equipment A i A i Optional Equipment Vehicle Options A 1 Roll Over Protection Structure ROPS A 2 Removal and Replacement A 2...

Page 84: ...Page No Contents Section A Optional Equipment A ii A ii...

Page 85: ...Equipment A 1 A 1 9803 9390 2 Optional Equipment Vehicle Options Fig 1 A Roll Over Protection Structure ROPS D Deluxe Lighting Worklights Beacon B Load Bay Steel or Moulded Plastic E Seat Belts C Tip...

Page 86: ...manufacturer may be dangerous and will invalidate the ROPS FOPS certification INT 2 1 9_6 Fig 2 MWARNING This component is heavy It must only be removed or handled using a suitable lifting method and...

Page 87: ...0 2 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section B Body and Framework Sec...

Page 88: ...Section 1 General Information 1 0 1 0 9803 9390 2 Notes...

Page 89: ...nels and Covers Centre Console B 3 Removal and Replacement B 3 Cooling Pack and System General Description B 5 Removal and Replacement B 6 Cooling Pack B 6 Fuel Tank Removal and Replacement B 9 Remova...

Page 90: ...Page No Contents Section B Body and Framework B ii B ii...

Page 91: ...L A Front End Panel G Fascia Panel B Wheel Fenders H Switch Panel C 1 1 Steel or Moulded Plastic load bay option Load Bay J Roll Over Protection Structure ROPS option D Side Panel Fuel Filler K Engin...

Page 92: ...e frame steel chassis houses the engine and transmission system at the rear of the vehicle beneath the load bay The body panels are moulded plastic construction They are removable to provide access Th...

Page 93: ...Centre Console Removal and Replacement 1 Park the machine on firm level ground 2 Unscrew and remove the control lever knobs 3 Rotate the seats forward to gain improved access to the console fixing sc...

Page 94: ...Section B Body and Framework Body Panels and Covers Centre Console B 4 B 4 9803 9390 2 Page left intentionally blank...

Page 95: ...nting Bracket Upper 7 Top Hose 2 Rubber Grommets 8 Bottom Hose 3 Radiator 9 Vent Overflow Tube 4 Electric Fan Connector 10 Filler Bottle 5 Temperature Switch Fan 11 Pressure Cap 6 Connection Vent Tube...

Page 96: ...ay Ensure that the load bay is properly supported while working beneath it refer to the Handbook 2 Disconnect the battery 3 Drain the coolant see Section 3 Routine Maintenance 4 Remove the centre cons...

Page 97: ...90 2 Fig 3 Replacement Replacement is the reverse of removal but note the following 1 Ensure all hose connections are tight and secure Torque tighten the wormdrive clips to 8 Nm Torque setting for rad...

Page 98: ...Section B Body and Framework Cooling Pack and System Removal and Replacement B 8 B 8 9803 9390 2 Page left intentionally blank...

Page 99: ...ction B Body and Framework B 9 B 9 9803 9390 2 Fuel Tank Removal and Replacement Fig 1 Fuel Tank and Sender Unit A Fuel Tank D Filler Cap B Fuel Gauge Sender Unit E Hose Clips C Filler Neck F Hand Pum...

Page 100: ...sed to gain access to the engine bay Ensure that the load bay is properly supported while working beneath it refer to the Handbook 2 Disconnect the battery before commencing work on the fuel tank 3 Dr...

Page 101: ...onnect the wiring K Fig 3 T B 10 4 Disconnect and plug the hoses 5 Remove the 6 off screws and lift out the fuel sender 6 Remove the gasket and clean the tank surface beneath the sender cover Replacem...

Page 102: ...Section B Body and Framework Fuel Tank Fuel Sender Removal and Replacement B 12 B 12 9803 9390 2 Page left intentionally blank...

Page 103: ...3 9390 2 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section C Electrics Section...

Page 104: ...Section C Electrics C 0 C 0 9803 9390 2 Notes...

Page 105: ...cy C 15 Testing a Diode or a Diode Wire C 16 Battery C 17 Maintenance C 17 First Aid Electrolyte C 17 Testing C 18 Specific Gravity Testing C 19 Alternator C 20 General Description C 20 Service Precau...

Page 106: ...Page No Contents Section C Electrics C ii C ii...

Page 107: ...r 24Ah Cold Cranking Amps EN 200 A Weight 7 8 kg Starter Motor 0 8 kW Alternator Nominal Output 60 Amp Tipper Ram 1 1 Powered tipper machines only Type DC motor driven ball screw linear actuator Bulb...

Page 108: ...t be equipped with all the fuses shown Fig 1 Fuse and Relay Locations Table 1 Secondary Fuse Box A Table 2 Secondary Fuse Box B Option Fig 2 Secondary Fuse Boxes A B P Fuse No Circuit FuseRating Amps...

Page 109: ...ses of different ratings as shown K Table 3 Primary Fuse Box T C 3 Fig 3 Primary Fuse Box Table 3 Primary Fuse Box Relays Fig 4 Relay Decals Table 4 Relays Fuse No Circuit Fuse Rating Amps PO1 Reverse...

Page 110: ...Section C Electrics Technical Data Fuses and Relays C 4 C 4 9803 9390 2 Page left intentionally blank...

Page 111: ...epeater n Trailer Indicator 16 Parkbrake Switch 17 Differential Lock Switch 18 Reverse Alarm 19 Auxiliary Power Supply Socket 20 Main Lighting Switch 21 LH Front Light 22 RH Front Light 23 Horn Switch...

Page 112: ...ht 61 LH Trailer Tail Light 62 Diode 63 Fog Light Switch 64 Fog Light Switch Illumination 65 LH Rear Fog Light 66 RH Rear Fog Light 67 LH Trailer Fog Light 68 RH Trailer Fog Light 69 Work Light Switch...

Page 113: ...C RH TRAILER FOG LIGHT 2 2 EARTH TERMINAL 3A 310E GLOW PLUG IND 001A 8 1 PARKBRAKE BRAKE RELAY 811D 7 2 15A 001G REAR WORK LIGHT 310F 179A FUSE B7 1 LH REAR REVERSE LIGHT 600FP 8 ALTERNATOR CHARGE HAZ...

Page 114: ...Section C Electrics Circuit Schematic Main Components C 8 C 8 9803 9390 2 Page left intentionally blank...

Page 115: ...ferences are given to tables showing kit contents Note Tools other than those listed will be required It is expected that such general tools will be available in any well equipped workshop or be avail...

Page 116: ...0 2 Tool Detail Reference Fig 1 AVO Test Kit AVO Test Kit 1 892 00283 Tool Kit Case 2 892 00298 Fluke Meter 85 3 892 00286 Surface Temperature Probe 4 892 00284 Venture Microtach Digital Tachometer 5...

Page 117: ...Way 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 118: ...Section C Electrics Service Tools Tool Detail Reference C 12 C 12 9803 9390 2 Page left intentionally blank...

Page 119: ...t finding and the use of the recommended test equipment in this case a FLUKE 85 or AVO 2003 digital multimeter or a moving pointer analogue multimeter The approach is based on a fault finding check li...

Page 120: ...2003 Move the right slider switch to position 2 A and the left hand slider switch to the appropriate range c On an analogue meter Turn the dial to the appropriate DC Volts range 2 Connect the black p...

Page 121: ...position 2 B and the left hand slider switch to position 2 C If there is continuity i e very low resistance between two points the buzzer will sound c On an analogue meter Turn the dial to the lowest...

Page 122: ...hand side of the display window b On the AV0 2003 i Move the right hand slider to position 2 A and the left hand slider switch to position 2 C ii Connect the black probe to the end of the diode marke...

Page 123: ...s Do not smoke when handling or working on the battery Keep the battery away from sparks and flames Battery electrolyte contains sulphuric acid It can burn you if it touches your skin or eyes Wear gog...

Page 124: ...read the battery no load voltage which should be at least 12 4 volts 5 Set the CHECK LOAD switch 4 A to LOAD and hold down for 5 10 seconds until the meter reading stabilises The reading should be at...

Page 125: ...sting Readings should be as tabulated and should not vary between cells by more than 0 04 A greater variation indicates an internal fault on that particular cell If the electrolyte temperature is othe...

Page 126: ...les 5 If slave starting is necessary connect the second battery in parallel without disconnecting the vehicle battery from the charging circuit The slave battery may then be safely removed after a sta...

Page 127: ...st Fig 7 1 Ensure that all battery and alternator connections are in place secure and making good metal to metal contact especially the earth connections to chassis and engine 2 Make sure that the alt...

Page 128: ...n or short circuited power stator windings 9 To check for fault a disconnect the capacitor and repeat the charging test Renew the capacitor if necessary 10 To check for faults b and c remove the regul...

Page 129: ...voltmeter across the battery terminals K Fig 8 T C 23 Reading in start position 10 0V approximately Minimum permissible reading in start position 9 5V A low reading probably indicates a fault in the s...

Page 130: ...and starter earth connection 12 B The reading in the start position should be practically zero maximum permissible reading 0 25V If the reading is above 0 25V a high resistance in the earth lead or co...

Page 131: ...K Fig 15 T C 25 identifies the following Table 3 Wire and Harness Number Identification Ident No Description B If applicable The colour of the flying lead that the harness wire should mate with For in...

Page 132: ...ems Wires 600 799 These numbers are used for earth wires When the number is printed onto a wire 16 A it is prefixed by the Earth symbol 16 B This symbol is printed onto the wire it may however be omit...

Page 133: ...is procedure extreme care should be taken when handling the gas heating tool to ensure that the flame does not damage or set fire to any items in the vicinity of the repair i e other wires floor panel...

Page 134: ...tion of the minus sign marked on the ring Fig 19 c Position the tube hanging down from inside the reflector assembly into the hole at the top of the gas cartridge Then press the gas cartridge up into...

Page 135: ...ady for use Note The fact that the sound of liquid cannot be heard when the cartridge is shaken does not mean it is empty No sound will be heard even when the cartridge is full Fig 23 g The heater can...

Page 136: ...Section C Electrics Service Procedures Wiring Harness Repair C 30 C 30 9803 9390 2 Page left intentionally blank...

Page 137: ...ners and lift the grille from the bottom locating plate 3 Disconnect the battery 4 Unplug the tipper ram electrical connector 5 Safely support the load bay MWARNING This component is heavy It must onl...

Page 138: ...Section C Electrics Tipper Ram Removal and Replacement C 32 C 32 9803 9390 2 Page left intentionally blank...

Page 139: ...wing 1 721 11884 Sht 1 1 Basic Harness Layout K Fig 1 T C 34 1 721 11884 Sht 2 1 Basic Harness Connections K Fig 2 T C 35 2 721 11902 Sht 1 3 Deluxe Lighting Harness Layout K Fig 3 T C 36 2 721 11902...

Page 140: ...Section C Electrics Harness Data Drawings and Interconnection C 34 C 34 9803 9390 2 Fig 1 Basic Harness Layout...

Page 141: ...Section C Electrics Harness Data Drawings and Interconnection C 35 C 35 9803 9390 2 Fig 2 Basic Harness Connections...

Page 142: ...Section C Electrics Harness Data Drawings and Interconnection C 36 C 36 9803 9390 2 Fig 3 Deluxe Lighting Harness Layout...

Page 143: ...Section C Electrics Harness Data Drawings and Interconnection C 37 C 37 9803 9390 2 Fig 4 Deluxe Lighting Harness Connections...

Page 144: ...Section C Electrics Harness Data Drawings and Interconnection C 38 C 38 9803 9390 2 Fig 5 Worklight Harness Layout and Connections...

Page 145: ...Section C Electrics Harness Data Drawings and Interconnection C 39 C 39 9803 9390 2 Fig 6 ROPS Worklight Harness Layout and Connections...

Page 146: ...Section C Electrics Harness Data Drawings and Interconnection C 40 C 40 9803 9390 2 Fig 7 Tipper Harness Layout and Connections...

Page 147: ...3 9390 2 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section D Controls Section...

Page 148: ...Section 1 General Information 1 0 1 0 9803 9390 2 Notes...

Page 149: ...Page No Contents Section D Controls D i D i Transmission Controls Forward Reverse Selector D 1 Operation D 1 Differential Lock D 2 Operation D 2...

Page 150: ...Page No Contents Section D Controls D ii D ii...

Page 151: ...n Mechanical linkages connect the selector lever to the transaxle shift arm 9 Note the location of the Neutral Start switch S Fig 1 1 Knob Lever 6 Clevis Pin 2 Selector Lever 7 Clevis Clip 3 Lever Arm...

Page 152: ...Operation The selector is connected via a cable to a lever arm on the transaxle L Fig 2 1 Knob Hand Lever 6 Cable 2 Lever Diff lock Bar 7 Washer 3 Linkage 8 Circlip 4 Bushes 9 1 Washer 5 Pivot Bar 1...

Page 153: ...Section D Controls Transmission Controls Differential Lock D 3 D 3 9803 9390 2 Fig 3 A Cable B Bracket C Arm B A C...

Page 154: ...Section D Controls Transmission Controls Differential Lock D 4 D 4 9803 9390 2 Page left intentionally blank...

Page 155: ...9390 2 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section E Hydraulics Section...

Page 156: ...Section E Hydraulics E 0 E 0 9803 9390 2 Notes...

Page 157: ...Page No Contents Section E Hydraulics E i E i Introduction Note THERE ARE NO HYDRAULICS ON THIS MACHINE E 1...

Page 158: ...Page No Contents Section E Hydraulics E ii E ii...

Page 159: ...Section E Hydraulics E 1 E 1 9803 9390 2 Introduction Note THERE ARE NO HYDRAULICS ON THIS MACHINE...

Page 160: ...Section E Hydraulics Introduction Note THERE ARE NO HYDRAULICS ON THIS MACHINE E 2 E 2 9803 9390 2 Page left intentionally blank...

Page 161: ...Section E Hydraulics Introduction Note THERE ARE NO HYDRAULICS ON THIS MACHINE E 2 E 2 9803 9390 2 Page left intentionally blank...

Page 162: ...9390 2 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section F Transmission Sectio...

Page 163: ...Section F Transmission F 0 F 0 9803 9390 2 Notes...

Page 164: ...ols Numerical List F 3 Tool Detail Reference F 4 General Description Overview F 5 Transaxle F 5 Driver Pulley Removal and Replacement F 7 Replacement F 7 Driven Pulley Removal and Replacement F 9 Repl...

Page 165: ...Page No Contents Section F Transmission F ii F ii...

Page 166: ...fixed the other moveable via centrifugal rollers Driven Clutch Transaxle input shaft mounted Type Fixed ratio gearbox Forward Neutral Reverse Full constant mesh Note The transaxle incorporates two bra...

Page 167: ...Section F Transmission Technical Data Data F 2 F 2 9803 9390 2 Page left intentionally blank...

Page 168: ...s described in this section These tools are available from JCB Service Note Tools other than those listed will be required It is expected that such general tools will be available in any well equipped...

Page 169: ...F Transmission Service Tools Tool Detail Reference F 4 F 4 9803 9390 2 Tool Detail Reference CVT Puller 825 10034 20 8 5 8 UNF THREAD 94 5 150 3 191 1 262 6 9 6 11 1 4 45 X 0 5 R 2 R A A TYP 22 2 SECT...

Page 170: ...due to the belt and its in built clutch spring As the effective diameter of the driver clutch pulley increases the driven pulley becomes smaller The transmission drive ratio therefore varies The tran...

Page 171: ...2 Note The vehicle must be stationary and the engine at idle when the differential lock is being engaged or disengaged or before forward reverse is selected The transaxle incorporates two wet brake pa...

Page 172: ...output shaft D may be removed from the flywheel Loosen and remove the three cap screws and washers E F When replacing torque tighten the screws E progressively to 72 Nm 53 lbf ft Fig 1 Driver Pulley...

Page 173: ...Section F Transmission Driver Pulley Removal and Replacement F 8 F 8 9803 9390 2 Fig 2 A B C025120 Dimension A 55 8 2 mm Dimension B Reference 394 2 2 mm...

Page 174: ...ote the location of the spacer D K Fig 1 T F 9 Fig 1 Replacement Replacement is the reverse of removal but note the following 1 Ensure that the spacer 1 D is fitted 2 Correctly torque tighten fastener...

Page 175: ...Section F Transmission Driven Pulley Removal and Replacement F 10 F 10 9803 9390 2 Page left intentionally blank...

Page 176: ...s shown 1 Remove the R clip A pivot pin B and the lever arm C 2 Remove the two screws D and the bracket E 3 If necessary remove and discard the oil seal F after first draining the transaxle oil Assemb...

Page 177: ...Section F Transmission Transaxle Differential Lock Lever Arm F 12 F 12 9803 9390 2 Page left intentionally blank...

Page 178: ...t axles Although all four axles are the same they should be kept in the same position once fitted This is due to the fit of the splined couplings Note The longest coupling 1 B is on the right hand sid...

Page 179: ...ction F Transmission Axles General F 14 F 14 9803 9390 2 Fig 1 Front Driven Axles A Axle D 1 Circlip B 1 1 Front axles only Splined Coupling Long E 1 Grease Nipple C 1 Splined Coupling Short F Transax...

Page 180: ...nd the rear axles 8 To remove an axle first remove bolts 3 Y 4 off The front axles must be kept horizontal until the hub splines are clear of the couplings 5 G and 5 H Fitting 1 The load bay needs to...

Page 181: ...loat is available Note Thoroughly grease the couplings after assembly see Section 3 Routine Maintenance Fig 4 Fig 5 7 Fit the drive chains to the axle sprockets 8 Adjust the chain tensioning bolts 2 F...

Page 182: ...03 9390 2 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section G Brakes Section 1...

Page 183: ...Section G Brakes G 0 G 0 9803 9390 2 Notes...

Page 184: ...Page No Contents Section G Brakes G i G i Basic System Operation Layout G 1 Technical Data System Type H 3...

Page 185: ...Page No Contents Section G Brakes G ii G ii...

Page 186: ...m Operation Layout Two wet disc brake packs are incorporated within the transaxle Mechanical linkages and cables connect both the foot pedal and park brake lever to the wet disc brakes Note The wet di...

Page 187: ...Section G Brakes Basic System Operation Layout G 2 G 2 9803 9390 2 Page left intentionally blank...

Page 188: ...ages to wet disc brake packs within transaxle operated from footpedal or park brake lever Service Brake Type Oil immersed multi plate disc Actuation Mechanical linkages Location Transaxle casing right...

Page 189: ...Section H Brakes Technical Data System Type H 4 H 4 9803 9390 2 Page left intentionally blank...

Page 190: ...3 9390 2 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section H Steering Section...

Page 191: ...Section H Steering H 0 H 0 9803 9390 2 Notes...

Page 192: ...ustment Wheel Alignment H 5 Rack and Pinion Steering Gear Removal and Replacement H 7 Tie Rod Outer Ball Joints H 7 Universal Joints H 7 Steering Rack Mountings H 8 Replacement H 8 Kingpins Removal an...

Page 193: ...Page No Contents Section H Steering H ii H ii...

Page 194: ...Section H Steering H 1 H 1 9803 9390 2 Technical Data Data System Type Rack and pinion Steering wheel turns lock to lock 1 5...

Page 195: ...Section H Steering Technical Data Data H 2 H 2 9803 9390 2 Page left intentionally blank...

Page 196: ...803 9390 2 General Description Steering System Fig 1 A B C H H D F E G F G C023870 A Steering Column E Clamp B Steering Column Shaft F Tie Rods and Ball Joints C Intermediate Shaft G 1 Kingpins D Stee...

Page 197: ...Section H Steering General Description Steering System H 4 H 4 9803 9390 2 1 Note The kingpins pivot on the suspension lower arms not shown...

Page 198: ...machine when working under it Disconnect the battery to prevent the engine being started while you are beneath the machine GEN 1 1 1 With the wheels in the straight ahead position and the tyres correc...

Page 199: ...Section H Steering Checking and Adjustment Wheel Alignment H 6 H 6 9803 9390 2 Page left intentionally blank...

Page 200: ...intenance Tie Rod Outer Ball Joints 3 Disconnect the steering tie rod outer ball joints from the kingpins a Remove the nut 1 A b Disconnect the ball joint track rod end from the kingpin If necessary u...

Page 201: ...Right Side 5 Remove the fasteners from both mountings Separate the pinion shaft 5 X from the universal joint and withdraw the steering rack assembly 4 D from the vehicle Fig 4 Fig 5 Replacement Note...

Page 202: ...ivot Bolt C Grease Nipple Within Swivel Boss H 3 Washers Hardened D Bush 2 off J 2 Nut Self locking E Pivot Pin 1 The kingpins are handed left and right sides 2 Grade 12 9 Nut grade equivalent to bolt...

Page 203: ...rs 1 H Remove the kingpin from the suspension arm swivel boss noting the locations of the upper and lower thrust washers Inspection Remove the pivot shaft from the suspension arm swivel boss Inspect a...

Page 204: ...e and chock the rear wheels 2 Raise and properly support the machine Remove the wheel see Section 3 Routine Maintenance 3 Apply moderate finger pressure to the sleeve 1 A in the middle of the hub The...

Page 205: ...Section H Steering Front Wheel Bearings Location H 12 H 12 9803 9390 2 Page left intentionally blank...

Page 206: ...03 9390 2 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section K Engine Section 1...

Page 207: ...Section K Engine K 0 K 0 9803 9390 2 Notes...

Page 208: ...Page No Contents Section K Engine K i K i Technical Data Specification K 1...

Page 209: ...Page No Contents Section K Engine K ii K ii...

Page 210: ...ater cooled diesel Power Output Gross 15 3 kW 20 5 hp 3600 rpm Maximum Torque 50 5 Nm 37 2 lbf ft 2400 rpm Bore nominal 67mm 2 64 in Stroke 72mm 2 83 in Total Displacement 762 cm3 46 5 in3 Compression...

Page 211: ...Injection Pump Type TBA Governing TBA Injection Timing TBA Injection Nozzle Type TBA Injection Pressure TBA Working TBA Setting TBA Lubrication System System Type Forced Lubrication by rotor type pump...

Page 212: ...9390 2 Publication No Issued by JCB Technical Publications JCB Aftermarket Training Woodseat Rocester Staffordshire ST14 5BW England Tel 44 1889 591300 Fax 44 1889 591400 Section S Suspension Section...

Page 213: ...Section S Suspension S 0 S 0 9803 9390 2 Notes...

Page 214: ...spension S i S i Technical Data Data S 1 Service Tools Numerical List S 3 Tool Detail Reference S 4 General Description Suspension S 5 Lower Arm Wishbone Removal and Replacement S 7 Spring Damper Stru...

Page 215: ...Page No Contents Section S Suspension S ii S ii...

Page 216: ...9390 2 Technical Data Data System Type Independent front suspension with single lower wishbones Suspension Strut Coil spring over damper Adjustment Spring Preload Adjuster TBA Spring Dual Rate 23 kg c...

Page 217: ...Section S Suspension Technical Data Data S 2 S 2 9803 9390 2...

Page 218: ...ese tools are available from JCB Service Note Tools other than those listed will be required It is expected that such general tools will be available in any well equipped workshop or be available loca...

Page 219: ...Section S Suspension Service Tools Tool Detail Reference S 4 S 4 9803 9390 2 Tool Detail Reference...

Page 220: ...n Suspension Note The vehicle is equipped with suspension to the front wheels only Fig 1 Suspension Arrangement Left Side Shown D A C C B C023750 A Lower Arm Wishbone B Spring Damper Assembly C Rubber...

Page 221: ...Section S Suspension General Description Suspension S 6 S 6 9803 9390 2 1 Note Steering rack and tie rod ball joints have been omitted for clarity...

Page 222: ...gpin may be left in position until the suspension arm is removed 4 Remove the lower link bolt from the spring damper assembly while supporting the weight of the lower arm K Fig 1 T S 5 5 Remove the ch...

Page 223: ...eering Observe important notes regarding assembling the kingpins 4 The correct grade of fasteners must be used Also where specified use hardened washers NOT ordinary washers 5 Correctly torque tighten...

Page 224: ...hydraulics or jacks to support the machine when working under it Disconnect the battery to prevent the engine being started while you are beneath the machine GEN 1 1 2 Raise and safely support the ma...

Page 225: ...Section S Suspension Spring Damper Strut Removal and Replacement S 10 S 10 9803 9390 2 Dismantling and Assembly Fig 1 A Damper B Spring D Bushes...

Page 226: ...nt S 11 S 11 9803 9390 2 Spring Damper Replacement Note Replacement is the reverse of removal but note the following 1 Renew all self locking nuts 2 The correct grade of fasteners must be used 3 Corre...

Page 227: ...Section S Suspension Spring Damper Strut Removal and Replacement S 12 S 12 9803 9390 2 Page left intentionally blank...

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