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jcb Groundhog 6x4 Service Manual
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jcb Groundhog 6x4 Service Manual

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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
Publication No.
9803-9390-2
World Class
Customer Support
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.
Issued by JCB Technical Publications, JCB Aftermarket Training, Woodseat, Rocester, Staffordshire, ST14 5BW, England. Tel +44 1889 591300 Fax +44 1889 591400

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Summary of Contents for jcb Groundhog 6x4

  • Page 1 Customer Support 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.
  • Page 2 THIS DOCUMENT DOWNLOAD FROM www.repair-manuals.com THE LARGEST PDF MANUALS COMPLEX FOR HEAVY MECHANICAL TECHNICIANS MEMBERSHIP ACCOUNT HOLDERS CAN DOWNLOAD ALL MANUALS WITHOUT ANY ADDITIONAL COST EXPLORE AVAILABLE PLANS...
  • Page 3 Customer Support 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.
  • Page 4 Section 1 - General Information Notes: 9803-9390-2...

  • Page 5: Table Of Contents

    Section 1 - General Information Contents Page No. Introduction 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 Numerical List ..................1-13 Consumables Sealing and Retaining Compounds ............
  • Page 6 Section 1 - General Information Contents Page No. 1-ii 1-ii...

  • Page 7: Introduction

    Section 1 - General Information Introduction About this Publication This publication is designed for the benefit of JCB Where a torque setting is given as a single figure it may be Distributor Service Engineers who are receiving, or have varied by plus or minus 3%. Torque figures indicated are received, training by JCB Technical Training Department.
  • Page 8 Section 1 - General Information Introduction About this Publication Page left intentionally blank 9803/9390-2...

  • Page 9: Machine Identification

    Section 1 - General Information Machine Identification Identifying Your Machine The machine has a Data Plate 1-X attached to the rear of Typical Vehicle Identification Number the machine. (VIN) The serial numbers of the machine, engine and gearbox are stamped on this plate. SLP 800 M10060000 If the engine is replaced, stamp the new serial number in...
  • Page 10 Section 1 - General Information Machine Identification Identifying Your Machine Page left intentionally blank 9803/9390-2...

  • Page 11: Torque Settings

    For the same reason, a Dacromet nut should not be used with a Zinc or Yellow plated bolt. Note: All bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.
  • Page 12 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 2. Torque Settings - UNF Grade 'S' Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 kgf m lbf ft kgf m lbf ft 7/16 11.2 10.0 5/16 22.3...
  • Page 13 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 4. Metric Grade 10.9 Fasteners Bolt Size Hexagon (A/F) Condition 1 Condition 2 ISO Metric Thread kgf m lbf ft kgf m lbf ft 13.9 10.2 12.5 34.0 25.0...
  • Page 14 Section 1 - General Information Torque Settings Zinc Plated Fasteners and Dacromet Fasteners Table 6. Torque Settings - Rivet Nut Bolts/Screws Bolt Size ISO Metric Thread kgf m lbf ft 10.0 24.0 18.0 48.0 35.5 82.0 60.5 Table 7. Torque Settings - Internal Hexagon Headed Cap Screws (Zinc) Bolt Size ISO Metric Thread...

  • Page 15: Hydraulic Connections

    Section 1 - General Information Torque Settings Hydraulic Connections Hydraulic Connections T11-003 'O' Ring Face Seal System Adaptors Screwed into Valve Blocks Adaptor screwed into valve blocks, seal onto an 'O' ring which is compressed into a 45° seat machined into the face of the tapped port.
  • Page 16 Section 1 - General Information Torque Settings Hydraulic Connections Hoses Screwed into Adaptors Fig 3. Hoses 3-B screwed into adaptors 3-A seal onto an `O' ring Note: Dimension 3-D will vary depending upon the torque 3-C which is compressed into a 45° seat machined into the applied.
  • Page 17 Section 1 - General Information Torque Settings Hydraulic Connections Adaptors into Component Connections with Bonded Washers Table 11. BSP Adaptors with Bonded Washers - Torque Settings BSP Size kgf m lbf ft 20.0 15.0 34.0 25.0 75.0 55.0 102.0 10.3 75.0 122.0 12.4...
  • Page 18 Section 1 - General Information Torque Settings Hydraulic Connections 'Torque Stop' Hose System Fig 4. `Torque Stop' Hoses 4-B screwed into adaptors 4-A seal Stop' Hoses have an additional shoulder 4-D, which acts onto an 'O' ring 4-C which is compressed into a 45° seat as a physical stop.
  • Page 19 These tools are available from JCB Service. Note: Tools other than those listed will be required. It is Some tools are available as kits or sets, the part numbers expected that such general tools will be available in any for parts within such kits or sets are not listed here.

  • Page 20: Service Tools Numerical List

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

  • Page 21: Consumables

    A medium strength sealant suitable for all sizes of 4102/1212 50 ml gasket flanges, and for hydraulic fittings of 25-65 mm diameter. JCB High Strength Threadlocker A high strength locking fluid for use with threaded 4102/0551 50 ml components. Gasketing for all sizes of flange where the strength of the joint is important.
  • Page 22 Section 1 - General Information Consumables Sealing and Retaining Compounds Page left intentionally blank 1-16 9803/9390-2 1-16...
  • Page 23 Customer Support 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.
  • Page 24 Section 2 - Care and Safety Notes: 9803-9390-2...
  • Page 25 Section 2 - Care and Safety Contents Page No. 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 Decals ..................2-11...
  • Page 26 Section 2 - Care and Safety Contents Page No. 2-ii 2-ii...

  • Page 27: Safety Notices

    You must understand and follow the instructions in the Operator Manual. You must observe all relevant laws and regulations. If you are unsure about anything, ask your JCB dealer or employer. Do not guess, you or others could be killed or seriously injured.

  • Page 28: Safety Checklist

    If you do not understand with a potentially explosive atmosphere. Sparks in anything, ask your employer or JCB dealer to explain such an area could cause an explosion or fire it. Keep the Operator Manual clean and in good resulting in death or serious injury.

  • Page 29: Operating Safety

    Breathing the machine exhaust gases can harm and altered in any way which could affect or invalidate any possibly kill you. Do not operate the machine in closed of these requirements. For advice consult your JCB spaces without making sure there is good ventilation. Distributor.
  • Page 30 Do not spoken commands. machine potentially explosive atmosphere, i.e. combustible vapours, gas or dust, INT-2-2-3 without first consulting your JCB Distributor. WARNING INT-2-1-14 Parking CAUTION An incorrectly parked machine can move without an operator. Follow the instructions in the Operator Regulations Manual to park the machine correctly.
  • Page 31 5-5-1-1_2 5-3-1-12_3 WARNING WARNING Use only the JCB approved attachments that are Keep the machine controls clean and dry. Your hands specified for your machine. Operating with non- and feet could slide off slippery controls. If that specified attachments can overload the machine, happens you could lose control of the machine.

  • Page 32: Maintenance Safety

    Section 2 - Care and Safety Safety Notices Safety Checklist WARNING WARNING Entering/Leaving Repairs Entering or leaving the cab or canopy must only be If your machine does not function correctly in any way, made where steps and handrails are provided. Always get it repaired straight away.
  • Page 33 Section 2 - Care and Safety Safety Notices Safety Checklist WARNING WARNING Battery Gases Hydraulic Pressure Batteries give off explosive gases. Keep flames and Hydraulic fluid at system pressure can injure you. sparks away from the battery. Do not smoke close to Before connecting or removing any hydraulic hose, the battery.
  • Page 34 Section 2 - Care and Safety Safety Notices Safety Checklist WARNING CAUTION Soft Ground 'O' rings, Seals and Gaskets A machine can sink into soft ground. Never work Badly fitted, damaged or rotted 'O' rings, seals and under a machine on soft ground. gaskets can cause leakages and possible accidents.
  • Page 35 Safety Notices Safety Checklist WARNING WARNING Certain seals and gaskets (e.g. crankshaft oil seal) on To avoid burning, wear protective gloves when JCB machines contain fluoroelastomeric materials handling hot components. To protect your eyes, wear such Viton, Fluorel Technoflon. goggles...
  • Page 36 JCB distributor, as qualified person who has a copy of the engine service the sudden release of the hydraulic fluid or gas may manual.

  • Page 37: Safety Decals

    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 decal from your JCB distributor. INT-3-3-3_1 WARNING If you need eye-glasses for reading, make sure you wear them when reading the safety decals.
  • Page 38 Section 2 - Care and Safety Safety Notices Safety Decals Page left intentionally blank 2-12 9803/9390-2 2-12...
  • Page 39 Customer Support 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.
  • Page 40 Section 3 - Routine Maintenance Notes: 9803-9390-2...
  • Page 41 Section 3 - Routine Maintenance Contents Page No. Routine Maintenance Health and Safety ..................3-1 Lubricants ....................3-1 Battery ....................3-3 First Aid - Electrolyte ................3-3 Service Schedules ..................3-5 Lubricants and Capacities ................. 3-8 Coolant Mixtures ...................3-8 Check for Damage and Cleaning ............3-10 Checking the ROPS Structure ..............
  • Page 42 Section 3 - Routine Maintenance Contents Page No. 3-ii 3-ii...

  • Page 43: Routine Maintenance

    New Oil Hygiene There are no special precautions needed for the handling JCB lubricants are not a health risk when used properly for or use of new oil, beside the normal care and hygiene their intended purposes. practices. However, excessive or prolonged skin contact can remove...
  • Page 44 Section 3 - Maintenance Routine Maintenance Health and Safety Throw away oil-soaked shoes. First Aid - Oil Eyes In the case of eye contact, flush with water for 15 minutes. If irritation persists, get medical attention. Swallowing If oil is swallowed do not induce vomiting. Get medical advice.

  • Page 45: Battery

    Section 3 - Maintenance Routine Maintenance Health and Safety Battery Warning Symbols The following warning symbols may be found on the WARNING battery. Batteries give off an explosive gas. Do not smoke when handling or working on the battery. Keep the Symbol Meaning battery away from sparks and flames.
  • Page 46 Section 3 - Maintenance Routine Maintenance Health and Safety WARNING Electrical Circuits Understand the electrical circuit before connecting or disconnecting an electrical component. A wrong connection can cause injury and/or damage. INT-3-1-4 DANGER Electrolyte Battery electrolyte is toxic and corrosive. Do not breathe the gases given off by the battery.

  • Page 47: Service Schedules

    Section 3 - Maintenance Routine Maintenance Service Schedules Service Schedules A badly maintained machine is a danger to the operator hourmeter readings to correctly gauge service intervals. and the people working around him. Make sure that the Do not use a machine which is due for a service. Make regular maintenance and lubrication jobs listed in the sure any defects found during the regular maintenance service schedules are done to keep the machine in a safe...
  • Page 48 Section 3 - Maintenance Routine Maintenance Service Schedules Pre-start Cold Checks, Service Points and Operation 10 Hr 50 Hr 100 Hr 250 Hr 500 Hr 1000 Fluid Levels (Daily) (First) External Oil Leaks - Check Cooling, Screen, Radiator Matrix and Oil Cooler - Clean Fuel Lift Pump - Clean...
  • Page 49 Section 3 - Maintenance Routine Maintenance Service Schedules Functional Test and and Final Inspection Operation 100 Hr 50 Hr 100 Hr 1000 (Daily) (First) ENGINE Idle Speed - Check and Adjust Exhaust System Security/Fouling - Check Exhaust Smoke (excesssive) - Check Throttle System and Control cable - Check BRAKES...

  • Page 50: Lubricants And Capacities

    20 litres (4.4 UK gal) Diesel oil 3-24)) ASTM D975-66T Nos. 1D, 2D Engine Oil (First 3.05 litres (0.67 UK gal) JCB 10W/30 Multigrade above 5 ºF (above -15 MIL-L-46152, API CC/SF 100 hours only) (plus filter qty) ºC) API/CC/SE (recommended) 5W/20 5 ºF to - 13 ºF (-15 ºC to - 25 ºC)
  • Page 51 Section 3 - Maintenance Routine Maintenance Lubricants and Capacities 60% Concentration (Extreme Conditions Only) Protects against damage down to -56 °C (-68 °F) Important: Do not exceed a 60% concentration, as the freezing protection provided reduces beyond this point. If you use any other brand of antifreeze: –...

  • Page 52: Check For Damage And Cleaning

    Section 3 - Maintenance Routine Maintenance Check for Damage and Cleaning Check for Damage and Cleaning Clean the machine using water and/or steam. Pay particular attention to the underside. Do not allow mud to build up on the engine and transmission. Make sure that the radiator grille is not blocked.

  • Page 53: Checking The Rops Structure

    (see opposite). Check the structure for damage and security. If necessary, have the structure repaired by suitably qualified personnel (consult your JCB distributor). If the damage is severe it will be necessary to obtain a complete new structure.

  • Page 54: Seat Belt

    Section 3 - Maintenance Routine Maintenance Seat Belt Seat Belt WARNING When a seat belt is fitted to your machine replace it with a new one if it is damaged, if the fabric is worn, or if the machine has been in an accident. Fit a new seat belt every three years.

  • Page 55: Greasing

    Greasing should be done with a grease gun. Normally, two strokes of the gun should be enough. Stop greasing when fresh grease appears at the joint. Use only JCB HP Grease. Before greasing, do the following: Fig 3.

  • Page 56: Lubricating The Drive Chain

    Section 3 - Maintenance Routine Maintenance Lubricating the Drive Chain Lubricating the Drive Chain Park the machine on firm, level ground and stop the engine. If the vehicle has a manually operated load bay, remove the starter key. Raise the load bay. If your vehicle has an electric tipper, ensure that the starter key is removed.

  • Page 57: Tyres And Wheels

    Section 3 - Maintenance Routine Maintenance Tyres and Wheels Tyres and Wheels Tyre Inflation b Inflate the tyre to the recommended pressure. Do not over-inflate. T3-010_2 These instructions are for adding air to a tyre which is already inflated. If the tyre has lost all its air pressure, call in a qualified tyre mechanic.

  • Page 58: Engine Air Filter

    Section 3 - Maintenance Routine Maintenance Engine Air Filter Engine Air Filter Changing the Element 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. CAUTION Clean the inside of the canister 6-B and dust valve 6- The outer element must be renewed immediately if the warning light on the instrument panel illuminates.

  • Page 59: Engine Oil And Filter

    Section 3 - Maintenance Routine Maintenance Engine Oil and Filter Engine Oil and Filter Checking the Oil Level Changing the Oil and Filter Park the machine on firm, level ground and stop the Note: The drain the oil when the engine is warm as engine.
  • Page 60 Section 3 - Maintenance Routine Maintenance Engine Oil and Filter Note: The old seal can stick to the filter head. Ensure that it is removed. c Smear the rubber seal on the new filter with oil. Screw in the new filter, hand-tight only. Fill the System.

  • Page 61: Engine Cooling System

    Section 3 - Maintenance Routine Maintenance Engine Cooling System Engine Cooling System Checking the Coolant Level WARNING The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system.

  • Page 62: Checking Radiator Hoses And Clamps

    Section 3 - Maintenance Routine Maintenance Engine Cooling System 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 from signs of leakage. Fig 11. 3-20 9803/9390-2 3-20...

  • Page 63: Draining, Flushing And Refilling The Coolant

    Section 3 - Maintenance Routine Maintenance Engine Cooling System Draining, Flushing and Refilling the Run the engine and raise the coolant to working temperature. Stop the engine. Check for leaks and Coolant check the coolant level. Top up as required. WARNING The cooling system is pressurised when the coolant is hot.

  • Page 64: Cleaning The Radiator

    Section 3 - Maintenance Routine Maintenance Engine Cooling System Cleaning the Radiator Park the machine on firm, level ground and stop the engine. If the vehicle has a manually operated load bay, remove the starter key. Raise the load bay. If your vehicle has an electric tipper, ensure that the starter key is removed.

  • Page 65: Alternator Drive Belt

    Section 3 - Maintenance Routine Maintenance Engine Cooling System Alternator Drive Belt Checking and Adjusting Park the machine on firm, level ground and stop the engine. If the vehicle has a manually operated load bay, remove the starter key. Raise the load bay. If your vehicle has an electric tipper, ensure that the starter key is removed.

  • Page 66: Fuel System

    CAUTION Low Temperature Fuels Consult your fuel supplier or JCB distributor about the suitability of any fuel you are unsure of. Special winter fuels may be available for engine operation at temperatures below 0°C (32°F). These fuels have a GEN-9-2 lower viscosity.

  • Page 67: Filling The Tank

    It is desirable not to allow the do at present. fuel level to fall below 1/4 full. Consult your JCB distributor for advice about the use of Important: Fatty Acid Methyl Ester fuels, as improper application may impair engine performance.

  • Page 68: Draining The Fuel Filter

    Section 3 - Maintenance Routine Maintenance Fuel System Draining the Fuel Filter Changing the Fuel Filter Element Park the machine on firm, level ground and stop the Park the machine on firm, level ground and stop the engine. If the vehicle has a manually operated load engine.

  • Page 69: Bleeding The Fuel System

    Section 3 - Maintenance Routine Maintenance Fuel System Bleeding the Fuel System CAUTION Running the engine with air in the fuel system could damage the fuel injection pump. Remove air from the system as detailed below. 0192 WARNING When the engine is turning, there are parts rotating in the engine compartment.

  • Page 70: Transmission

    Section 3 - Maintenance Routine Maintenance Transmission Transmission Checking the Transaxle Oil Level Park the machine on firm, level ground. Engage the park brake. Stop the engine. Raise the load bay. Remove dipstick 17-1, wipe it clean then screw it fully back into the transaxle case.

  • Page 71: Changing The Transaxle Oil

    Section 3 - Maintenance Routine Maintenance Transmission Changing the Transaxle Oil When Refilling Park the machine on firm, level ground. Engage the Fill the System. park brake. Stop the engine. Fill the transmission to the upper mark on the dipstick Raise the load bay.

  • Page 72: Checking The Drive Chain Tension

    Section 3 - Maintenance Routine Maintenance Transmission Checking the Drive Chain Tension Park the machine on a level surface, but do not engage the park brake. Stop the engine and remove the starter key. Set the forward/reverse lever to Neutral and set the differential lock to OFF.

  • Page 73: Adjusting The Drive Chain Tension

    If the tensions remain correct, repeat this procedure twice more. If no change occurs, the adjustment is complete. (If there are tight spots, contact your JCB Distributor.) Fig 20. 3-31...

  • Page 74: Battery

    Section 3 - Maintenance Routine Maintenance Battery Battery Checking the Battery Terminals WARNING Do not top the battery up with acid. The electrolyte Park the vehicle on firm level ground and lower the could boil out and burn you. boom. 2-3-4-6 Apply the park brake and select neutral.

  • Page 75: Fuses

    Section 3 - Maintenance Routine Maintenance Fuses Fuses See Fuses and Relays, Section C. 3-33 9803/9390-2 3-33...

  • Page 76: Troubleshooting

    If the well as immediately isolating any problem found and cause cannot be isolated, contact your JCB distributor. dealing with it. If the machine is operated with the problem uncorrected, it may lead to larger trouble and possibly to a big accident.
  • Page 77 Section 3 - Maintenance Routine Maintenance Troubleshooting Table 8. Exhaust gas from engine is black or dark grey Cause Remedy Improper Fuel Replace with corrrect fuel Improper valve clearance Adjust Defective fuel injection pump Adjust or replace if necessary Low compression Disassemble and repair, replace parts Insufficient air intake (air cleaner clogged) Clean or replace the element...
  • Page 78 Section 3 - Maintenance Routine Maintenance Troubleshooting Table 11. Abnormal noise (fuel or mechanical) Cause Remedy Bad fuel Replace Damage inside silencer Replace Table 12. Engine oil filter Cause Remedy Engine oil dirty Replace engine oil, oil filter Defective sensor Replace 3-36 9803/9390-2...

  • Page 79: Monitor Display - Fault Messages

    Section 3 - Maintenance Routine Maintenance Troubleshooting Monitor Display - Fault Messages Table 13. Water and Hydraulic oil temperature Message Cause Remedy WATER TEMP Water Leakage Repair Belt elongation, soiled with oil Clean or replace Defective radiator Repair or replace Broken fan Replace Incorrect anti-freeze mixture...
  • Page 80 Section 3 - Maintenance Routine Maintenance Troubleshooting Page left intentionally blank 3-38 9803/9390-2 3-38...
  • Page 81 Customer Support 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.
  • Page 82 Section 1 - General Information Notes: 9803-9390-2...
  • Page 83 Section A - Optional Equipment Contents Page No. Optional Equipment Vehicle Options ..................A-1 Roll Over Protection Structure (ROPS) ............ A-2 Removal and Replacement ..............A-2...
  • Page 84 Section A - Optional Equipment Contents Page No. A-ii A-ii...
  • Page 85 Section A - Option Equipment Optional Equipment Vehicle Options Fig 1. Roll Over Protection Structure (ROPS) Deluxe Lighting (Worklights, Beacon) Load Bay - Steel or Moulded Plastic Seat Belts Tipper 9803/9390-2...
  • Page 86 Section A - Option Equipment Optional Equipment Roll Over Protection Structure (ROPS) Roll Over Protection Structure (ROPS) Removal and Replacement Access to the ROPS mounting bolts is obtained by raising the load bay. Ensure that the load bay is safely supported while working beneath it - refer to the Handbook.
  • Page 87 Customer Support 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.
  • Page 88 Section 1 - General Information Notes: 9803-9390-2...
  • Page 89 Section B - Body and Framework Contents Page No. General Description Overview ....................B-1 Body Panels 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 ..................
  • Page 90 Section B - Body and Framework Contents Page No. B-ii B-ii...
  • Page 91 Section B - Body and Framework General Description Overview Fig 1. K Fig 2. ( T B-2) Also see Front End Panel Fascia Panel Wheel Fenders Switch Panel Load Bay Roll Over Protection Structure (ROPS) - option Side Panel (Fuel Filler) Engine Bay Rear Access Grille Side Panel (Radiator Grille) Lights (Rear)

  • Page 92: General Description Overview

    Section B - Body and Framework General Description Overview The space frame steel chassis houses the engine and The body panels are moulded plastic construction. They transmission system at the rear of the vehicle, beneath the are removable to provide access. load bay.
  • Page 93 Section B - Body and Framework Body Panels and Covers Centre Console Removal and Replacement Park the machine on firm level ground. Unscrew and remove the control lever knobs. Rotate the seats forward to gain improved access to the console fixing screws. Remove the six screws 1-A and remove the centre console.

  • Page 94: Body Panels And Covers Centre Console

    Section B - Body and Framework Body Panels and Covers Centre Console Page left intentionally blank 9803/9390-2...

  • Page 95: Cooling Pack And System

    Section B - Body and Framework Cooling Pack and System General Description C025470 Fig 1. Mounting Bracket - Upper Top Hose Rubber Grommets Bottom Hose Radiator Vent Overflow Tube Electric Fan Connector Filler Bottle Temperature Switch (Fan) Pressure Cap Connection - Vent Tube Return Flow from Thermostat (Engine) Flow to Water Pump (Engine) 9803/9390-2...

  • Page 96: Removal And Replacement

    Section B - Body and Framework Cooling Pack and System Removal and Replacement Removal and Replacement Cooling Pack WARNING The cooling system is pressurised when the coolant is hot. When you remove the cap, hot coolant can spray out and burn you. Make sure that the engine is cool before you work on the cooling system.
  • Page 97 Section B - Body and Framework Cooling Pack and System Removal and Replacement Fig 3. Replacement Replacement is the reverse of removal, but note the following. Ensure all hose connections are tight and secure. Torque tighten the wormdrive clips to 8 Nm. Torque setting for radiator fittings - 20 Nm.
  • Page 98 Section B - Body and Framework Cooling Pack and System Removal and Replacement Page left intentionally blank 9803/9390-2...

  • Page 99: Fuel Tank

    Section B - Body and Framework Fuel Tank Removal and Replacement Fig 1. Fuel Tank and Sender Unit Fuel Tank Filler Cap Fuel Gauge Sender Unit Hose Clips Filler Neck Hand Pump 9803/9390-2...

  • Page 100: Removal

    Section B - Body and Framework Fuel Tank Removal and Replacement Removal Disconnect the wiring from the fuel gauge sender unit 3-B. WARNING Disconnect the fuel feed and return hoses 3-A. Plug the hoses. Diesel Fuel Diesel fuel is flammable; keep naked flames away from the fuel system.

  • Page 101: Fuel Sender - Removal And Replacement

    Section B - Body and Framework Fuel Tank Fuel Sender - Removal and Replacement Fuel Sender - Removal and Replacement K Fig 1. ( T B-9) Refer to illustration, Replacement Removal Check that the fuel tank is empty and the battery is disconnected.
  • Page 102 Section B - Body and Framework Fuel Tank Fuel Sender - Removal and Replacement Page left intentionally blank B-12 9803/9390-2 B-12...
  • Page 103 Customer Support 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.
  • Page 104 Section C - Electrics Notes: 9803-9390-2...
  • Page 105 Section C - Electrics Contents Page No. Technical Data General Electrical Data ................C-1 Bulbs ....................C-1 Fuses and Relays ..................C-2 Fuses ....................C-2 Primary Fuses ..................C-3 Relays ....................C-3 Circuit Schematic Main Components ..................C-5 Service Tools Numerical List ...................
  • Page 106 Section C - Electrics Contents Page No. C-ii C-ii...

  • Page 107: Technical Data

    Section C - Electrics Technical Data General Electrical Data System Type 12 Volt, negative earth Battery Type Capacity (20 hr) 24Ah Cold Cranking Amps - EN 200 A Weight 7.8 kg Starter Motor 0.8 kW Alternator Nominal Output 60 Amp Tipper Ram Type: DC motor driven ball screw linear actuator (1) Powered tipper machines only.
  • Page 108 Section C - Electrics Technical Data Fuses and Relays Fuses and Relays Fuses Table 1. Secondary Fuse Box A Fuse Circuit Fuse Rating (Amps) CAUTION Instrument Panel Fuses E.S.O.S. Always replace fuses with ones of correct ampere Water Temperature Switch, Engine rating to avoid electrical system damage.

  • Page 109: Fuses And Relays

    Section C - Electrics Technical Data Fuses and Relays Primary Fuses Table 4. Relays Four primary fuses further protect the machine wiring Relay Description harnesses and electrical circuits. The fuse holder P is K Fig 1. ( T located near the battery, C-2).
  • Page 110 Section C - Electrics Technical Data Fuses and Relays Page left intentionally blank 9803/9390-2...

  • Page 111: Circuit Schematic Main Components

    Section C - Electrics Circuit Schematic Main Components Circuit Schematic Main Components K Fig 1. ( T C-7) For Schematic Diagram Main Lighting Switch LH Front Light Table 1. Key to Schematic Diagram RH Front Light Battery Horn Switch Glowplug Common Rail Front Horn Primary Fuses Beacon (option)
  • Page 112 Section C - Electrics Circuit Schematic Main Components RH Front Indicator RH Rear Indicator RH Trailer Rear Indicator RH Tail Light RH Trailer Tail Light No. Plate Light LH Tail Light Trailer No. Plate Light LH Trailer Tail Light Diode Fog Light Switch Fog Light Switch Illumination LH Rear Fog Light...
  • Page 113 RELAY A 600Y 106F 1850 TIPPER MOTOR TIPPER (OPTION) TIPPER RELAY B 001G 179A FUSE A5 600Z 114JB 1850A 179C JCB 701/60009 TIPPER SWITCH EARTH TERMINAL 310F BRAKE 001A RELAY BRAKE SWITCH 106G 600MJ 600W FUSE B1 816D 600G LH BRAKE LIGHT...
  • Page 114 Section C - Electrics Circuit Schematic Main Components Page left intentionally blank 9803/9390-2...

  • Page 115: Service Tools

    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 workshop or be available locally from any good tool supplier.

  • Page 116: Tool Detail Reference

    Section C - Electrics Service Tools Tool Detail Reference Tool Detail Reference 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 5 892/00282 100 amp Shunt - open type 6 892/00285 Hydraulic Temperature Probe Fig 1.
  • Page 117 Section C - Electrics Service Tools Tool Detail Reference K Electrical Repair Kit ( T C-11) Electrical Repair Kit :7212/0002 2 Way Pin Housing :7212/0004 2 Way Pin Retainer :7212/0003 2 Way Socket Retainer :7212/0001 2 Way Socket Connector :7213/0002 3 Way Pin Housing :7213/0004 3 Way Pin Retainer...
  • Page 118 Section C - Electrics Service Tools Tool Detail Reference Page left intentionally blank C-12 9803/9390-2 C-12...
  • Page 119 Section C - Electrics Service Procedures Using a Multimeter TC-002 In order to obtain maximum benefit from the fault finding information contained in Section C it is important that the technician fully understands the approach to fault 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.

  • Page 120: Service Procedures Using A Multimeter

    Section C - Electrics Service Procedures Using a Multimeter Make sure that the test leads are plugged into the Measuring Resistance correct sockets. The black test lead should be plugged into the black socket (sometimes, this socket Make sure there is no power to the part of the circuit is also marked by a "-", or "E"...

  • Page 121: Measuring Continuity

    Section C - Electrics Service Procedures Using a Multimeter Measuring Continuity Measuring Frequency Make sure there is no power to the part of the circuit The AVO 2003 and the analogue meter are not capable of you are checking for continuity. measuring frequency, therefore a Fluke 85 digital multimeter must be used.

  • Page 122: Testing A Diode Or A Diode Wire

    Section C - Electrics Service Procedures Using a Multimeter Testing a Diode or a Diode Wire c On an analogue meter. Select the Ohms 1000s (1k) range. A diode wire is a diode with male connector fitted on one end and a female connector fitted on the other end. The Connect the black probe to the end of the diode is sealed in heatshrink sleeving.

  • Page 123: Battery

    Section C - Electrics Service Procedures Battery Battery TC-001_3 Maintenance WARNING Batteries give off an explosive gas. Do not smoke To ensure that the battery provides optimum performance when handling or working on the battery. Keep the the following steps should be observed: battery away from sparks and flames.

  • Page 124: Testing

    Section C - Electrics Service Procedures Battery Testing 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 least 9 volts. This test is to determine the electrical condition of the battery and to give an indication of the remaining useful Note: Do not hold the switch in the LOAD position for more `life'.

  • Page 125: Specific Gravity Testing

    Section C - Electrics Service Procedures Battery Specific Gravity Testing 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. The specific gravity of the electrolyte gives an idea of the state of charge of the battery.

  • Page 126: Alternator

    Section C - Electrics Service Procedures Alternator Alternator TC-006 General Description Charging Circuit Test The alternator is a three phase generator having a rotating Ensure that all battery and alternator connections are field winding and static power windings. in place, secure and making good metal - to - metal contact, especially the 'earth' connections to chassis When the start switch is turned on, current from the battery and engine.

  • Page 127: Alternator Charging Test

    Section C - Electrics Service Procedures Alternator Alternator Charging Test Fig 5. Check 2 Note: The following checks should be made using an analogue (moving pointer) type meter. Stop the engine and turn the starter switch to OFF. Fig 7. Withdraw the alternator plug and connect the test meter between the large terminals and 'earth'.
  • Page 128 Section C - Electrics Service Procedures Alternator Faults d, e, and f may be checked only by removing AVO 2002 – Red lead to volts (middle) socket on and dismantling the alternator for further testing. meter. – Black lead to negative on meter. –...

  • Page 129: Starter Motor

    Section C - Electrics Service Procedures Starter Motor Starter Motor TC-005 Starting Circuit Test than 0.5V below the reading obtained in Step 1. Minimum permissible reading in 'start' position 9.0V. Before carrying out the voltmeter tests, check the battery If the reading is within this limit, continue to Step 3. If condition and ensure that all connections are clean and the reading is outside the limit, proceed to Step 4 and tight.
  • Page 130 Section C - Electrics Service Procedures Starter Motor b If the reading between terminal 11-D and earth is Connect the voltmeter between battery positive and below 8.0V, connect the voltmeter between the starter main terminal 13-A. With the starter switch terminal 11-E and earth.

  • Page 131: Wire And Harness Number Identification

    B-819 9/371. The wire's unique identification number. The wire functions and numbers allocated to them are consistent through out the JCB range of products. 9/371 The part number of the harness that the wire originates from. If the harness part number is 719/37100, the number printed on the harness wires will be 9/371 (71 and 00 are common numbers and therefore deleted).

  • Page 132: Wire Numbers And Functions

    Section C - Electrics Service Procedures Wire and Harness Number Identification Wire Numbers and Functions Wires 800-999 These numbers are reserved for switched supplies to Wires 000-199 electrical loads, i.e. to lights, etc. These numbers are reserved for ignition feeds, heater start Wires In Splices circuits and start circuits.
  • Page 133 Repair Procedure acceptable standard it is strongly recommended that the following tools, equipment and procedures are always used. Note that JCB harnesses have an International Table 4. Tools Required Protection rating of 67 (I.P.67). Part No.

  • Page 134: Wiring Harness Repair

    Section C - Electrics Service Procedures Wiring Harness Repair readily visible. They secured using corresponding size and matching colour-coded jaws of the crimp tool to ensure joint security. This tool also incorporates a ratchet closing mechanism which will not release until the splice is fully closed to the correct compression size.
  • Page 135 Section C - Electrics Service Procedures Wiring Harness Repair Side wings 24-G down, reflector head completely open. In this mode the infra-red heat waves are dominant (recommended for the light coloured plastic splices). Fig 22. Hold the heater vertically and, using a match or cigarette lighter, light the gas as shown.
  • Page 136 Section C - Electrics Service Procedures Wiring Harness Repair Page left intentionally blank C-30 9803/9390-2 C-30...
  • Page 137 Section C - Electrics Tipper Ram Removal and Replacement Park the machine on firm level ground. Apply the Replacement parking brake and chock the wheels. When replacing, note the following: Note: Ensure that the load bay is empty. Renew all self-locking nuts. Operate the tipper ram to fully raise the load bay.
  • Page 138 Section C - Electrics Tipper Ram Removal and Replacement Page left intentionally blank C-32 9803/9390-2 C-32...
  • Page 139 Section C - Electrics Harness Data Drawings and Interconnection Harnesses The basic machine has a single main harness. Machines with Deluxe lighting equipment will also have a Deluxe Lighting Harness. Table 1. Harnesses Harness No. Issue Remarks Drawing K Fig 1. ( T 721/11884 Sht 1 Basic Harness Layout C-34)
  • Page 140 Fig 1. Basic Harness Layout...
  • Page 141 Fig 2. Basic Harness Connections...
  • Page 142 Fig 3. Deluxe Lighting Harness Layout...
  • Page 143 Fig 4. Deluxe Lighting Harness Connections...
  • Page 144 Fig 5. Worklight Harness Layout and Connections...
  • Page 145 Fig 6. ROPS Worklight Harness Layout and Connections...
  • Page 146 Fig 7. Tipper Harness Layout and Connections...
  • Page 147 Customer Support 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.
  • Page 148 Section 1 - General Information Notes: 9803-9390-2...
  • Page 149 Section D - Controls Contents Page No. Transmission Controls Forward - Reverse Selector ..............D-1 Operation ....................D-1 Differential Lock ..................D-2 Operation ....................D-2...
  • Page 150 Section D - Controls Contents Page No. D-ii D-ii...

  • Page 151: Transmission Controls

    Section D - Controls Transmission Controls Forward - Reverse Selector Operation Mechanical linkages connect the selector lever to the transaxle shift arm 9. Note the location of the Neutral Start switch S. C025440 Fig 1. Knob (Lever) Clevis Pin Selector Lever Clevis Clip Lever Arm Gear Linkage...

  • Page 152: Differential Lock

    Section D - Controls Transmission Controls Differential Lock Differential Lock Operation The selector is connected via a cable to a lever arm on the transaxle L. C025450 Fig 2. Knob (Hand Lever) Cable Lever Diff-lock Bar Washer Linkage Circlip Bushes Washer Pivot Bar (1) Shared with Forward-Reverse Lever installation.
  • Page 153 Section D - Controls Transmission Controls Differential Lock Fig 3. Cable Bracket 9803/9390-2...
  • Page 154 Section D - Controls Transmission Controls Differential Lock Page left intentionally blank 9803/9390-2...
  • Page 155 Customer Support 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.
  • Page 156 Section E - Hydraulics Notes: 9803-9390-2...
  • Page 157 Section E - Hydraulics Contents Page No. Introduction Note: THERE ARE NO HYDRAULICS ON THIS MACHINE ....E-1...
  • Page 158 Section E - Hydraulics Contents Page No. E-ii E-ii...

  • Page 159: Introduction

    Section E - Hydraulics Introduction Note: THERE ARE NO HYDRAULICS ON THIS MACHINE 9803/9390-2...
  • Page 160 Section E - Hydraulics Introduction Note: THERE ARE NO HYDRAULICS ON THIS MACHINE Page left intentionally blank 9803/9390-2...
  • Page 161 Section E - Hydraulics Introduction Note: THERE ARE NO HYDRAULICS ON THIS MACHINE Page left intentionally blank 9803/9390-2...
  • Page 162 Customer Support 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.
  • Page 163 Section F - Transmission Notes: 9803-9390-2...
  • Page 164 Section F - Transmission Contents Page No. Technical Data Data ......................F-1 Variable Speed Drive System ..............F-1 Transaxle ....................F-1 Axles ......................F-1 Wheels and Tyres ..................F-1 Service Tools Numerical List .................... F-3 Tool Detail Reference ................F-4 General Description Overview ....................F-5 Transaxle ....................F-5 Driver Pulley Removal and Replacement ...............
  • Page 165 Section F - Transmission Contents Page No. F-ii F-ii...

  • Page 166: Technical Data

    Section F - Transmission Technical Data Data Variable Speed Drive System System Type Friction, single V-belt, continuously-variable transmission (CVT). Driver Clutch (Variator) Engine crankshaft mounted. Two half pulleys, one fixed, the other moveable via centrifugal rollers. Driven Clutch Transaxle input shaft mounted. Transaxle Type Fixed ratio gearbox.
  • Page 167 Section F - Transmission Technical Data Data Page left intentionally blank 9803/9390-2...

  • Page 168: Service Tools

    Note: Tools other than those listed will be required. It is carrying out the procedures described in this section. expected that such general tools will be available in any These tools are available from JCB Service. well equipped workshop or be available locally from any good tool supplier.

  • Page 169: Tool Detail Reference

    Section F - Transmission Service Tools Tool Detail Reference Tool Detail Reference CVT Puller 825/10034 262.6 191.1 150.3 94.5 5/8 UNF THREAD SECTION A-A 9803/9390-2...

  • Page 170: General Description

    Section F - Transmission General Description Overview K Fig 1. ( T F-5) Refer to illustration increases, the driven pulley becomes smaller. The transmission drive ratio therefore varies. Power is transferred from the engine to the transaxle via an ‘automatic’ continuously-variable transmission system The transaxle gearbox unit 1-D operates in Neutral, (CVT system).
  • Page 171 Section F - Transmission General Description Overview 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 packs which act as service brakes and parking brake, see Section ‘G’...

  • Page 172: Driver Pulley

    Section F - Transmission Driver Pulley Removal and Replacement Park the machine on firm level ground. Apply the Replacement parking brake and chock the wheels. Replacement is the reverse of removal, but note the The load bay needs to be raised to gain access to the following: engine bay.
  • Page 173 Section F - Transmission Driver Pulley Removal and Replacement C025120 Fig 2. Dimension A: 55.8 +/- 2 (mm) Dimension B (Reference): 394.2 +/- 2 (mm) 9803/9390-2...

  • Page 174: Driven Pulley

    Section F - Transmission Driven Pulley Removal and Replacement Park the machine on firm level ground. Apply the Replacement parking brake and chock the wheels. Replacement is the reverse of removal, but note the The load bay needs to be raised to gain access to the following: engine bay.
  • Page 175 Section F - Transmission Driven Pulley Removal and Replacement Page left intentionally blank F-10 9803/9390-2 F-10...

  • Page 176: Transaxle

    Section F - Transmission Transaxle Differential Lock Lever Arm Transaxle Differential Lock Lever Arm Note: Also refer to Section ‘D’ Controls - ‘Differential Assembly Lock’. Use new seals and washers as necessary. Dismantling Lubricate the new seal F with suitable grease and Note: If the transaxle has been removed from the vehicle, install into its recess in the housing G.
  • Page 177 Section F - Transmission Transaxle Differential Lock Lever Arm Page left intentionally blank F-12 9803/9390-2 F-12...
  • Page 178 Section F - Transmission Axles General K Fig 1. ( T F-5) Refer to illustration The front axles are the driving axles from the transaxle unit. The rear axles are chain-driven by the front axles. Although all four axles are the same, they should be kept in the same position once fitted.

  • Page 179: Axles General

    Section F - Transmission Axles General Fig 1. Front (Driven) Axles Axle Circlip Splined Coupling (Long) Grease Nipple Splined Coupling (Short) Transaxle (1) Front axles only. F-14 9803/9390-2 F-14...

  • Page 180: Removal And Replacement

    Section F - Transmission Axles Removal and Replacement Removal and Replacement Removal Note: Ensure the axle hubs are clearly marked before K General ( T F-13) removal. Drive the machine onto a dry, firm and level area. Ensure the park brake is on. The load bay needs to be raised to gain access to the engine bay.
  • Page 181 Section F - Transmission Axles Removal and Replacement C006210 C006220 Fig 5. Fig 3. Fit the drive chains to the axle sprockets. Important: Ensure that there is end float in the couplings after assembly. Transaxle and front axles must be in-line to Adjust the chain tensioning bolts 2-F until the chain ensure this end float is available.
  • Page 182 Customer Support 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.
  • Page 183 Section G - Brakes Notes: 9803-9390-2...
  • Page 184 Section G - Brakes Contents Page No. Basic System Operation Layout ....................... G-1 Technical Data System Type ..................... H-3...
  • Page 185 Section G - Brakes Contents Page No. G-ii G-ii...
  • Page 186 Section G - Brakes Basic System 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 disc brake packs and transaxle are non- serviceable.
  • Page 187 Section G - Brakes Basic System Operation Layout Page left intentionally blank 9803/9390-2...
  • Page 188 Section H - Brakes Technical Data System Type Mechanical linkages 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 and left) Park Brake Type: As Service Brake Actuation:...
  • Page 189 Section H - Brakes Technical Data System Type Page left intentionally blank 9803/9390-2...
  • Page 190 Customer Support 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.
  • Page 191 Section H - Steering Notes: 9803-9390-2...
  • Page 192 Section H - Steering Contents Page No. Technical Data Data ......................H-1 General Description Steering System ..................H-3 Checking and Adjustment Wheel Alignment ..................H-5 Rack and Pinion Steering Gear Removal and Replacement ..............H-7 Tie-Rod Outer Ball Joints ..............H-7 Universal Joints ..................
  • Page 193 Section H - Steering Contents Page No. H-ii H-ii...

  • Page 194: Technical Data

    Section H - Steering Technical Data Data System Type Rack and pinion Steering wheel turns (lock to lock) 9803/9390-2...
  • Page 195 Section H - Steering Technical Data Data Page left intentionally blank 9803/9390-2...

  • Page 196: General Description

    Section H - Steering General Description Steering System C023870 Fig 1. Steering Column Clamp Steering Column Shaft Tie-Rods and Ball Joints Intermediate Shaft Kingpins Steering Rack Universal Joints 9803/9390-2...
  • Page 197 Section H - Steering General Description Steering System (1) Note: The kingpins pivot on the suspension lower arms (not shown). 9803/9390-2...

  • Page 198: Checking And Adjustment

    Section H - Steering Checking and Adjustment Wheel Alignment The steering geometry is only adjustable for toe i.e. alignment. Specification: Neutral Toe Wheels in straight-ahead position (parallel) For improved control and safety, the steering geometry should be correctly adjusted. This will also help reduce tyre wear.
  • Page 199 Section H - Steering Checking and Adjustment Wheel Alignment Page left intentionally blank 9803/9390-2...

  • Page 200: Rack And Pinion Steering Gear

    Section H - Steering Rack and Pinion Steering Gear Removal and Replacement Apply the park brake and chock the rear wheels. Disconnect the battery. WARNING A raised and badly supported machine can fall on you. Position the machine on a firm, level surface before raising one end.

  • Page 201: Steering Rack Mountings

    Section H - Steering Rack and Pinion Steering Gear Removal and Replacement Fig 4. Fig 2. Steer Rack Mounting (Left Side) and Universal Joint Connection Steering Rack Mountings On the left hand side, the steering rack connects to the chassis through the steer rack body 2-B. On the right hand side, it is secured to the chassis by a U-shaped mounting K Fig 3.
  • Page 202 (2) Grade 12.9 (Nut grade equivalent to bolt). (3) Hardened washers - NOT ordinary washers. Using incorrect specification items could result in a reduction of clamping efficiency. Use correct grade JCB hardened washers. Fig 1. Sectional View of Steering Swivel (Kingpin)

  • Page 203: Inspection

    Apply the parking brake and chock the rear wheels. washers - NOT ordinary washers. If renewing, renew Disconnect the battery. with correct grade JCB hardened washers. Raise and properly support the machine. Remove the Renew the nut 1-J (grade 12.9) and torque tighten to...

  • Page 204: Front Wheel Bearings

    Section H - Steering Front Wheel Bearings Location The wheel bearings are press-fitted into the hubs of the road wheels. C025830 Fig 1. Replacement of Worn Bearings Apply the park brake and chock the rear wheels. Raise and properly support the machine. Remove the wheel, see Section 3 - Routine Maintenance.
  • Page 205 Section H - Steering Front Wheel Bearings Location Page left intentionally blank H-12 9803/9390-2 H-12...
  • Page 206 Customer Support 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.
  • Page 207 Section K - Engine Notes: 9803-9390-2...
  • Page 208 Section K - Engine Contents Page No. Technical Data Specification ..................... K-1...
  • Page 209 Section K - Engine Contents Page No. K-ii K-ii...
  • Page 210 Section K - Engine Technical Data Specification For additional information, see the following publication: Engine Service Manual, publication number 9806/2195 Model Perkins 403C-07 Emission Compliance Tier 2 Type Vertical in-line, 3 cylinder, naturally aspirated, 4 stroke, water cooled diesel. Power Output (Gross) 15.3 kW (20.5 hp) @ 3600 rpm Maximum Torque 50.5 Nm (37.2 lbf-ft) @ 2400 rpm...
  • Page 211 Section K - Engine Technical Data Specification Fuel System Combustion System Indirect Injection Injection Pump Type Governing Injection Timing Injection Nozzle Type Injection Pressure (Working) (Setting) Lubrication System System Type Forced Lubrication by rotor type pump Oil Pressure @ Idle (minimum allowable) Oil Pressure @ Rated Speed (minimum allowable) Oil Pressure Regulated 9803/9390-2...
  • Page 212 Customer Support 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.
  • Page 213 Section S - Suspension Notes: 9803-9390-2...
  • Page 214 Section S - Suspension Contents Page No. 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 Strut Removal and Replacement ..............S-9...
  • Page 215 Section S - Suspension Contents Page No. S-ii S-ii...

  • Page 216: Technical Data

    Section S - Suspension 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/cm 234mm > 156mm 30 kg/cm 156mm > 106mm 9803/9390-2...
  • Page 217 Section S - Suspension Technical Data Data 9803/9390-2...

  • Page 218: Service Tools

    Note: Tools other than those listed will be required. It is carrying out the procedures described in this section. expected that such general tools will be available in any These tools are available from JCB Service. well equipped workshop or be available locally from any good tool supplier.

  • Page 219: Tool Detail Reference

    Section S - Suspension Service Tools Tool Detail Reference Tool Detail Reference 9803/9390-2...
  • Page 220 Section S - Suspension General Description Suspension Note: The vehicle is equipped with suspension to the front wheels only. C023750 Fig 1. Suspension Arrangement (Left Side Shown) Lower Arm (Wishbone) Spring/Damper Assembly Rubber Bush (Metal Bonded) Kingpin - Refer to Section ‘H’ Steering 9803/9390-2...
  • Page 221 Section S - Suspension General Description Suspension (1) Note: Steering rack and tie-rod ball joints have been omitted for clarity. 9803/9390-2...

  • Page 222: Lower Arm (Wishbone)

    Section S - Suspension Lower Arm (Wishbone) Removal and Replacement Apply the park brake and chock the rear wheels. Replacing Bushes Disconnect the battery. Inspect the rubber bushes for wear, damage or signs of ageing. WARNING A raised and badly supported machine can fall on you. Also remove the kingpin, see Section ‘H’...

  • Page 223: Removal And Replacement

    Section S - Suspension Lower Arm (Wishbone) Removal and Replacement Lower Arm Replacement Correctly torque tighten fasteners: Table 1. Torque Settings Note: Replacement is the reverse of removal, but note the Item Bolt lbf ft following: Grade Renew all self-locking nuts. Kingpin Pivot Bolt 12.9 Lower Arm to Chassis...
  • Page 224 Section S - Suspension Spring/Damper Strut Removal and Replacement Apply the park brake and chock the rear wheels. Replacing Bushes Disconnect the battery. Inspect the rubber bushes 1-C for wear, damage or signs of ageing. WARNING A raised and badly supported machine can fall on you. Use a suitable press to remove the old bushes and to Position the machine on a firm, level surface before insert new ones.
  • Page 225 Section S - Suspension Spring/Damper Strut Removal and Replacement Dismantling and Assembly Fig 1. Damper Spring Bushes S-10 9803/9390-2 S-10...
  • Page 226 Section S - Suspension Spring/Damper Strut Removal and Replacement Spring/Damper Replacement Note: Replacement is the reverse of removal, but note the following: Renew all self-locking nuts. The correct grade of fasteners must be used. K Fig 1. Chassis Correctly torque tighten fasteners, Mountings ( T S-8) S-11 9803/9390-2...
  • Page 227 Section S - Suspension Spring/Damper Strut Removal and Replacement Page left intentionally blank S-12 9803/9390-2 S-12...

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