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Routine Maintenance

Electrical System

132

9811/5700-7

Relays

All Models

The relays are located behind the side console

. They are

separated into the banks.

To access the relays, unscrew the five fasteners

and

remove the panel.

Important:

Isolate the machine's electrics before

removing the panel.

Fig 95. Side Console

Note:

All the relays are shown (including optional

equipment relays). Your machine may not be equipped
with all the relays shown.

Fig 96.

Buzzer

Flashers

Park brake lamp

Ignition

Neutral start

Transmission dump

Forward

Reverse

Содержание RTFL 926

Страница 1: ...Printed In England Dear JCB Customer Even if you have operated this type of equipment before it is very important that your new machines operations and functions are explained to you by a JCB Dealer...

Страница 2: ...0 0 9811 5700 Notes...

Страница 3: ...ification 17 Identifying Your Machine 19 Machine Identification Plate 19 Component Identification Plates 21 ROPS FOPS Certification Plate 23 Machine Security 24 Introduction 24 JCB Plantguard 24 Const...

Страница 4: ...tices and Site Safety 60 Clothing and Safety Equipment 60 Danger Zone 60 Log Moving Handling 60 Safety Practices 60 Working with the Mast 62 Use of Machines on Gradients or Slopes 73 Operating Environ...

Страница 5: ...ce 104 Introduction 104 How to Make the Machine Safe Mast Lowered 105 How to Make the Machine Safe Mast Lifted 105 Cleaning the Machine 108 Introduction 108 Preparing the Machine for Cleaning 108 Clea...

Страница 6: ...56 Tyre Inflation 156 Changing a Wheel 157 Forks 159 Inspecting the Forks 159 Changing the Forks 159 Windscreen Washer 161 Checking the Level 161 Fire Extinguisher if fitted 162 Checking the Fire Exti...

Страница 7: ...180 Introduction 180 Specifications 181 Warranty Information Machine Service Record Sheet 183 Registration Information 185 European Community Standards EC Declaration of Conformity 187 Introduction 1...

Страница 8: ...Contents vi vi Page No Contents...

Страница 9: ...adable 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 Denotes an extreme hazard...

Страница 10: ...Safety Notices Important Information viii viii 9811 5700 7 Page left intentionally blank...

Страница 11: ...in this manual are for guidance only Where the machines differ the text and or the illustration will specify This manual contains original instructions verified by the manufacturer or their authorise...

Страница 12: ...achine is intended to be used under normal conditions for the applications described in this manual If the machine is used for other purposes or in dangerous environments for example in a flammable at...

Страница 13: ...Introduction Machine Description 3 3 9811 5700 7 Fig 2...

Страница 14: ...Introduction Machine Description 4 4 9811 5700 7 T047530 4 Fig 3 Engine Compartment 20 9 22 19 11 17 12 23 8 21 10 13 18 15 16 14...

Страница 15: ...ow the machine and have the skill to use it You must abide by all relevant laws health and safety regulations that apply to the country you are operating in The Operator Manual instructs you on the ma...

Страница 16: ...ulations INT 1 3 7_2 MWARNING Raised Equipment Never walk or work under raised equipment unless it is supported by a mechanical device Equipment which is supported only by a hydraulic device can drop...

Страница 17: ...working on it You could be killed or injured if the ground gives way under your machine or if piled material collapses onto it Check for potholes and hidden debris logs ironwork etc Any of these could...

Страница 18: ...or more often if required Before opening the engine cover ensure that the top is clear of debris 5 3 1 12_3 MWARNING Keep the machine controls clean and dry Your hands and feet could slide off slipper...

Страница 19: ...ction Structure ROPS Falling Objects Protection Structure FOPS has been in an accident do not use the machine until the structure has been renewed Modifications and repairs that are not approved by th...

Страница 20: ...off or the transmission in neutral INT 2 2 7 MWARNING Visibility Accidents can be caused by working in poor visibility Use your lights to improve visibility Keep the road lights windows and mirrors c...

Страница 21: ...neath or behind the machine People can be killed or injured if these precautions are not taken INT 3 1 5 MWARNING Repairs If your machine does not function correctly in any way get it repaired straigh...

Страница 22: ...ne oil contains harmful contaminants which can cause skin cancer Do not handle used engine oil more than necessary Always use barrier cream or wear gloves to prevent skin contact Wash skin contaminate...

Страница 23: ...elastomeric materials such as Viton FluorelTM and Technoflon Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid THIS ACID CAN SEVERELY BURN New f...

Страница 24: ...be fitted with counterweights They are extremely heavy Do not attempt to remove them INT 3 2 5 MWARNING Compressed air is dangerous Wear suitable eye protection and gloves Never point a compressed ai...

Страница 25: ...r all repair work 2 3 2 7_2 MWARNING Jacking A machine can roll off jacks and crush you unless the wheels have been blocked Always block the wheels at the opposite end of the machine that is to be jac...

Страница 26: ...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 then refer to Safet...

Страница 27: ...Introduction Safety Labels 17 17 9811 5700 7 Safety Label Identification Fig 4 Safety Label Locations ISO 10A ISO 05B ISO 04A ISO 011C ISO 05C ISO 15C ISO 06B ISO 01A...

Страница 28: ...cross the terminals ISO 06B 332 F5860 1 Part Number 332 F5860 Description Pressure hazard Refer to Cooling System Routine Maintenance Section 2 2 ISO 011C 817 70011 2 Part Number 817 70011 Description...

Страница 29: ...tamp the new number of the unit on the identification plate or simply stamp out the old number This will prevent the wrong unit number being quoted when replacement parts are ordered The machine and e...

Страница 30: ...Identification 3 Digits 2 Machine Model 3 Digits 3 Wheel Drive Option 2 Digits 4 Check letter 1 Digit The Check Letter is used to verify the authenticity of the machine s PIN 5 Machine Serial Number...

Страница 31: ...entification number is explained as follows 1 Engine Type S 4 4 litre series 2 Engine part number 3 Country of manufacture U United Kingdom 4 Engine Serial Number 5 Year of Manufacture The last three...

Страница 32: ...a data plate mounted to the front of the left hand axle arm K Fig 7 T 22 T047530 3 Fig 7 Front Axle The rear axle serial number is also stamped on a plate mounted to the left hand front face of the a...

Страница 33: ...the machine is used in any application where there is a risk of falling objects then a falling objects protective structure FOPS must be installed For further information contact your JCB Dealer The f...

Страница 34: ...d of machine identification and registration that operates throughout the United Kingdom and Ireland and across the whole spectrum of JCB products CESAR is a scheme to help reduce plant theft and was...

Страница 35: ...ess If there is anything you do not understand ask your JCB distributor The operator must always be aware of events happening in or around the machine Safety must always be the most important factor w...

Страница 36: ...ses and rear view mirrors b Remove dirt and debris especially from around the linkages rams pivot points and radiator c Make sure the cab step s and handholds are clean and dry d Clean all safety and...

Страница 37: ...ep s handrails and your boot soles are clean and dry Do not jump from the machine Do not use the machine controls as handholds use the handrails INT 2 1 7_1 Make sure the machine is stopped and correc...

Страница 38: ...om the inside by pulling it firmly it will latch itself To open a door from inside pull lever A to the rear K Fig 12 T 28 Each door can be secured fully open Swing it all the way round and push the kn...

Страница 39: ...want Release the lever Make sure the seat is locked in position 2 Backrest Angle Press your back firmly against the backrest Press down either of the two levers 2 and put the backrest at the angle yo...

Страница 40: ...e it fully horizontal in the direction Operate ratchet handle 3 to adjust the seat up or down to the desired height A light driver will require the pointer 4 to be close to the small person symbol To...

Страница 41: ...hat it is over your hips not your stomach C006840 1 Fig 17 Note If the belt locks before the male fitting A has been engaged allow the belt to fully retract in its reel holder and then try again The i...

Страница 42: ...Operation Cab Layout 32 32 9811 5700 7 Cab Layout Note The cab layout illustration is of a typical machine for variations see the relevant page in this manual S715280 5 Fig 19 7...

Страница 43: ...Brake Pedal T 34 7 K Transmission Dump Disconnect Switch T 35 8 K Operating Levers T 44 9 K Side Console T 36 10 K Instrument Panel T 41 11 K Multi Purpose Steering Column Switch T 38 12 K Heater Cont...

Страница 44: ...release the park brake simply lower the lever all the way When the park brake is engaged the transmission drive is automatically disconnected Transmission Lever MWARNING You and others can be killed...

Страница 45: ...le before selecting a gear The machine can be moved off in any gear depending on ground conditions To change gear on the move 1 Press the transmission dump switch 7 2 Select the new gear 3 Release the...

Страница 46: ...ON and OFF positions Position 1 OFF Backlight OFF Position 3 Side Lights ON Backlight ON Position 2 starter switch in the ON position Headlights ON Backlight ON Position 2 starter switch in the OFF p...

Страница 47: ...Work Lights ON Note The work lights work independently of the main lights circuit Rear Fog Light if fitted 340051 1 Two position rocker switch The switch functions operate when the starter switch is i...

Страница 48: ...the indicators off when you have completed the turn Functions only with the starter switch at position I 3 Windscreen Wiper Rotate the lever barrel to switch the windscreen wipers on and off The follo...

Страница 49: ...o switch on roof window wiper The wiper does not self park It functions only with the starter switch on Fig 27 0 Off Stop Engine Turning the key to this position will stop the engine Make sure the tra...

Страница 50: ...essories from the battery Only connect items which are compatible with the power rating of the socket Refer to Electrical System Fuses and have the correct plug Always operate the engine during prolon...

Страница 51: ...t condition or you might damage the engine and or the transmission All instruments and indicators will be turned off when the starter switch is set to off But the hazard warning indicator will still o...

Страница 52: ...perature rises too far 5 Cold Start If fitted Visual Only With the starter switch in position III if the outside air temperature is 6 C 21 F or below the light will illuminate indicating that the mani...

Страница 53: ...he cab Air conditioning reduces moisture from the air and can be used to demist windows quickly in damp weather Used in conjunction with the heater it also makes the interior of the cab warm and dry I...

Страница 54: ...neath overhead power cables You must obtain details from your local electricity supplier 2 2 5 4 MWARNING Make sure that it is clear overhead before raising the mast 9 2 1 2 The mast and its carriage...

Страница 55: ...Mast Lower Mast To raise the mast A and carriage pull the lever back To lower the mast B and carriage push the lever forward Fig 34 Tilt Mast Forward Tilt Mast Back To tilt the mast forward C push the...

Страница 56: ...ary Installation Single Auxiliary Option To operate the auxiliary circuit On machines fitted with a standard carriage move lever 3 in direction G or H depending on the attachment fitted or the functio...

Страница 57: ...700 7 Sideshift Carriage if fitted If the machine is fitted with a sideshift carriage it can be operated by lever 3 To move the carriage to the left E push the lever forward To move the carriage to th...

Страница 58: ...the controls 1 Make sure that the control levers A are in the neutral position 2 Lower the locking bars B into the horizontal position K Fig 39 T 48 3 Push the locking bars into clips C to secure the...

Страница 59: ...Note Be careful when you operate the machine with a beacon The total height of the machine is increased when the beacon is in the operating position 1 Put the beacon A on the cab roof Note The beacon...

Страница 60: ...se the fire extinguisher If necessary refer to the instructions found on the fire extinguisher Only try to extinguish a fire if the circumstances permit and your safety is not endangered If necessary...

Страница 61: ...ne See Before Entering the Cab Also complete the daily checks as detailed in the Service Schedules b Remove dirt and rubbish from the cab interior specially around the pedals and control levers MWARNI...

Страница 62: ...ck against the seat back 5 If fitted adjust the armrest so that you can reach and operate the controls without stretching 6 If possible adjust the steering column so that you can reach the steering wh...

Страница 63: ...III and hold it there until the engine starts Note Do not operate the starter motor for more than 10 seconds without the engine firing If the engine fires but does not fully start do not operate the...

Страница 64: ...fully back Lower the carriage so that the heels of the forks if fitted are 100 mm 150 mm 4 in 6 in above the ground Fig 43 3 In the UK before travelling on public roads it is your responsibility as a...

Страница 65: ...commendations given below ARE NOT necessarily the applied law please make sure you are complying with the relevant local laws 1 Centralise the carriage Tilt the mast fully back Lower the carriage so t...

Страница 66: ...se the brake pedal to prevent overspeeding down a slope Approach deep mud in first gear 1 with the front wheels straight Take particular care when reversing If the machine has mirrors make sure your v...

Страница 67: ...tely reverse direction without warning to others Follow the recommended procedure for proper use of this selector 2 2 2 4_2 4 Select Forward or Reverse and move off MWARNING Travelling at High Speeds...

Страница 68: ...MWARNING Do not dismount a moving machine 3 2 3 12 4 Set the forward reverse lever to neutral Make sure the lever is in its detent position 5 Select neutral gear MDANGER Before lowering the attachment...

Страница 69: ...ving the cab or canopy must only be made where steps and handrails are provided Always face the machine when entering and leaving Make sure the step s handrails and your boot soles are clean and dry D...

Страница 70: ...ind out the correct procedure Your local JCB distributor will be glad to advise you There are a wide variety of situations in which your machine may be used Consequently in all cases the applicability...

Страница 71: ...20 MWARNING Underground Gas Pipes Before you start using the machine check with your local gas company if there are any buried gas pipes on the site If there are buried gas pipes we recommend that yo...

Страница 72: ...t of the load before trying to lift it Raise the load only a few inches at first to check that the machine is stable Lower the load straight away if the machine begins to feel unstable Do not exceed t...

Страница 73: ...commodate all the wheels of the machine and stabilisers if fitted It should not be necessary for the machine to make tight turns with an elevated load However your machine may safely be used for loadi...

Страница 74: ...y for example debris excavations man hole covers power lines Is the space adequate for safe manoeuvring Are any other vehicles or persons likely to be in or to enter the area whilst operations are in...

Страница 75: ...on of their single rated capacity Forks must be used in matched pairs The maximum rated load capacity of the machine is shown in Performance Dimensions Specifications Section The forks used on this ma...

Страница 76: ...9200 7 Fig 46 MWARNING If the fork locking pin is not fully engaged the fork could become unintentionally disengeged 12 6 1 13 5 Remove the lifting equipment and make sure the forks are correctly loca...

Страница 77: ...tilt to aid load pick up and placing and to compensate for small variations in gradient Loading 1 Space the forks as wide as possible to suit the load K Repositioning the Forks T 66 Fig 48 2 Put the f...

Страница 78: ...Manual for unloading 5 1 4 4_2 1 Approach the unload area on centre with the rear wheels straight Stop the machine with the load directly over the unload point 2 Engage the park brake Put the transmis...

Страница 79: ...r platform Fig 51 3 Drive forward in first gear until the load is directly above its required position Stop the machine Engage the park brake Put the transmission in neutral 4 Set the forks level with...

Страница 80: ...erstand how to handle palleted loads The basic procedure is the same but remember the following points MWARNING The machine s load centre is extended when using a drum clamp attachment Do not overload...

Страница 81: ...Slowly withdraw the carriage away from the drums the clamp will automatically open c Return the mast and carriage to the travel position Handling Irregular Loads Handle irregular loads only after you...

Страница 82: ...Pallets Stack box pallets straight and square For extra stability stagger the top row 151990 3 Fig 55 Cylindrical Loads Stack cylindrical loads tightly together and level Wedge both ends of each row...

Страница 83: ...a gradient Drive an unladen machine forward down a gradient and in reverse up a gradient Fig 57 Drive a laden machine forward up a gradient and in reverse down a gradient Fig 58 Driving Across Gradie...

Страница 84: ...above the ground with the machine on a gradient Important Lifting operations should not be undertaken on gradients unless the machine is level across its width i e laterally level Ensure you have tak...

Страница 85: ...be needed Examples are fuel oil and coolant heaters Ask your JCB distributor for advice Important Do not connect two batteries in series to give 24 volts for starting as this can cause damage to the...

Страница 86: ...ility of any fuel you are unsure of GEN 9 2 MWARNING Fuel Fuel is flammable keep naked flames away from the fuel system Stop the engine immediately if a fuel leak is suspected Do not smoke while refue...

Страница 87: ...Operation Refuelling a Machine 77 77 9811 5700 7 Fig 60...

Страница 88: ...wo Four Wheel Drive to 2WD 4 Prepare the machine for travel See Preparing for Road Travel If the engine cannot be run the mast may have to be hoisted into the transport position and secured The proced...

Страница 89: ...the ramp angle See Static Dimensions in SPECIFICATION section for the minimum ground clearance of your machine 2 2 7 5_1 1 Place blocks at the front and rear of the trailer wheels 2 Move the Machine...

Страница 90: ...Operation Transporting the Machine 80 80 9811 5700 7 298261 2 Fig 63...

Страница 91: ...he following 1 Unfasten both tilt cylinder restraint wires from the mast a Unscrew and remove bolt A and washer B from each mast tilt cylinder pivot pin b Remove the restraint wires C if fitted Fig 64...

Страница 92: ...n the loading ramps securely on the transporter Note Ramps should be level with each other in the lowered position 4 Remove the securing straps from the machine and stow them 5 Start the machine tilt...

Страница 93: ...for TRANSPORTING on trucks or trailer only and not on the work site Both tilt cylinder restraint wires MUST be secured at both ends while the machine is being used on the work site 9 1 3 5 1 Make sure...

Страница 94: ...1 3 7_2 5 Attach lifting equipment to lifting points as shown Note Look for instructional label A to identify the correct lifting points 6 Take the weight of the machine If the lifting equipment is f...

Страница 95: ...cessary 4 Fill the fuel tank to prevent a build up of condensation in the tank 5 Examine the coolant condition Replace if necessary 6 Examine all fluid levels Top up if necessary Put the Machine into...

Страница 96: ...orage Take the Machine Out of Storage T2 079 1 Examine the coolant condition Replace If necessary 2 Examine all fluid levels Top up if necessary 3 Clean the machine to remove unwanted material and cor...

Страница 97: ...service requirements and keep a service history record It should be dated signed and stamped by your Distributor each time your machine is serviced Remember if your machine has been correctly maintai...

Страница 98: ...local JCB distributor for further advice Obtaining Replacement Parts T3 096 If you use non genuine JCB parts or consumables then you can compromise the health and safety of the operator and cause mac...

Страница 99: ...d of in accordance with local regulations Use authorised waste disposal sites INT 3 2 14 All waste products should be disposed of in accordance with all the relevant regulations The collection and dis...

Страница 100: ...on Swallowing If oil is swallowed do not induce vomiting Get medical advice Skin In the case of excessive skin contact wash with soap and water Spillage Absorb with sand or a locally approved brand of...

Страница 101: ...tive 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 Understand the elec...

Страница 102: ...elp 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 remove aff...

Страница 103: ...heck on the hourmeter readings to correctly gauge service intervals When there is no hourmeter fitted use the calendar equivalents to determine the service intervals Refer to Calendar Equivalents Do n...

Страница 104: ...e FEAD Belt Condition Check Front End Accessory Drive FEAD Belt Change Engine Mounting Bolts for Tightness Check All Hoses Condition Check Radiator 4 Clean Breather Gauze Clean Valve Clearances 6 Chec...

Страница 105: ...HYDRAULICS System for Leaks Check Oil Level Check Oil 6 Change and Clean Strainer Oil Filter Change Hoses Damage or Leaks Check Pipework Damage or Leaks Check Rams External Leaks Check Rams Chrome Con...

Страница 106: ...urs Service only to be completed by your JCB Distributor 2 If operating under arduous conditions change the engine oil and filter every 250 hours 3 The oil service interval will be affected if there i...

Страница 107: ...se and Gear Change Operation Check Transmission Operation Check Transmission Main Line Pressure 2 Check Transmission for Leaks Check Clutch Disconnect Check Clutch Pack Pressures 2 Check Oil Cooler an...

Страница 108: ...heck Doors and Hinges Fitment Leaks Check Locks and Keys Check ATTACHMENTS Attachment Operation Check Circuit Pressures Check LIFTING EQUIPMENT Fit for Purpose Test 4 Complete 1 First 100 Hours Servic...

Страница 109: ...C to 40 C 4 F to 104 F 4001 1700 20 Litres Engine Coolant 17 3 7 JCB Antifreeze HP Coolant Water K Coolant Mixtures T 100 4006 1120 20 Litres Transmission JCB Extreme Performance EP 10W 3 3 Friction...

Страница 110: ...y 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 Performance Antifr...

Страница 111: ...or use with low sulphur fuels K Additives T 102 MIL T38219 XF63 NATO F63 French EN590 RME5 with 5 maximum AVTURFSII NATO F34 JP8 MIL T83133 DERD 2463 DEF STAN 91 87 All Dieselmax engines Important Eng...

Страница 112: ...elated 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 mico bacterial growth Make sure that...

Страница 113: ...ontaminant Finely machined and mated surfaces such as delivery valves and distributor rotors are susceptible to the abrasive nature of dirt particles increased wear will almost inevitably lead to grea...

Страница 114: ...the battery when you are not using electrical power If you do not take these precautions you could be killed or injured 8 3 1 1 Make the machine safe before you start a maintenance procedure You can...

Страница 115: ...Install the mast support chains before working beneath a raised mast carriage 9 1 4 2_2 MCAUTION Stand on a serviceable working platform to fit remove chain s Do not lean a ladder against the mast it...

Страница 116: ...Machine for Maintenance 106 106 9811 5700 7 7 Vent the hydraulic system Refer to Hydraulic System Releasing the Hydraulic Pressure 8 Check the support chain s for total safety Fig 70 Typical Duplex M...

Страница 117: ...hine for Maintenance 107 107 9811 5700 7 Fig 72 Typical Freelift Mast Removing the Mast Support Chains 1 Raise the mast carriage to take the weight off the chains 2 Switch OFF the engine and remove th...

Страница 118: ...face shield as well as protective clothing Steam can cause serious personal injury 13 3 2 10_2 MCAUTION The engine or certain components could be damaged by high pressure washing systems special prec...

Страница 119: ...or damp cloth 8 3 4 8 Pay particular attention to the following areas 1 Cleaning the Tubes Fins If the radiator tubes fins get clogged the radiator will be less efficient a Remove the radiator grille...

Страница 120: ...wash any part of the i Fuel injection pump ii Cold start device iii Electrical shut off solenoid ESOS iv Electrical connections d Ensure that the alternator starter motor and any other electrical comp...

Страница 121: ...condition of the tyres Incorrect tyre pressures will affect the stability of the machine Check the tyres daily for the correct tyre pressure and signs of damage For example Signs of distortion bulges...

Страница 122: ...Objects Protection Structure FOPS has been in an accident do not use the machine until the structure has been renewed Modifications and repairs that are not approved by the manufacturer may be danger...

Страница 123: ...attachments MCAUTION Waxoyl contains turpentine substitute which is flammable Keep flames away when applying Waxoyl Waxoyl can take a few weeks to dry completely Keep flames away during the drying pe...

Страница 124: ...Routine Maintenance Greasing 114 114 9811 5700 7 Daily Rear Axle Pivot Pin 2 Grease Points Fig 76...

Страница 125: ...Routine Maintenance Greasing 115 115 9811 5700 7 Rear Axle 14 grease points Fig 77...

Страница 126: ...Routine Maintenance Greasing 116 116 9811 5700 7 Rear Driveshafts 4 Wheel Drive Machines 3 grease points Fig 78 Front Driveshaft 3 grease points Fig 79...

Страница 127: ...Routine Maintenance Greasing 117 117 9811 5700 7 Mast Tilt Rams and Pivots 6 grease points Fig 80...

Страница 128: ...Routine Maintenance Greasing 118 118 9811 5700 7 250 Hours Mast Chains Fig 81 Remove old oil and apply JCB Chain Lubricant Make sure the chains are slack before applying lubricant...

Страница 129: ...he engine being started while you are beneath the machine GEN 4 1_1 Park Brake Cable MWARNING Oil on the brake disc will reduce brake effectiveness Keep oil away from the brake disc Remove any oil fro...

Страница 130: ...Routine Maintenance Oiling 120 120 9811 5700 7 Cylinder Bores and Rods Fully raise and lower the mast daily to lubricate the cylinder bores and cylinder rods Fig 84...

Страница 131: ...t use the machine with the engine cover open 5 2 6 5 MWARNING Touching hot surfaces can burn skin The engine and machine components will be hot after the unit has been running Allow the engine and com...

Страница 132: ...of the engine The panels can be removed to provide better access for maintenance tasks Fig 86 To remove a panel 1 Open the engine cover K Access Panels T 121 2 Remove the four panel fasteners located...

Страница 133: ...e machine on a level dry surface 2 Fully apply park brake 3 Start the engine and raise the attachments to the appropriate travel position 4 Select fourth gear 5 Push down hard on foot brake pedal 6 Se...

Страница 134: ...est adjust the park brake and repeat the test Refer to Park Brake Adjustment Park Brake Adjustment MWARNING Over adjustment of the park brake could result in the park brake not fully releasing 0011 1...

Страница 135: ...mast lowered Refer to Prepare the Machine for Maintenance 2 The correct fluid level is marked on the reservoir If necessary add fluid as in Step 3 If the level has fallen below the MIN mark get the sy...

Страница 136: ...ush or abrasive paper c After cleaning apply a thin coat of petroleum jelly to the terminal 2 Re connect the leads Connect the earth terminal last 3 If the machine has a battery isolator move the swit...

Страница 137: ...left unattended provided the lights are not required the battery must be isolated Before attempting to start the engine or use the machine electrics the battery isolator key must be fitted and switche...

Страница 138: ...onnected Do not connect the booster slave supply directly across the starter motor Doing this by passes the neutral gear safety switch If the machine is in gear it may runaway and kill or injure bysta...

Страница 139: ...earth on the machine away from and below the battery Note A good frame earth is part of the main frame free from paint and dirt Do not use a pivot pin for an earth d Connect the other end of this cab...

Страница 140: ...To access the fuses remove the cover s Fig 92 All Models Note All the fuses are shown including optional equipment fuses Your machine may not be equipped with all the fuses shown 823620 2 Fig 93 Circ...

Страница 141: ...ircuit fuses as well as the link box fuses shown on this page Note An additional optional fuse may be fitted for cold start Fig 94 Fuse Circuit Rating 1 Main lighting Direction indicators Heater fan W...

Страница 142: ...ys unscrew the five fasteners K and remove the panel Important Isolate the machine s electrics before removing the panel Fig 95 Side Console Note All the relays are shown including optional equipment...

Страница 143: ...nce Electrical System 133 133 9811 5700 7 Air Conditioning if fitted Machines with air conditioning are fitted with two additional relays A The relays are located in the engine compartment next to the...

Страница 144: ...NG Do not exceed the correct level of engine oil in the sump If there is too much engine oil the excess must be drained to the correct level An excess of engine oil could cause the engine speed to inc...

Страница 145: ...e When all the oil has drained unscrew the drain tube assembly and fit the dust cap K C012110 1 Fig 99 4 Place a container of suitable size under drain plug E to catch the oil K Fig 100 T 135 5 Loosen...

Страница 146: ...Important Water in the expansion bottle A and not in the radiator indicates expansion bottle tube leaking or a non sealing radiator pressure cap 1 Get access to the engine Refer to Access Panels Engin...

Страница 147: ...tem using clean water After flushing reconnect the bottom hose to the radiator 6 Use the necessary mix of clean soft water and antifreeze K Fluids Lubricants and Capacities T 99 Fill to the MIN level...

Страница 148: ...G Turning the Engine Do not try to turn the engine by pulling the fan or fan belt This could cause injury or premature component failure 0094 To get access to the drive belt for maintenance open the e...

Страница 149: ...e belt off the tensioner pulley F 4 Slowly release the spring force by rotating the tensioner unit in the opposite direction 5 Before fitting a new belt check that the tensioner roller and fan pulley...

Страница 150: ...engine with the dust valve K removed Check the dust valve K is not blocked Inspect the rubber flaps for cuts and nicks and check that the rubber is not perished Renew if necessary Fig 104 Changing th...

Страница 151: ...when removing the filters 4 Clean the inside of cover B and canister E 5 Carefully insert the new inner element D into the canister Make sure it seats correctly by smearing seal F with grease and chec...

Страница 152: ...kin get medical help immediately 0177 MCAUTION Do not allow dirt to enter the system Before disconnecting any part of the system thoroughly clean around the connection When a component has been discon...

Страница 153: ...r in the element A by turning tap B 3 Drain off any water in the water separator bowl C by opening tap D Do not disconnect the electrical connector E if fitted 4 If there is sediment in the bowl after...

Страница 154: ...er separator bowl C K Draining the Water Separator and Engine Fuel Filter T 143 3 To remove the filter element A release locking ring B and discard element 4 Fit new element and secure in position wit...

Страница 155: ...n into a suitable container 4 Remove the low pressure fuel lines C and E Mark the pipes prior to removal to ensure they are refitted in the correct position 5 Loosen the filter strap retaining screw D...

Страница 156: ...e fuel lift pump priming lever C until air free fuel exits from the fuel line K Fig 112 T 146 3 Reconnect fuel line B 4 The engine is now ready to start If the engine runs smoothly for a short time an...

Страница 157: ...re 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 been vented before connecting or removing h...

Страница 158: ...servo operated services turn the starter key to the ON position Operate the controls of the service to be disconnected Important To release the hydraulic pressure from the electrical and servo operate...

Страница 159: ...Set forks on the ground Stop the engine Remove the starter key MCAUTION If the fluid is cloudy then water or air has contaminated the system This could damage the hydraulic pump Contact your JCB Distr...

Страница 160: ...afe with the mast lowered Refer to Prepare the Machine for Maintenance 2 Vent the hydraulic system Refer to Releasing the Hydraulic pressure 3 Place a container of suitable size below the hydraulic fi...

Страница 161: ...not exceeding five minutes This allows the oil to fill filter pump torque converter oil cooler and hoses 3 Switch OFF the engine and remove the starter key wait one minute 4 Open the engine cover Ref...

Страница 162: ...3 4 1 3 Place a container of suitable size beneath the suction strainer Remove bolts D Pull out the strainer E and its gasket F Allow the oil to drain into the container Be aware that the oil may be h...

Страница 163: ...1 Make the machine safe with the mast lowered Refer to Prepare the Machine for Maintenance 2 Clean the area around fill level plug A then remove the plug and its sealing washer Oil should be level wi...

Страница 164: ...il Remove the drain plug B and its seal Allow oil to drain out The drain plug is magnetic Wipe it clean Metallic particles should be carefully removed Fit drain plug B and its washer MCAUTION Oil will...

Страница 165: ...the fill level plug 121 C Remove the plug Oil should be level with the bottom of the hole If necessary add the recommended oil Clean the plug before refitting it Fig 121 Changing the Hub Oil Change th...

Страница 166: ...r checking or amending the tyre pressure always replace and secure the valve cap Always deflate the tyre before removing foreign obstacles from the tread Procedure T3 067_2 These instructions are for...

Страница 167: ...s follows a Park the machine on firm level ground b Apply the park brake and select neutral c Stop the engine and remove the ignition key d Jack up the machine to gain access to whichever wheel you wi...

Страница 168: ...l must be changed as a set since the remaining studs may have been damaged 2 3 2 8 On new machines and whenever a wheel has been removed check the wheel nut torques every two hours until they stay cor...

Страница 169: ...suitable lifting equipment is used to support and transport them 12 5 1 7_2 1 Park the machine on level solid ground 2 Apply the park brake and select neutral 3 Depending on the fork type fitted remo...

Страница 170: ...iage Forks Removal 1 Remove the location pins A K Fig 127 T 160 2 Release the retaining clips G from the bar securing pins and remove the bar H from the carriage K Fig 127 T 160 3 Using suitable lifti...

Страница 171: ...Washer 161 161 9811 5700 7 Windscreen Washer Checking the Level Fill the windscreen washer bottle A with a suitable liquid The liquid should contain a de icing fluid to prevent freezing Do not use eng...

Страница 172: ...igns of leaking Check that the gauge A indicates that the extinguisher is charged i e the needle is in the GREEN segment Note If the needle is in or very near the RED segment at either end of the gaug...

Страница 173: ...hment read again Working With The Machine in the Operation section and consider how the attachment is going to affect operational safety With the attachment fitted there may be changes in the machine...

Страница 174: ...ase the productivity of your machine for more information contact your JCB Distributor Remember do not operate attachments until you have read and fully understand the attachment operating instruction...

Страница 175: ...hoses are open INT 3 1 11_2 Some attachments are hydraulically powered The following procedures show how to connect and disconnect the hydraulic hoses safely Connecting the Hydraulic Hoses 1 Make the...

Страница 176: ...g the Hydraulic Hoses 1 Make the machine safe Refer to Routine Maintenance Prepare the Machine for Maintenance 2 Vent the hydraulic system Refer to Routine Maintenance Releasing the Hydraulic Pressure...

Страница 177: ...eeve and twist the couplings apart Sticking is normally caused by dirt in the coupling or physical damage due to abuse Connect and disconnect new couplings two or three times to work the PTFE seals So...

Страница 178: ...ean 3 Make sure that ball C in the female coupling is located in one of its slots 4 Fit the male coupling into the female coupling 5 Where applicable rotate sleeve E half a turn and make sure that the...

Страница 179: ...ner operator and supplier of the work platform to ensure compliance with the relevant legislation in the relevant territory In the case of uncertainty guidance should be sought from the relevant local...

Страница 180: ...Optional Attachments Work Platforms 170 170 9811 5700 7 Page left intentionally blank...

Страница 181: ...cab height 2570 8 5 2570 8 5 2570 8 5 2570 8 5 B Overall width over tyres 1 2200 7 3 2200 7 3 2200 7 3 2200 7 3 C Overall length to front of carriage 2 3600 11 10 3600 11 10 3580 11 9 3840 12 6 D Insi...

Страница 182: ...10 21 8 6610 21 8 6730 22 1 5 7660 25 2 5 6 55 m mast 7670 25 2 7670 25 2 NA NA 6 7 m mast NA NA 7840 25 9 5 NA J 1 Mast Tilt Forwards 18 18 10 22 J 2 Mast Tilt Backwards 10 10 10 10 K Load Centre 500...

Страница 183: ...g data is intended for quick reference only Always refer to the rating plate in the cab Refer to Fork Ratings Working with the Machine Operation Fig 135 Lift Performance A 3 6m 11ft 10in Duplex mast B...

Страница 184: ...or quick reference only Always refer to the rating plate in the cab Refer to Fork Ratings Working with the Machine Operation Fig 136 Lift Performance A 3 6m 11ft 10in Duplex mast B 4 5m 14ft 9in Free...

Страница 185: ...data is intended for quick reference only Always refer to the rating plate in the cab Refer to Fork Ratings Working with the Machine Operation Fig 137 Lift Performance A 3 6m 11ft 10in Duplex mast B 4...

Страница 186: ...e Machine Operation 823680 2 Fig 138 Lift Performance Maximum Wading Depth The maximum wading depth of these machines is 370mm 14 5in Water can enter the engine and axles and the cooling fan can be da...

Страница 187: ...ved attachments please refer to the literature accompanying the attachments All Machines Table 9 Definition of terms LpA A weighted sound pressure level measured at the operator s station 1 1 Determin...

Страница 188: ...es see Dominant Axis X Y or Z Fig 139 Minimising Exposure to Vibration Exposure to vibration can be minimised through Selection of the correct size and capacity of machine equipment and attachments fo...

Страница 189: ...fined in SAE J1166 Note If SRS Smooth Ride System is fitted the whole body vibration emission for D3 Roading rough terrain is 0 59 m s2 Hand arm vibration determined in accordance with dynamic test co...

Страница 190: ...e pressure stated below Inflate to the pressures in the tables these are agreed with the tyre manufacturer s in accordance with the European Tyre and Rim Technical Organisation ETRTO standards to sati...

Страница 191: ...m Size Ply Make Name Pressure Rim bar lbf in2 Size Offset 1 16 5 85 X 24 8 SOLIDEAL SLR1 2 9 41 14 x 24 ET 20 2 15 5 80 X 24 12 GOODYEAR SURE GRIP IMPLEMENT SGI 2 5 36 14 x 24 ET 20 3 14 x 17 5 10 SOL...

Страница 192: ...RIP LOADER SGL 4 0 58 12 x 25 ET 20 3 12 5 80 X 18 10 GOODYEAR PLY RIB BAR AM IMPLEMENT 3 1 46 11 x 18 ET 7 4 14 x 17 5 10 SOLIDEAL SD SKS CLASSIC 3 85 56 10 5 x 17 5 ET 12 5 12 5 x 18 12 SOLIDEAL MPT...

Страница 193: ...Date Hour reading 1500 Hrs 18 Month Date Hour reading 2000 Hrs 24 Month Annual insurance Date Hour reading 2500 Hrs 30 Month Date Hour reading 3000 Hrs 36 Month Annual insurance Date Hour reading 3500...

Страница 194: ...84 Month Annual insurance Date Hour reading 7500 Hrs 90 Month Date Hour reading 8000 Hrs 96 Month Annual insurance Date Hour reading 8500 Hrs 102 Month Date Hour reading 9000 Hrs 108 Month Annual insu...

Страница 195: ...e Registration Date Installing Engineer Installing Engineer Customer s Name Dealer Copy U K and Eire only Do not send back to JCB Service A copy of the registration details to be sent direct to The Eq...

Страница 196: ...Warranty Information Registration Information 186 186 9811 5700 7 Page left intentionally blank...

Страница 197: ...f the EC Declaration of Conformity is supplied with all machines manufactured according to EC type examination and or self certification requirements A sample copy of the EC Declaration of Conformity...

Страница 198: ...European Community Standards EC Declaration of Conformity 188 188 9811 5700 7 9814 0850 4 GB Fig 140...

Страница 199: ...r to Typical Product Identification Number PIN E EN 474 1 2006 A1 2009 EN 474 4 2006 A1 2009 F Engineering Manager JCB Compact Products Ltd Harewood Estate Leek Road Cheadle Stoke on Trent United King...

Страница 200: ...European Community Standards EC Declaration of Conformity 190 190 9811 5700 7 Page left intentionally blank...

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