Contents

Introduction

Actions in emergency situations

• Protective equipment
• Freeing the car
• Moving an immobilized vehicle
• Transporting the machine
• Lifting the machine
• Tools
• Method of starting from an external power source
• Fuses and relays
• Tires and wheels

Maintenance

• Maintenance requirements
• Health and safety
• Maintenance schedules
• Fluids, lubricants and containers
• Preparing the machine for maintenance
• Cleaning the machine
• Checking status
• Lubrication
• Access panels
• Maintenance procedures

Operating instructions

• Introduction
• Technical information and specifications
• Cabin layout
• Engine and drive controls, switches and instruments
• Before starting the engine
• Starting the engine
• Preparing the car for movement
• Ensuring the movement of the machine
• Stopping and parking a car
• Working with the machine
• Working conditions
• Refueling the car
• Car storage

Warnings and safety 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

Mechanical part of the engine (PERKINS engines)

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

Mechanical part of the engine (JCB DIESELMAX engines)

• General information and precautions
• Removing and installing the engine assembly
• Compression check
• Cylinder head and its elements
• Cylinder block and its elements
• 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
• Coolant pump
• Oil cooler
• Service data and specification

Lubrication system (PERKINS engines)

• General information
• Filter head
• Oil pan
• Oil pump
• Reducing valve
• Idler gear axis
• Service data and specification

Lubrication system (JCB DIESELMAX engines)

• General information
• Checking the oil pressure
• Oil filter head
• Oil pan
• Oil pump
• Oil cooler
• Service data and specification

Power system (PERKINS engines)

• General information
• Car service
• High pressure fuel pump
• Fuel filter
• Fuel injectors
• Fuel lift pump
• Service data and specification

Power system (JCB DIESELMAX engines)

• General information
• Car 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
• Car service
• Turbocharger
• Exhaust manifold
• Intake manifold
• Connection fastening specifications

Transmission

• Car service
• Cardan shaft
• Front axles
• Rear axles
• Gearboxes and torque converter
• Service data and specification

Brake system

• Car service
• Brake master cylinder and servo boosters
• Parking brake
• Specification

Machine controls

• Steering column
• Controls – version 1
• Controls – version 2
• Control rods and connections
• Control cables

Steering

• Car service
• Steering rods and hydraulic steering cylinder
• Main valve
• Steering mode valves
• Hydraulic steering unit
• Service data and specification

Hydraulic system

• Component location
• Car service
• Hydraulic pump
• Valve block (hydraulic distributor) for loader
• Excavator valve block (hydraulic distributor)
• Hose burst protection valves (HBPV) (if equipped)
• Hydraulic cylinders (power/lift cylinders)
• Hydraulic oil cooler
• Smooth ride system (SRS) battery
• Service data and specification

Machine attachments

• General information
• Machine attachments
• Connecting / disconnecting hydraulic hoses
• Quick release connections
• Optional accessories

Cabin, frame, air conditioning

• Health protection and precautions
• Car service
• Glass
• Replacing cab and machine frame components
• Air conditioning system (if equipped)
• Service data and specification

Electrical equipment

• Generator
• Starter
• Battery
• Sensors / switches
• Wire harnesses
• Service data and specification
• Ground connection points (grounding)
• Electrical circuits
• Basic version of the car
• Transmission control
• Optional equipment
• Engine (JCB Dieselmax 444)