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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)
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Introduction JCB 3CX / 4CX since 2010

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