Contents

Introduction

About this manual

Emergency procedures

• Protective equipment
• Freeing the machine
• Moving the immobilized machine
• Transporting the machine
• Lifting the machine
• Tools
• Jump starting procedure
• Fuses and relays
• Tires and wheels

Maintenance

• Service requirements
• Health and safety
• Service schedules
• Fluids, lubrication and containers
• Preparing the machine for maintenance
• Cleaning the machine
• Checking the condition
• Lubrication
• Access panels and engine cover
• Maintenance procedures

Operating manual

• Introduction
• Technical information and specifications
• Cab layout
• Engine and drive controls, switches and instruments
• Before starting the engine
• Starting the engine
• Preparing the machine for movement
• Ensuring the movement of the machine
• Stopping and parking the machine
• Working with the machine
• Conditions work
• Fueling the machine
• Storing the machine

Safety precautions and rules when working on the machine

Basic tools, measuring instruments and methods of working with them

• Basic set of necessary tools
• Methods of working with measuring instruments

Engine mechanical part (Perkins engines)

• General information and precautions
• Removing and installing the engine assembly
• Cylinder head and its components
• Cylinder block and its components
• Engine synchronization
• Service data and specification

Engine mechanical part (JCB Dieselmax engines)

• General information and precautions
• Removing and installing the complete engine
• Compression test
• Cylinder head and its components
• Cylinder block and its components
• Service data and specification

Cooling system (Perkins engines)

• General information
• Thermostat
• Coolant pump
• Fan and fan drive
• Oil cooler
• Service data and specification

Cooling system (JCB Dieselmax engines)

• General information
• Thermostat
• Coolant inlet pipe
• Coolant pump
• Oil cooler
• Service data and specification

Lubrication system (Perkins engines)

• General information
• Filter head
• Oil pan
• Oil pump
• Pressure relief valve
• Idler pinion shaft
• Service data and specification

Lubrication system (JCB Dieselmax engines)

• General information
• Checking oil pressure
• Head oil filter
• Oil sump
• Oil pump
• Oil cooler
• Service data and specification

Fuel system (Perkins Engines)

• General information
• On-machine service
• High pressure fuel pump
• Fuel filter
• Fuel injectors
• Fuel priming pump
• Service data and specification

Fuel system (JCB Dieselmax engines)

• General information
• On-machine service
• Fuel Lines
• Fuel lift pump
• High pressure fuel pump
• Fuel injectors
• Service data and specification

Intake and exhaust system (JCB Dieselmax engines)

• General information
• On-machine maintenance
• Turbocharger
• Exhaust manifold
• Intake manifold
• Joint fastening specifications

Transmission

• On-machine maintenance
• PTO shaft
• Front axles
• Rear axles
• Gearboxes and torque converter
• Service data and specification

Brake system

• On-vehicle service
• Master brake cylinder and servo boosters
• Parking brake
• Specification

Machine controls

• Loader control handle
• Steering column
• Forward/reverse lever
• Boom lock system
• Unload pedal microswitch (machines up to serial number 430000)

Hydraulic system

• General information
• Hydraulic pump
• Loader valve block (hydraulic distributor)
• Valve block (hydraulic distributor) excavator
• Hose burst protection valves (HBPV)
• Stabilizer check valve
• Main valve
• Hydraulic steering system
• Hydraulic cylinders (power/lift cylinders)
• SRS accumulator (if equipped)
• Service data and specification
• System diagrams

Machine attachments

• General information
• Machine attachments
• Connecting/disconnecting hydraulic hoses
• Quick disconnect couplings
• Optional accessories

Cab, frame, air conditioning

• Health and safety
• On-machine service
• Glass
• Replacing cab and machine frame components
• Air Conditioning system (if equipped)
• Service data and specification

Electrical

• Alternator
• Starter
• Battery
• Sensors/switches
• Relay and fuse box (servo)
• Wiring harnesses
• Service data and specification
• Ground connection points (ground)
• Wiring diagrams
• Machines up to serial number 430000
• Machines from serial number 430001 to 460000
• Machines from serial number 460001 to 495454
• Machines from serial number 495455

Appendices

• General tightening torques for threaded connections
• Thread lockers, sealants and adhesives
• Spare parts catalog