SERVICE

SERVICE MANUAL

Wheeled

Loader

PUBLISHED BY THE TECHNICAL PUBLICATIONS DEPARTMENT OF JCB SERVICE: @ ROCESTER, STAFFORDSHIRE, ST14 SLS, ENGLAND Tel. ROCESTER(0889) 590312 PRINTED INENGLANO

Publication No. 9803/4100

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GB Service Manual P blication No. 9803/4100

Chargeurs Sur Pneus

Radlader

Manual de reparaciones Publicación No. 9803/4100A,

Cargadoras Sobre Ruedas.

' Wheeled Loader

Italian

Manuale de servizio Stampato No. 9B03/4100B

Caricatore Gommato

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JCB SERViCE

CATALOGUE/ MANUAL - REPLACEMENT PAGES

These peges should be sedia immediately in their conect positions and pages of a lower issue no. removed and destroyed. The total contents of this pt ination can be checked using the index below. Retain Indax at frofc of booL Replacement pages bsued in this set ere indicated by an asterisk (°).

1 - 1A

1 - 2

1 - 3

2 6 - 24

4 6 - 25

5 • 26

6 - 28

8 6 - 29

3 5 -30

8° 6 - 1

2 6 - 3

2 • 6

3 - 7

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2 • 10

2 • 11

2 - 12

2 • 13

2 • 14

3 - 6B

3 • 8

3 • 9

3 • 10

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3 - 12

taeue

2 • 3

3 - 2

Section 3

1 - 1B

1 • 3

2 • 1

2 - 2

1. - ZA

   g- 3

2. - 1

3 - 2

3 - 3

3 • 4

3 • 5

J - 1

J - 2

4 • 3

S • 3

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s-7

s- e

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S - 21 S • Z2 6 • SS

10 6 • 5

6 7 - 2

7 • 3

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3 7-7

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3 7 - 13

6 7 • 14

3 7 • 15

2 7 • 16

4 8 • 1

1 6 - 2

3 9 • 1

2 10 • 1

1 10 - 1A

1 10 • 1B

1. IO • 1D

   3 10 - 2

   3 10 - 3

   
   

   3 11 - 3

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1 12 • 3

1. Section 4

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   1 2 • 2

   1 2 • 3

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      1 1 - 3

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      3 4 • 4

      1 6 - 1

      
      

      2 6 - J

      2 8 - 1

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2 1 - 2

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2 3 - S

1 3 • 6

1 3 - 6A

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10”

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6-2

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6 - 31 2

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5-35 3

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Page No	Issue	Page No		Issue		Page No	Iss ue
Section 6 (Cont'd) 5 - 39 5 - 40 5 - 41 5 - 42 S - 43 S - 44 5 - 45 5 - 46 5 - 47 6 • 1 6 - 2 6 - 3 7 - 1 8 • 1 8-2 8 - 3 8 - 4 8 - 5 8 - 6 8 - 7 8 - 8 8 - 9 9 - 1 9 - 2 9 - 3 9 - 4 9 - 5 9 - 6 9 - 7 9 - 8 9 - 8A 9 - 9 9 - 9A 9 - 10 9 - 11 9 - 12 9 - 13 9 - 14 9 - 15 9 - t6 $0 - $ 10-2 11 - 1 11 - 2 Section 7 - t - 1 2 - 2 - 1 3 - 2 - 1 4 - 2 4 - 3 4 - 4 • 1 5 - 2 5 - 3 S • 4 5 - 5 5 - 6 5 - 7 - t 6•2 6•3 6 - 4 6 - 4A 6 - 5	2 2 2 2 3 2 3 2 2 3 2 2 3 1 t 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 2 4 1 1 1 1 t 2 2 3 2 4 1 10 5 2 5 2 8 8 2 2 1 2 4 1 2 7 1 2 2 2 4 1 2	6 - SA 6 - 6 6 - 7 6 - 8 6 - 9 6 • 10 6 • 11 6 - 12 6 • 13 6 - 14 6 - 15 6 - 16 7 - 1 7 - 2 Section 8 1 - 1 1 - 2 2 - 1 2 - 2 2 - 3 2 - 4 2 - S 2 - 6 2 - 7 3 - 1 4 • 1 5 - 1 S - I A 5 - 1B 5 - 2 S - 3 Section 9 1 - 1 2 - t 2-2 2•3 3-1 3-2 4-1 4-2 .-3 4-4 4 - 5 4 - 6 5 - 1 5-2 5-3 5-4 6-1 7-1 7-2 7-3 7 - 4 7 - 5 7 - 6 7 - 7 7 - 8 8 - 1 8 - 2 8 - 3 8 - 4 8 - 5 9 - 1 IO - 1	1 1 1 2 3 J 2’ 2 1 2” 1 1 t* 1* 9 2 3 2 1 1 2 3 1 6 6 3 2 1 4 2 7 5 4 S 6 9 2 2 2 2 2 2 t 4 1 1 3 1 1 2 2 1 1 1 1 1 t 1 1 1 1 1	Section 10 1 - 1 1 - 2 1 - 3 - t - 1 3 - 2 - 1 4 - 1A 4 - 1B 4 - 2 4 - 3 4 - 4 4 - 5 4 - 6 4 - 7 4 - 8 4 - 9 4 - 10 4 - 11 4 - 12 4 - 13 4 - 14 - 1 5 - 2 - 1 6 - 2 6 - 3 6-4 6-5 6-6 6•7 6 • 8 7 - 1 7 - 2 7-3 7-4 7-5 7-6 7-7 7 - 8 7 - 9 7 - 10 7 - 11 7 - 12 7 - 13 7 - 14 8 - 1 8 - 2 9 - 1 9 - 2 9 - 3 9 - 4 9 - 5 9 - 6 10 - 1 10 - 2 10 - 3 10 - 4 10 - 5 10 - 6 10 • 7 10 - 8 10 - 9 10 - 10 Section 11 1 - 1 1 - 2		1 - 3	2 4 1 2 5 2 2 14” 14” 14* 14” 14” 14“
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4

Contents

9B03/4100

General Hydraulics

Body 6 Framework Engine Transmission

Axles

Brakes

Hydraulic Steering Electrics

“Service Tools Index

1

2

4

5

6

7

8

9

10

11

Issue 2’

Introduction

This publication is designed fOF the benefit of JCB Distributor Service Engineers who are receiving or have received training by the JCB Technical Training Department.

It is assumed that these personnel have a sound knowledge of good workshop practice, safety procedures and general techniques associated with the maintenance and repair of hydraulic earthmoving equipment. Therefore these basic subjects are omitted from this manual, the intention being to convey only more specia|ised information concerning particular aspects of the machine or component.

For example, ranewal ol oil seals, gaskets, etc. and any component showing obvious wear or damage is expected as a matter o| course, and therefore information of this nature is included in the context of specialised procedures or where a range of wear tolerances is requirad. Similarly it is expected that components will be cleaned and lubricated where appropriate, also that any opened hose or pipe connections will be blanked to prevent excessive loss of hydraulic Iluid and ingress of dirt.

For convenience the manual is compiled in sections, e.g. "Hydraulics", "Electrics" etc., but to find details of a specific component, reference should be made to the alphabetical index at the back of the book,

Illustration which show a dismantled component are numbered as a guide to the dismantling sequence, which generally can be reversed for assembly.

Torque settings are given as a 'mean' Figure which may be varied by + or - 3%. Torque figures indicated are for dry threads, hence for lubricated threads may be reduced by one third. Where no figure is quoted in the text, refer to page 1/1 - 3.

'Left Hand' and 'Right Hand' are as viewed from the rear ot the machine looking forward.

Tone Coding

The following coding is used on hydraulic circuit illustrations with no colour, to denote various conditions of oil pressure and flow.

1. Neutral Circuit Pressure.

   
   

2. Pressure generated by the operation of a service. Depending on application, this may be anything between neutral Circuit Pressure and MRV Operating Pressure.

   
   

3. Pressure that is above neutral pressure but

   lower than that denoted by 2.

   
   

4. Exhaust.

WARNING

Asbestos

Asbestos dust can damage your lungs. Some engine joints and gaskets may contain asbestos. Take the following pfecautions when working on them.

1. Wear a face mask and gloves.

2. Work in a well ventilated area and do not smoke.

3. Do not use a rotary wire brush, use a hand scraper.

4. Make sure the material ]o be removed is wet with oil or water to contain loose particles.

5. Place all material into plastic bags and dispose of in accordance with local regulations.

9e03/4100

WARNING

Fluoroelastomerlc Materials

Certain seals and gaskets (e.g. crankshaft oil seal) on JCB machines contain fluoroel astom eric mater ials such as Viton, Fluorel and Technoflon. Fluoroelastomeric materials subjected to high temperatures can produce highly corrosive hydrofluoric acid. THIS ACID CAN SEVERELY BURN.

New fluoroelastomeric components at ambien1 temperature require no special safety precautions.

Used fluoroelastomeric components whose temperatures have not exceeded 300°C require no special safety precautions. If evidence of decomposition (e.g. charring) is found, refer to the next paragraph for safety instructions DO NOT TOUCH COI IPONENT OR SURROUNDING AREA.

Used lluoroelastomeric components subjected to temperatures greater lhan 300°C (e.g. engine fire) m ust be treated using 1he following safety procedure. Make sure that heavy duty gloves and special safety glasses are worn:

1. Ensure that components have cooled then remove and place material into plastic bags.

2. Thoroughly wash contaminated area with 10% calcium hydroxide or other suitable alkali solution, if necessary use wire wool lo remove burnt remains.

4 Contain all removed material, gloves etc used in this operation in sealed plastic bags and dispose of in accordance with Local Authority Regulations.

DO NOT BURN FLUOROELASTOMERIC MATERIALS.

If contamination of skin or eyes occurs, wash the affected area with a continuous supply o| clean water or with calcium hydroxide solution for 15-60 minutes. Get medical attention immediately.

INT-3-3-W1

Issue 4

Colour Coding

The following colour coding, used on illustra tions to denote various conditions of oil pressure and flow, is standardised throughout J CB Service Publica tions.

Blue:

Red:

Pink:

Green:

Neutral Circuit Pressure.

Pressure generated by the opera- tion of a service. Depending on application this may be anything between Neutral Circuit Pressure and M.R.V. Operating Pressure.

Pressure that is above Neutral Circuit Pressure but lower than that denoted by Red.

Exhaust.

Light Oil subjected to a partial vacuum Green: due to a drop in pressure lcavi-

tation).

Yellow: Oil trapped within a chamber or line, preventing movement of components (lock-up) .

“ ” “ ' O range: Oil pressure used in a controlling device (servo).

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Colou r Coding

The following colour coding, used on illustrations to denote various conditions of oil pressure and flow, is standardised throughout JCB Service Publica tions.

Blue:

Red:

Pink:

Green:

Neutral Circuit Pressure.

Pressure generated by the opera- tion of a service. Depending on applica tion this may be anything between Neutral Circuit Pressure and M.R.V. Operating Pressure.

Pressure that is above Neutral Circuit Pressure but lower than that denoted by Red.

Exhaust.

Light Oil subjected to a partial vacuum Green: due to a drop in pressure (cavi-

tation).

Yellow: Oil trapped within a chamber or line, preventing movement of components (lock-up) .

' Orange: Oil pressure used in a controlling device (servo).

1

I - 1

ENGINE LUBRICANTS and CAPACITIES.

General 1

1 - 1

Note: To promote thorough running-in, engines of new machines are filled at the factory with JCB 10W/30 Multlgrade oil. This oil

- should be drained after the first 100 hours operation and the englne filled with the recommended grade' as shown in the engine ubrication chart JCB 10W/30 Multigrade should also be used for the first 100 hours operation whenever a new or reconditioned engine is fitted Into the machine. Alternatively, where a new or reconditioned engine requires protection against corrosion during prolonged storage, Mobilarma 524 may be used during the storage period and for the first 100 hours operation. It is essential that

° oth these oils are replaced by the recommended lubricant after the first 100 hours operation.

ENGINE LUBRICATION CHART

JCB SAE 30 Engine Oil

SAE 40 APICD MIL-L-2104C

JCB 20W/20

15W/40 Multigrade

JCB Torque Converter Fluid (10W)

JCB Super Universal Agricultural 10W/30)

-30

9803/4100

-20

-10

0 10 20

AMBIENT TEMPERATURE (DEGREES C)

30 40 50

Issue 8

1

1 - 1A

TRANSMISSION LUBRICANTS and CAPACITIES.

General

1

1 - 1A

Model

Lubricant

Capacity

‘ HYDRAULIC FLUIDS and CAPACITIES

Model

Lubricant

Capacity (see Note)

A = up to 38 deg C ( 100 deg F ) B = above 38 deg C ( 100 deg F )

+ These oils meet the following specifications: API CD

MIL- L-2104D MIL- L- 46152

Note: Hydraulic capacities shown are approximate and depend on equipment specified.

9803/4100 Issue 3’

LUBRICANTS and CAPACITIES

t denotes Multi-purpose Lithium grease with Molybdenum di-sulphide

tt denotes 410 and 412 machines built after September 1989

§ denotes 45 litre (10 UK galls) auxiliary fuel tank fitted.

9803/4100

1

1—3

General 1

1—3

TOROUE SETTINGS

Use only where no torque setting is specified in the text. Values are for Dry threads and may be within three per cent of the figures stated. For lubricated threads the values should be REDUCED by one third.

UNF Grade ’S’ Bolts

in.

Bolt Size

(mm)

Hexagon (A/ F) in.

Nm.

Torque Settings kgf m

Ibf ft

Metric Grade 8.8 Bolts

Bolt Size

(mm)

Hexagon (A/ F) mm

Nm.

Torque Settings kgf m

lbf ft

"ZF Transmission (use only on ZF Transmission) — in Nm

Metric Coarse Thread Metric Fine Thread

Note: ALL bolts used on JCB machines are high tensile and must not be replaced by bolts of a lesser tensile specification.

lssue2’

1

2 - 1

SERVICE SCHEDULES

EVERY 10 OPERATING HOURS OR DAILY

whlchevar occurs first

General

EVERY 50 OPERATING HOURS OR WEEKLY

whichever occurs first

1

2 - 1

CLMN

Machine generally

Engine air filter pre-cleaner

CHECK (engine stopped)

Generally for damage

" Engine Coolant level and condition Engine oil level and condition Hydraulic fluid level

Tyre pressures and condition Tightness of wheel nuts Parking brake operation

• Service brake operation Windscreen washer level

  “ All pivot pin grease seals

• Air cleaner hose security

  Seat belt condition and security (when fitted)

  CHECK (engine running)

  Operation of all services

  " Hydraulic system for leaks ’ Transmission oil level

  Operation of all electrical equipment Exhaust (excessive smoke)

  “ Fuel system for leaks

• Engine generally for leaks

  " Instrument readings, warning lights and audible alarm ” DRAIN

  Fuel Filter

  GREASE

  ” Bucket pivot pins (415 8 425)

• Hydraulic Tow Hitch (410 & 412) (if fitted)

  
  

  9803/4100

  Do the daily jobs plus:

  CHECK (engine stopped) Fan belt/tension

  • Air conditioner compressor belt tension (if fitted)

    Radiator and hose condition

  • Electrolyte level Axle oil level

  • Brake fluid level

  • Condition of ram piston rod

  • Hoses and pipework for chafing/security

    CLEAN

  • Fuel sediment bowl GREASE

  • Bucket pivot pins (410 & 412 from m/c No. 524349)

  • Loader arm pivot pins (415 & 425) Lower centre pivot

    Steer ram pins

  • CHANGE

    Transmission oil filter (First 50 hours onIy)

    
    

  • Note: Initial transmission oil filter change at 50 hours and f 00 hours on new and rebuilt transmissions.

  • OIL

  All linkages, hinges and cables

  
  

  Issue 10*

  1        

  2-2

  SERViCE SCHEDULES (cont'd)

  INITIAL 100 HOURS SERVICE (new machines only)

  
  

  Do the Daily to 50 hour jobr plus:

  
  

  CLEAN

  
  

  fuel litt pump Heater fiber

  General

  
  

  EVERY 100 OPERATING HOURS OR MONTHLY

  whichever occurs first

  Do the Daily to 50 hour jobs plus:

  GREASE

  “ Loader pivot pins (410 & 412 from m/c No. 524349)

  1

  2 - 2

  
  

  CHECK (englne stopped)

  Condition of ram piston rods

  All pivot pin grease seals

  Hoses and pipework for chafing/damage Fuel system for leaks/contamination Exhaust system security

  Cylinder head torque settings (4 cyl. only; LJ builds up to

  Eng. No. UO27773M)

  Valva clearances Engine mountings

  Air cleaner hose security Wiring harness for chafing Rear axle pivot end float

  CHECK (engine running)

  MRV pressure

  ARV pressure

  Steering relief pressure

  Idling spead

  Maximum governed speed Pulled down speed Operation of clutch cutoff

  
  

  CHANGE

  
  

  Engina oil

  Engine oil filter element Fuel filter element Hydraulic filter element Transmission lilier element

  GREASE

  
  

  • Loader pivot pins (410 & 412 from m/c No. 524349)

  
  

  9803/4100

  “ CHANGE

  
  

  Transmission oil filter (First 1 00 Hours only)

  
  

  “ Note: Initial transmission oil filter chanpe at 50 hours and 100 hours on new'and rebuilt transmissions.

  
  

  EVERY 250 OPERATING HOURS OR MONTHLY

  whichever occurs first

  Do the Daily to 100 hour jobs plus; ‘ CLEAN

  Air filter dust valve

  CHECK (engine stopped)

  Exhausted oil level (412 and 415 only)

  * Battery electrolyte level and condition ” CHECK (engine running)

  Air conditioner |ilter/drier sight glass for fluid (wilh air conditioner system running). (if fitted).

  
  

  CHANGE

  
  

  Engine oil

  Engine oil filter element Fuel filter element

  * GREASE

  Intermediate propshaft (425)

  Front propshatt (410,412 and 415)

  
  

  Iss ue 10”

  1

  2 - 3

  
  

  SERVICE SCHEDULES (cont'd)

  
  

  EVERY 500 OPERATING HOURS OR THREE MONTHS

  whlchaver occurs flrst

  Do the Daily to 250 hour jobs plus:

  
  

  CLEAN

  Battery terminals

  ” Fuel lift pump gauze

  Engine injectors and test (4.98)

• Transmission oil strainer

• Cab heater air filter (weekly in very dusty conditions)

  
  

  CHECK (engine stopped)

  
  

  Exhaust system security Engine mountings Parking brake adjustment

  
  

  CHECK (engine running)

  
  

  ARV pressure

  Steering relief pressure Idling speed

• Maximum no load speed

  Pulled down speed Operation of clutch cut-off

• Converter oil pressure

• Clutch oil pressure

• Servo pressure

CHANGE

General

EVERY 1000 OPERATING HOURS OR SIX MONTHS

whichever oocurs first

Do the Daily to 500 hour jobs plus;

CLEAN

Air cleaner dust valve

CHECK

Engine œmpression Valve clearances (4.98)

‘ ROPS/FOPS structure

CHANGE

Outer air cleaner element Brake system fluid

Axle oil

‘ Transmission oil ' GREASE

Rear propshaft (415 & 425)

Front propshaft (425)

EVERY 2000 OPERATING HOURS OR YEARLY

whichever occurs first

CHANGE

1

2 - 3

Hydraulic fiher element Inner air cleaner element

Transmission oil liltsr * Hydraulic fluid (clean suction strainer) ' Axle oil (When operation in regions where ambient * Engine coolant, clean system

temperature exceeds 32°C (90•F)

GREASE

Upger cenlre pivot (later machines)

“ Rear propshaft (4J 0 & 412)

9803/4100

‘ CLEAN

Engine injectors and test (4.236, 6.354, 1004, 1006) Hydraulic suction strainer

Emergency steer pump strainer (il fitted) ’ CHECK (engine stopped)

Valve Clearances (4.236, 6.354, 1004, 1006)

Issue10”

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1

3 — 1

GREASING

General

1

3 - 1

Loader Arms for interval see Service Schedule

Note: ALWAYS grease with loader arms fully down, never wilh arms raised.

WARNING

WARNING

Make sure the articulation lock is fitted before greasing the steer ram pins.

Make sure the articulation lock is fitted before greasing Steer Ram Pins lor interval see Service Schedule

the centre pivot.

Centre Pivot (upper and lower) for interval see Service Schedule

9803/4100

S 493550

S096560

Issue 6”

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